REELITE | 15T-E

TISSUE REWINDER

INSTRUCTION MANUAL
(TRANSLATION OF ORIGINAL INSTRUCTIONS)

VALMET S.p.a.
Via delle Molina, 69 51017 Veneri di Pescia (PT)
Url: www.valmet.com E-mail: -

Document: UM.260240.A-Use and Maintenance manual_PFR_it

Language:Italiano (it)
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1 TABLE OF CONTENTS
1 TABLE OF CONTENTS...................................................................................................................... 3
2 IDENTIFICATION................................................................................................................................ 9
2.1 Identification of the instruction manual ........................................................................................... 9
2.2 Manufacturer’s identification .......................................................................................................... 9
2.3 Machine identification ...................................................................................................................10
2.4 Identification plate ........................................................................................................................11
2.5 Dichiarazione UE di conformità ....................................................................................................12
3 INFORMATION FOR THE USER .....................................................................................................13
3.1Aim of the instruction manual .......................................................................................................13
Receipt and conservation of the instructions ...................................................................13
Requests for further copies and/or updates ....................................................................14
3.2 Reference information ..................................................................................................................15
References within the manual .........................................................................................16
3.3 Glossary .......................................................................................................................................17
Glossary of safety terms ..................................................................................................17
Glossary of industry terms ...............................................................................................19
3.4 Illustrations ...................................................................................................................................19
3.5 Warranty .......................................................................................................................................20
4 SAFETY ............................................................................................................................................21
4.1 Intended use ................................................................................................................................21
4.2 Reasonably foreseeable incorrect use .........................................................................................21
4.3 General safety rules .....................................................................................................................23
Safety rules for the customer and/or employer ...............................................................23
Safety rules for ordinary persons.....................................................................................23
Safety rules for operators ................................................................................................23
Safety rules for maintenance personnel ..........................................................................24
Safety rules for contracted work ......................................................................................24
4.4 Personnel training and qualification .............................................................................................25
Personnel training ............................................................................................................25
Competencies and roles ..................................................................................................25
4.4.2.1 Specific requirements for electric/electronic maintenance technicians .......................26
Qualification with respect to tasks ...................................................................................27
4.5 Work areas ...................................................................................................................................28
4.6 Adopted safety measures ............................................................................................................29
Time limits ........................................................................................................................29
Emergency Stop ..............................................................................................................30
Lock-out/Tag-out..............................................................................................................31
Fixed Guard .....................................................................................................................32
4.6.4.1 Perimeter protections...................................................................................................32
4.6.4.2 Unwinders ....................................................................................................................33
4.6.4.3 Rewinder ......................................................................................................................33
Movable guard (with guard lock) .....................................................................................34
Hold-to-run device ...........................................................................................................36
Photoelectric barrier ........................................................................................................37
Signal tower .....................................................................................................................38
Valvola di Check valve ....................................................................................................39
4.6.9.1 Rewinding head ...........................................................................................................39
4.6.9.2 Extractor ......................................................................................................................40
Blade protection ...............................................................................................................41
Fall prevention device ......................................................................................................42
Lock-out/Tag-out (valves) ................................................................................................43
Keys to the electrical board .............................................................................................44
Protection against direct and indirect contacts ................................................................45
4.7 Checking the safety measures .....................................................................................................46
4.8 Information and warnings on the machine ...................................................................................48

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T Summary table of information and warnings ............................................................... 48

4.8.1.1 EL – Electrical system ................................................................................................ 50
4.8.1.2 General ....................................................................................................................... 51
4.8.1.3 Unwinder area............................................................................................................. 53
4.8.1.4 Rewinding head area .................................................................................................. 54
4.8.1.5 Extractor area ............................................................................................................. 56
4.9 User safety measures ................................................................................................................. 57
Type of personal protection equipment (P.P.E.) ............................................................. 57
4.10 Warnings regarding residual risks .......................................................................................... 59
5 DESCRIPTION AND TECHNICAL DATA ....................................................................................... 65
5.1Operating principle ...................................................................................................................... 65
5.2Identification of the main units ..................................................................................................... 67
5.3Description main unit ................................................................................................................... 68
Unwinder ......................................................................................................................... 68
Rewinding head .............................................................................................................. 69
5.3.2.1 Machine head unit....................................................................................................... 69
5.3.2.2 Paper rollers ................................................................................................................ 69
5.3.2.3 Walkway ...................................................................................................................... 71
5.3.2.4 Cutting unit .................................................................................................................. 72
5.3.2.5 Carry drums ................................................................................................................ 73
5.3.2.6 Chucks group .............................................................................................................. 74
5.3.2.7 Rider roller group ........................................................................................................ 75
5.3.2.8 Width-wise cutting group ............................................................................................ 76
5.3.2.9 Ejector group............................................................................................................... 77
Extractor.......................................................................................................................... 78
Hydraulic control unit ...................................................................................................... 79
Electrical cabinet ............................................................................................................. 79
5.4 Additional groups ......................................................................................................................... 80
Trim removal ................................................................................................................... 80
Unwinders – rewinder paper threading system .............................................................. 80
Rewinding head paper threading system ....................................................................... 80
Automatic lubrication system .......................................................................................... 81
5.5 Technical data ............................................................................................................................. 82
General characteristics ................................................................................................... 82
Product characteristics ................................................................................................... 82
System characteristics .................................................................................................... 82
5.5.3.1 Electrical system ......................................................................................................... 82
5.5.3.2 Pneumatic system....................................................................................................... 83
5.5.3.3 Oil-hydraulic system.................................................................................................... 83
Characteristics of the work environment ........................................................................ 83
Overall size and space requirements ............................................................................. 84
5.6 Noise ........................................................................................................................................... 85
6 TRANSPORTATION AND UNLOADING ........................................................................................ 87
6.1 Shipping information .................................................................................................................... 87
6.2 Equipment required for unloading ............................................................................................... 88
6.3 Preparing the unloading area ...................................................................................................... 89
6.4 Unloading from the means of transportation ............................................................................... 90
6.5 Handling the load units ................................................................................................................ 91
6.6 General notes for lifting and handling ......................................................................................... 92
6.7 Unpacking ................................................................................................................................... 93
6.8 Lifting the machine ...................................................................................................................... 94
Identification of load units ............................................................................................... 94
Examples of lifting of load units ...................................................................................... 95
6.8.2.1 General ....................................................................................................................... 95
6.8.2.2 Unwinder ..................................................................................................................... 96
6.8.2.3 Rewinding head .......................................................................................................... 97
6.8.2.4 Extractor ...................................................................................................................... 98
6.9 Temporary storage ...................................................................................................................... 99
7 INSTALLATION AND START-UP ................................................................................................. 101

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7.1Floor requirements .....................................................................................................................101

Civil engineering work ...................................................................................................101
Preparation of flooring and machine bases ...................................................................102
7.2 Mechanical assembly .................................................................................................................103
Requirements for mechanical assembly .......................................................................103
Assembly and positioning ..............................................................................................104
7.3 Installation and assembly instructions to reduce noise ..............................................................105
7.4 Installation and assembly instructions to reduce vibrations .......................................................105
7.5 Illumination .................................................................................................................................105
7.6 System connections ...................................................................................................................106
Electrical connections ....................................................................................................106
7.6.1.1 Notes for the correct connection of the power line or earth line ................................107
7.6.1.2 Connection to the equipotential protection circuit ......................................................108
7.6.1.3 Pneumatic panel (main disconnector) .......................................................................109
Hydraulic system connections .......................................................................................110
7.7 Commissioning (first start-up) ....................................................................................................111
Checks required prior to first start-up ............................................................................111
Testing machine movements .........................................................................................111
First machine start-up ....................................................................................................112
7.8 Start-up after a long idle period ..................................................................................................112
8 CONTROLS AND WARNING SIGNS ............................................................................................113
8.1 Position of the control panels and warning signs .......................................................................113
8.2 Main control panel – 151JB630 .................................................................................................114
8.3 Pushbutton Unwinder 1 - CB 122 ..............................................................................................115
8.4 Pushbutton Unwinder 1 – CB120 ...............................................................................................116
8.5 Pushbutton Unwinder 2 - CB 222 ..............................................................................................117
8.6 Pushbutton Unwinder 2 – CB220 ...............................................................................................118
8.7 Pushbutton Unwinder 1/2 – CB121 – CB 221............................................................................119
8.8 Walkway pushbutton control panel– 151CB620 ........................................................................120
8.9 Walkway pushbutton control panel – 151CB621 .......................................................................122
8.10 Rewinder pushbutton control panel– 151CB616 ...................................................................124
8.11 Rewinder pushbutton control panel – 151CB614 ..................................................................126
8.12 Unloading table pushbutton control panel – 151CB775 ........................................................127
8.13 Extractor pushbutton control panel – 151CB831 ...................................................................128
8.14 Hydraulic control unit pushbutton control panel – 151JB670 ................................................129
8.15 Access request pushbutton control panels – CB124 – CB 224 – CB 225 - CB121 - 151CB612
- 151CB618 – CB824 – CB826 ............................................................................................................130
8.16 Signal tower ...........................................................................................................................131
8.17 Electrical cabinet....................................................................................................................132
9 USE .................................................................................................................................................133
9.1 Turning on the machine .............................................................................................................133
9.2 Resetting safety devices ............................................................................................................134
9.3 Access procedures .....................................................................................................................135
Access to the unwinders ................................................................................................135
Access to the cutting area .............................................................................................136
9.3.2.1 Access from the walkway ..........................................................................................136
9.3.2.2 Access from the ground .............................................................................................137
Access to the area inside the rewinding head ...............................................................138
Access to the reel outfeed area .....................................................................................139
Access to the core feeder area......................................................................................140
9.4 Operating adjustments and procedures .....................................................................................141
Preparing the mother reel ..............................................................................................141
Unwinder enabling / disabling ........................................................................................142
Loading the mother reel .................................................................................................144
Paper splicing ................................................................................................................146
Replacing the mother reel .............................................................................................147
9.5 Operating procedures in the rewinding and doffing area ...........................................................149
Cleaning the reel............................................................................................................149
Paper splicing ................................................................................................................151

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9.6 Cutting group setup procedures ................................................................................................ 153

Activating the knives ..................................................................................................... 154
Replacing the knives ..................................................................................................... 155
Adjusting the position of the knives .............................................................................. 157
9.7 General operating procedures .................................................................................................. 159
JOG mode..................................................................................................................... 159
9.7.1.1 JOG in unwinding area ............................................................................................. 159
Paper threading ............................................................................................................ 160
9.7.2.1 Threading the first ply ............................................................................................... 160
9.7.2.2 Threading all subsequent plies ................................................................................. 163
9.7.2.3 Paper threading after the ply breaks......................................................................... 164
9.7.2.4 Positioning the plies on the cores ............................................................................. 166
9.7.2.5 Paper threading diagram .......................................................................................... 167
Changing type of rewinding Shafted - Shaftless........................................................... 168
9.8 Work cycle ................................................................................................................................. 169
Preparing for start-up .................................................................................................... 169
Starting the rewinding cycle .......................................................................................... 171
Loading the cardboard cores ........................................................................................ 172
Adjusting the height of the inflator ................................................................................ 173
Adjusting the moving stopper ....................................................................................... 174
End of the rewinding cycle – doffing and starting a new cycle ..................................... 175
9.9 Machine stop ............................................................................................................................. 177
Working stop ................................................................................................................. 177
FAST STOP working stop ............................................................................................. 177
Emergency stop and restart.......................................................................................... 178
9.9.3.1 Emergency pushbutton ............................................................................................. 178
9.10 Operating instructions to be followed in case of an accident or malfunction ........................ 179
Procedure to unlock the doors from the outside ........................................................... 179
Procedure to release the door from the inside ............................................................. 180
9.11 Turning off the machine ........................................................................................................ 181
10 MAINTENANCE ............................................................................................................................. 183
10.1 Introduction to maintenance ................................................................................................. 183
LockOut/TagOut concept (LOTO)................................................................................. 184
10.2 Access procedures for maintenance .................................................................................... 185
Access to the machine with isolation of power supplies ............................................... 185
Location of cut-off and lock-out devices ....................................................................... 186
10.2.2.1 Electrical board ......................................................................................................... 186
10.2.2.2 Area pneumatic cut-off valves .................................................................................. 187
Access to the electrical board ....................................................................................... 188
10.2.3.1 Access for maintenance work with the power on ..................................................... 188
10.2.3.2 Access for maintenance work with the power cut off................................................ 189
Bleeding off residual pressure ...................................................................................... 190
10.2.4.1 Procedure to bleed pneumatic pressure. .................................................................. 190
Blocking the doffing table .............................................................................................. 191
10.3 Inspections ............................................................................................................................ 192
10.4 Cleaning ................................................................................................................................ 194
Cleaning the hydraulic control unit radiator. ................................................................. 195
10.5 Lubrication and greasing ...................................................................................................... 196
Lubrication and greasing .............................................................................................. 197
Lubrication and greasing .............................................................................................. 198
10.5.2.1 Unwinder ................................................................................................................... 198
10.5.2.2 Rewinding head ........................................................................................................ 201
10.5.2.3 Shaft Handler ............................................................................................................ 211
10.6 Mechanical maintenance ...................................................................................................... 219
Replacing the reel unwinding belts ............................................................................... 220
10.7 Electrical maintenance .......................................................................................................... 221
11 DISMANTLING AND SCRAPPING ............................................................................................... 223
11.1 General information .............................................................................................................. 223
11.2 Decommissioning for prolonged periods .............................................................................. 223

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11.3 Decommissioning and scrapping ...........................................................................................224

separation, classification and disposal ..........................................................................224
Types of waste produced by machine demolition .........................................................225

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2 IDENTIFICATION
2.1 Identification of the instruction manual

DOCUMENT N. UM.260240.A-Use and Maintenance manual_PFR_it

REVISION: A
DATE: 11/10/2023

2.2 Manufacturer’s identification

MANUFACTURER: VALMET S.p.a.

ADDRESS: Via delle Molina, 69

51017 Veneri di Pescia (PT) - ITALY
CONTACTS: Tel. +39 0572 429053

Fax +39 0572 429306

Url: www.valmet.com

E-mail: -

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2.3 Machine identification

TRADE NAME: TISSUE WINDER

MODEL: REELITE
TYPE: 15 T

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2.4 Identification plate

Machine identification data are written on the identification plate (1), the position of which on the machine
is illustrated below.

IMPORTANT

Machine identification data must always accompany any request for information, spare parts, etc.
• Do not remove or replace the plate.
• In the event of damage, always contact the manufacturer.
• Please write down the plate data and file them for future reference.

2 3

4
5
6
7 1
8

# DATO Description
1 - Identification plate.
2 COMPANY NAME Manufacturer identification.
MARKING The logo relating to the type of certification issued is placed in this
3
IDENTIFICATION area of the plate
GENERIC
4 Identification of the machine
DENOMINATION
5 MODEL Identification of the model of the machine
6 TYPE Identification of the type of machine
7 SERIAL NR. Univocal machine identification number.
YEAR OF
8 Year in which the machine manufacturing was completed
COSTRUCTION

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2.5 Dichiarazione UE di conformità

La dichiarazione è fornita in allegato al presente manuale di istruzione. Si riporta di seguito un facsimile dei
contenuti della dichiarazione fornita.

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3 INFORMATION FOR THE USER

3.1 Aim of the instruction manual
In compliance with paragraph 1.7.4 of the 2006/42/EC European directive, this manual provides important
instructions on safety and correct management of the machine.

• This instruction manual is absolutely necessary to train and inform machine operators. Given the
specificity of machine use instructions have been drawn up for professional operators, thus taking
into consideration the general level of training and perspicacity that can be reasonably expected
from these operators.
• Although the manual provides information on how to run the machine correctly and on residual
risks of operations, it cannot replace the experience of “expert personnel", who have been trained
and informed of their tasks and are familiar with operative and safety procedures associated
thereto.
• To select suitable personnel, see the paragraph “Personnel qualification” in the “Safety”
chapter.
• Carefully read and thoroughly understand all chapters of this manual before running the machine.
• Follow only the instructions provided and in case of doubt always contact the manufacturer
• Do not perform operations for which information has not been provided by the manufacturer.
• Do not perform operations the instruction for which are difficult to interpret; if necessary, always
contact the manufacturer.
• Do not perform operations differently from how instructed in this manual.
• Do not perform operations that are expressly forbidden in this manual.
• In the event of unforeseen operating conditions or conditions that are not described in this manual,
please contact the manufacturer immediately.
• The manufacturer declines all responsibility for failure to abide by the contents of this manual.
• This instruction manual and all attached documents are an integral part of the machine that has
been purchased and provide useful information for correct use of the same.
• For personal safety and for the safety of persons exposed to risks during the machine’s service life,
it is mandatory to always refer to the instructions provided and contact the manufacturer in case of
any doubts deriving from lack of or unclear instructions.
• This manual and all attached documents must always accompany the machine, of which they are
an integral part, for its entire service life.
• Keep this manual and all attached documents in a place that is easy to reach and known to all
users (operators and maintenance personnel.
• The “original instructions” are written in ITALIAN. Any other language is a “translation of the original
instructions”, in compliance with the provisions of European Directive 2006/42/EC.
• The information contained in this manual is the property of the manufacturer.
• All rights to the reproduction of this manual are reserved to the manufacturer.
• Reproduction of this manual, even in part, without prior written consent is forbidden.
• This manual cannot be reproduced or sold to third parties without written authorization by the
manufacturer.
• The manufacturer reserves the right to modify product characteristics and the contents of this
manual without prior notice.
• The descriptions and illustrations provided in this manual are not binding; see the Chapter
“Information for the User”, paragraph “Illustrations”.
• Before running the machine, read and comprehend the technical instructions contained in this
manual and all attached documents, and follow the instructions provided carefully.

Receipt and conservation of the instructions

Customers and/or employers are responsible for the training and information of appointed machine
operators and must disseminate the information contained in the instruction manual to the final users.

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It is obligatory to keep all instructions (instruction manual and attached documentation) in a safe place, that
is easy to reach and known to all users for future reference. This documentation must always accompany
the machine even if the machine is given to third parties.

The manufacturer reserves the right to provide a soft copy of the instructions.

Requests for further copies and/or updates

Further copies of the instructions, in addition to those contractually agreed upon during the sale, must be
requested from the manufacturer by regular purchase order.

Updates of the manual, where necessary, must be requested to the manufacturer who will assess the
manual review modalities. Updates must be requested by regular purchase order; all old copies the
customer has must be destroyed and replaced and the manufacturer must be informed thereof.

Requests for specific notes on the manual, as well as requests for interpretative notes and clarifications
thereupon, must be agreed upon with the manufacturer.

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3.2 Reference information

Warnings regarding individual safety and correct machine use are illustrated as follows:

“RISK LEVEL”

TYPE OF RISK
Consequences
• What to do.
• ...

The heading “RISK LEVEL” may be one of the following:

DANGER

This indicates a situation of imminent risk which may lead to death or serious injury if not avoided.

WARNING

This indicates a potentially hazardous situation which may lead to death or serious injury if not avoided.

ATTENTION

This indicates a potentially hazardous situation which may lead to light or moderate injury if not avoided.

Suggestions and particularly useful information are written in the following way:

IMPORTANT

This indicates an obligation with respect to a conduct or special task for safe machine management or a
possible incorrect use of the machine.

NOTE: useful information.

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References within the manual

The manual makes reference to commands described in the “CONTROLS” chapter, using the following
format:

“NAME OF THE CONTROL (Control panel > #)”

The name refers to the information present in the specific section:

8.4 Control panel being referenced

# Function
# NAME OF THE CONTROL
Description

References to controls present on the software interface are made in the following format:

“NAME OF THE CONTROL (HMI > Software page)”

“HMI” indicates that the control to which the text refers is described in the software manual.

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3.3 Glossary
Glossary of safety terms
Pursuant to the Machinery Directive (2006/42/EC) and European Directives currently in force regarding
worker health and safety on the workplace, these are the definitions of the terms used inside this instruction
manual.

Term Definition
HAZARD A potential source of injury or damage to health.
DANGER AREA Any area within and/or around machinery in which a person is
subject to a health or safety risk.
EXPOSED PERSON Any person wholly or partially in a danger area.
OPERATOR The person or persons installing, operating, adjusting, maintaining,
cleaning, repairing or
moving the machinery.
RISK The combination of the probability and the degree of an injury or
health damage that may arise in a dangerous situation.
GUARD A part of the machine used specifically to provide protection by
means of a physical barrier.
SAFETY DEVICE A device (other than a guard) that reduces a risk, by itself or in
conjunction with a guard.
INTENDED USE Use of the machine in accordance with the information provided in
the user instructions.
REASONABLY FORESEEABLE Use of the machine in a way that is different from that indicated in
MISUSE the user instructions, but which may derive from easily predictable
human behaviour.
PERSONAL PROTECTION Personal protection equipment (PPE) stands for any device or
EQUIPMENT (PPE) appliance designed to be worn or held by employees for protection
against one or more health and safety hazards at work, as well as
any supplement or accessory intended for this use. The following
are not to be understood as personal protection equipment:

• Ordinary work clothes and overalls that are not specifically

designed to protect employee safety and health;
• Emergency, aid and rescue services equipment;
• Personal protective equipment of armed forces, police
forces and public order personnel;
• Personal protection equipment used on road transport
vehicles;
• Sports equipment;
• Self-defence materials or deterrent materials;
• Hand-held devices used to identify and signal risks and
harmful events.

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Term Definition
EMPLOYEE A person who provides his/her work in the service of an employer,
excluding domestic workers, in salaried work conditions.
Partners of cooperatives or companies who provide their services
on behalf of companies and organisations and users of school,
university and professional orientation and training services hired
by employers to facilitate or optimise their professional choices are
also recognised as employees.

Students of training institutes and universities and the participants

in vocational training courses where laboratories, machinery,
devices and work equipment in general, chemical, physical and
biological agents are used are also recognised as employees. The
subjects referred to in the previous sentence are not taken into
account in the calculation of the number of employees whose
obligations are established in this directive.
EMPLOYER The legal entity that controls and directs a labourer or employee or
an entity which, depending on its type and entrepreneurial
organisation, is responsible for the enterprise or the productive unit
as beneficiary of decision-making and spending powers.
INTERLOCKING DEVICE A device of mechanical, electric or other nature the aim of which is
(INTERLOCK) to prevent machine parts from functioning in specific conditions
(generally until the guard has been closed).
INTERLOCKED GUARD A guard associated to an interlocking device and a guard locking
device, so that:
• the dangerous machine functions covered by the guard
may not be performed until the guard has been closed and
locked;
• The guard remains closed and locked until the danger or
injury deriving from the dangerous machine functions has
ceased;
• Closure and locking of the guard enable execution of the
dangerous machine functions covered by the guard,
without however starting them.

INTERLOCKED GUARD WITH
GUARD LOCK
GUARD LOCKING DEVICE
A guard associated to an interlocking device and a guard locking
device, so that:
• the dangerous machine functions covered by the guard
may not be performed until the guard has been closed and
locked;
• The guard remains closed and locked until the danger or
injury deriving from the dangerous machine functions has
ceased;
• Closure and locking of the guard enable execution of the
dangerous machine functions covered by the guard,
without however starting them.
A device designed to lock a guard in closed position and connected
to the control system so that:
• the machine may not run until the guard has been closed
and locked;
• the guard remains locked until the risk has ceased to exist.

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Glossary of industry terms

The following definitions may be used in this manual, with specific reference to the machine and its intended
use.

Term Definition
WINDING SHAFT Support around which the paper is wound.
PARENT REEL Large paper reel exiting the paper making machine before it is cut;
a large reel for end users.
REEL (OR SMALL REELS) Reels that are smaller than the parent reel from which they are
created.
PAPER FOR SANITARY USES Paper for sanitary uses includes cellulose wadding, paper tissue
(PAPER TISSUE) and crepe paper for hygiene, made from scrap paper and/or
chemical pulp, also with the addition of mechanical cellulose to the
mix.
Currently, considering the importance of paper tissue, this name is
internationally used as the comprehensive definition for sanitary
paper.
MACHINE WIDTH Width of the paper web in the paper machine.
OPERATOR (O.S.) The side of the machine where machine controls are located and
where the operator usually stands during machine operation
DRIVE SIDE (D.S.) The side of the machine that is opposite to the OPERATOR SIDE
and that is usually only accessed for maintenance purposes.
PAPER WEB Continuous sheet of paper formed on the wire of the paper
machine.
REWINDER Machine that both pairs the plies for more than one reel and cuts
the reels into formats that can be used in paper converting
processes.

3.4 Illustrations
The illustrations contained in this manual may show colours different from those actually on the machine,
for the machine structure or parts. Colour differences do not compromise the validity or correctness of the
information herein provided, save for colours closely associated with the safety of exposed persons and
machine safety.

Where used to show certain machine functions, the illustrations in this manual may differ from your machine
or may be incomplete. If necessary, to complete the instructions provided in the manual, please refer to the
specific machine drawing (e.g. the installation layout, assembly layout etc.) of the component or unit that
requires interventions. Please request such drawings from the manufacturer.

DANGER

VARIOUS RISKS DERIVING FROM INCORRECT MACHINE USE.

For the purpose of clarity, some illustrations may show the machine with the guards and/or safety devices
removed.
• IT IS FORBIDDEN to use the machine with guards and/or safety devices removed and/or disabled.

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3.5 Warranty
The manufacturer guarantees the machine and equipment against material and/or machining faults and/or
defects for the period agreed upon by contract and, in any event, in accordance with current law provisions
regarding warrantees. All disputes shall be subject to the exclusive jurisdiction of the Court of Justice agreed
upon by contract.

IMPORTANT

The warranty shall be valid only if machine assembly is performed by specialised manufacturer
personnel. The warranty shall be null and void in any of the cases described below.
• Extraordinary maintenance carried out on the machine without the supervision of a support technician
or performed by a technician not authorised by the manufacturer.
• Replacement of machine parts with non-original spare parts.
• Removal, disassembly or tampering with guards of machine safety devices during machine use.
• The manufacturer is not liable for defective products deriving from the assembly of non-original spare
parts.
• Authorised interventions under warranty performed by the customer without the supervision of a
manufacturer support technician.
• Failure to respect the terms and conditions of payment.

DANGER

ALTERATIONS
The manufacturer is not liable for injury due to disassembly, tampering with (alteration) or bypassing of
guards and or/safety devices, nor accidents due to operations performed by personnel with a specific
training level inferior to that defined in this instruction manual.
• Keep the machine in optimal working conditions, in compliance with the original project and the
provisions of this instruction manual.
• Use only personnel qualified for the tasks to be performed.

DANGER

COMPONENT REPLACEMENT
Unauthorised tampering with/replacement of one or more built-in machine components and/or the use of
accessories, tools and consumables different from those recommended by the manufacturer may
represent an accident hazard and release the manufacturer from all criminal and civil liability.
• Use only original spare parts.

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4 SAFETY
4.1 Intended use
Intended use means use of the machine in accordance with the information provided in the user manual.

The machine may be used only by professional operators who have been trained and instructed regarding
the contents of this instruction manual.

A detailed description of the machine is provided in the Chapter “Description and technical data

FUNCTION
The machine has been designed and manufactured to unwind one or more reels of paper tissue, bond
the plies, cut the paper lengthwise, and rewinding it, to create reels of different formats.

4.2 Reasonably foreseeable incorrect use

Reasonably foreseeable incorrect use means machine use that is different from that indicated in the user
instructions but that may stem from easily foreseeable human behaviour.

DANGER

VARIOUS RISKS DERIVING FROM INCORRECT MACHINE USE.

Incorrect machine use is extremely dangerous. The manufacturer declines all responsibility for any injury
to persons or damage to property deriving from any use other than intended machine use.
• Use the machine in compliance with the intended use and the instructions provided.

The manufacturer’s experience allows signalling out the following cases of incorrect use, for which the
machine is not intended.

The following are considered incorrect uses:

A) INSTALLATION
Installing the machine in environments where the atmosphere is or may probably become explosive
during normal work activities, for either long or short periods of time (classification according to European
Union ATEX Directive 1999/92/EC).
Installing the machine in the open or in environments with characteristics that do not comply with the
environmental technical data contained in these instructions.
Installing the machine without abiding by the manufacturer’s instructions.

B) USE
Use of the machine by operators who are not of legal working age according to the laws currently in force
in the country of machine use.
Use of the machine by operators who have not been duly trained, formed and instructed regarding all
machine risks and residual and trained regarding safety rules.
Failure to use personal protection equipment (PPE) as required by the instruction and regulations
currently in force in the country of use.
Tampering with or bypassing machine safety devices, even temporarily.
Where it is possible to access inside the safety guards with the entire body, it is FORBIDDEN to close
oneself inside voluntarily.

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B) USE
Using the machine even when it shows signs of malfunction or is in partial breakdown.
Failure to abide by technical data regarding machining limits (materials, speeds, etc.).
Simultaneous use of the machine by two or more operators who may inadvertently put each other at risk
or engender risks for other exposed persons.
Machine use by the designated operator without having first made sure that there are no exposed
persons in the machine hazard areas.

C) PERSONNEL TRAINING AND INFORMATION

Operating the machine without having read and understood the instructions provided by the
manufacturer.
Performing operations for which the manufacturer has not provided information.
Performing actions for which the information provided by the manufacturer is difficult to interpret.
Performing machine operations in ways other than those described in the instructions.
Performing operations that are expressly forbidden in the instructions.

D) MODIFICATIONS
Altering the machine in any way that changes the intended machine use.

E) SPARE PARTS
Using non-original spare parts and/or spare parts not recommended by the manufacturer, in order to
avoid jeopardizing operator health and safety.

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4.3 General safety rules

Following is a series of general rules for correct machine use, to be integrated with specific information
regarding operations to be performed for machine use and maintenance.

Safety rules for the customer and/or employer

On making machine use available to operators and maintenance personnel, the customer and/or employer
must abide by European Union directives regarding occupational health and safety as well as by the
regulations of the State in which the machine is installed and used. These obligations are not manufacturer
responsibilities. Please pay special attention to the following obligations:
• It is obligatory to perform a risk assessment for the machine, regarding the characteristics of the
environment where the machine is to be installed and the characteristics of the work methods of
the user company. It is obligatory to assess and understand every risk including residual risks
indicated in the manual, and to adopt appropriate technical, organizational and procedural
measures to inform and train personnel designated to machine use and maintenance.
• It is obligatory to select personnel and provide training and instruction. The personnel selected
must be of legal working age and meet the mental and physical requirements for the work to be
performed.
• It is obligatory to choose personal protection equipment (PPE) suited to the work to be performed
and supply personnel with said equipment.

Safety rules for ordinary persons

Ordinary persons (not trained and not instructed) cannot run the machine and may approach it only if duly
informed:
• It is OBLIGATORY for the customer and/or employer to inform ordinary persons of machine risks
and supervise them when they are in proximity of the machine.
• Ordinary persons are FORBIDDEN to use the machine

Safety rules for operators

Operators are actively involved in maintaining high machine safety standards over time. Operators are
therefore required to take into account the following aspects regarding responsible machine use.
• Run the machine only after having obtained employer authorisation to do so.
• Be familiar with the contents of this manual and use the information correctly.
• Before running the machine, operators must obligatorily undergo specific training provided by the
manufacturer or employer and must abide by all operating and safety procedures contained in the
instruction manual.
• Comply with warnings placed in hazard areas.
• Use personal protection equipment (PPE).
• Operator work wear must comply with basic safety requirements in force in the country of use, as
foreseen by specific directive on the matter.
• Machine operators must also abide by the following specific rules: do not wear bracelets, watches,
rings or chains and keep long hear tied back under a safety cap.
• Assume ergonomically correct positions to avoid excessive strain or fatigue while working.
• Make sure that the work area and machine are free from machining residues and any objects not
necessary for machine use.
• Check that all guards, alarm devices and safety devices are in perfect working order every day and
before every machine use; do not run the machine in case of malfunctions and restore correct
machine working order before use.
• Do not run the machine if the guards and/or safety device have been removed.
• Do not voluntarily bypass or tamper with guards and safety devices.
• Preserve machine characteristics, and strictly avoid alterations that may modify machine operation
in any way.

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• Do not use the machine in the event of malfunction or breakdown.

Safety rules for maintenance personnel

Maintenance technicians are actively involved in maintaining high machine safety standards over time.
Maintenance technicians are therefore required to take into account the following aspects regarding
responsible machine use.
• Run the machine only after having obtained employer authorisation to do so.
• Before servicing the machine, operators must obligatorily undergo specific training provided by the
manufacturer or employer and must abide by all operating and safety procedures contained in the
instruction manual.
• Be familiar with and abide by all rules for operators.
• Implement a correct machine maintenance schedule, in compliance with manufacturer
recommendations.
• Check machine conditions daily and immediately replace worn or damaged parts.
• Do not service or lubricate the machine while it is running.
• Be familiar with and carry out all the operations required to keep the machine safe.
• Use appropriate tools and equipment for machine repairs.
• Remove all tools used for maintenance from the work area and store them properly, before
restarting the machine.
• Restore all guards and safety devices that may have been removed and check that they are
working properly before restarting the machine.

Safety rules for contracted work

Customer and/or employer obligations include training and informing personnel employed to perform
contracted work on or around the machine regarding machine risks related to the work they are to carry
out. Please refer to current legislation regarding occupational health and safety in force in the country where
the machine is installed and run.

NOTE: Contracted work may include clearing the workplace and/or the machine, or maintenance and/or
installation work carried out on or in proximity of the machine itself.

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4.4 Personnel training and qualification

Personnel training

IMPORTANT

The machine may be run only by trained and qualified personnel. The employer is responsible for
providing training for personnel designated to using the machine.
• Personnel must follow and operational training course before using the machine.

The instructions provided in this manual and in the attached documents may include important issues to be
taken into consideration during operation training, to allow employers to fulfil appropriate personnel training
requirements.

The manufacturer is not obliged to provide a complete training programme, nor a training manual, as these
services are not within the range of application of the Machine Directive.

Manufacturer assistance for training may in any event be requested, negotiating a training course for the
specific machine.

Competencies and roles

The machine directive defines the term OPERATOR as: the person or persons given the task of installing,
operating, adjusting, maintaining, cleaning, repairing or transporting machinery.

Based on the above general definition, this manual classifies personnel more precisely according to the
definitions that follow.

PRODUCTION Professional personnel with the specific skills required to operate the
OPERATOR machine, trained and instructed to operate machine controls and carry out
(OPERATOR) previously defined operations and adjustments.

THE PRODUCTION OPERATOR is not qualified to carry out mechanical

and/or electrical maintenance and may provide only non-specialised
maintenance, such as visual inspection and machine cleaning, which do
not require specific competencies.
GENERAL WORKER Non-skilled personnel, with basic competencies, who may carry out only
simple tasks, after having been duly trained and instructed regarding
procedures and risks inherent to the work to be carried out.

GENERAL WORKERS are ordinary persons duly trained and instructed for
the tasks to be carried out and may operate only in the presence of
professional personnel who are responsible for safe machine management,
handling any emergency situation that may arise, and supervising ordinary
persons.
MAINTENANCE Professional personnel possessing specific competencies required to carry
TECHNICIAN out machine maintenance, and also capable of carrying out the tasks of
PRODUCTION OPERATOR personnel.

MAINTENANCE TECHNICIANS may carry out mechanical or electrical

maintenance required on the machine.
SPECIALISED Professional personnel possessing specific competencies required to carry
TECHNICIAN out ordinary and extraordinary machine maintenance or specialised
operations (for example, transport, waste disposal, etc.).

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MANUFACTURER Professional personnel possessing specific competencies required to carry

TECHNICIAN out operations required on the machine.

NOTE: OPERATORS, MAINTENANCE TECHNICIANS and SPECIALISED TECHNICIANS must be

sufficiently qualified, and have sufficient know-how and experience to be able to assess risks and avoid
hazards inherent to work activities, or have been sufficiently trained to be able to avoid the hazards that
work activities may engender.

4.4.2.1 Specific requirements for electric/electronic maintenance technicians

Work on live parts must be performed by personnel designated by the employer as qualified for the work
to be carried out, in compliance with the requirements set forth in the pertinent technical standards.
Therefore, it is important to take into account that:
• Personnel designated to electrical work must be trained and qualified for such work;
• Personnel designated to electrical work on live parts must be possess a specific qualification from
the employer for this type of activity.

Electrical technicians are defined in the pertinent technical standards as specified below:

OPERATOR
Qualified person (PEI)
Expert person (PES)
Warned person (PAV)
DEFINITION
Person with recognised technical capacities to perform electrical
work under tension.
Person with significant training, knowledge and experience,
sufficient to allow assessing risks and avoiding hazards engendered
by electricity.
Persons adequately warned by expert persons, enough to be able
to avoid the dangers engendered by electricity.

I Persons that falling into the PAV and PES categories are defined common persons (PEC) and, as such,
may carry out electrical work on parts that are not powered and only if supervised by a PAV or PES.

Electrical work such as “intervention on systems or equipment with access to live parts (powered or not
powered) within the scope of which, if safety measures are not adopted, an electrical risk is present”, is
divided into 3 types:

• Work on powered parts: whenever a worker comes within a given distance from accessible
powered parts with a part of the body or with a tool (insulated or conductor).
• Work near powered parts: when the worker comes within a given distance from accessible
powered parts with a part of the body or with a tool (insulated or conductor). For this type of work,
specific precautions against electrical risks must be taken (those adopted for electrical work on
parts that are not powered are not sufficient).
• Work on parts that are not powered: work on electrical circuits that are not powered and free of
electrical charges.

NOTE: IEC EN 60204-1 standards for electrical circuits on machines do not distinguish between work
carried out on powered electrical equipment or disconnected electrical equipment and therefore do not
require that the latter be carried out only by qualified persons (PEI).

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Qualification with respect to tasks

In accordance with the risk assessment performed by the manufacturer, the table below summarises
personnel qualification required to perform various machine tasks.

MAINTENANCE MANUFACTUR
TASK ORDINARY OPERATOR SPECIALISED
TECNICIAN ER
PERSON TECHNICIAN
TECHNICIAN
Walking or standing
near the machine
Transport, unloading
and storage
(1)
Installation and
assembly
Start-up
Use
Non-specialised
maintenance
(cleaning, inspections)
Specialised
maintenance
(adjustments and
replacements)
Troubleshooting and
repairs

Dismantling and
scrapping (2)
A B C
PERSONNEL TRAINING

A) PERSONNEL NOT TRAINED AND NOT INFORMED

B) TRAINED AND INFORMED PERSONNEL
C) TRAINED AND INFORMED PERSONNEL (SKILLED TECHNICIAN)

Key: authorised not authorised

NOTES
(1): Load handling technician.
(2): Waste disposal technician.

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4.5 Work areas

DANGER

VARIOUS RISKS DERIVING FROM INCORRECT MACHINE USE.

The work area must always be free of obstacles and nothing must interfere with the operator’s freedom
of movement.
• In case of an emergency, immediate access to the machine must be guaranteed for personnel in
charge.
• Access to this area is not permitted to persons that are not directly involved in machine operation, so
as to avoid hazards deriving from carelessness or negligence during work activities.
• Operators are therefore recommended to always keep the work area free of any equipment and ban
access to unauthorised persons, in order to guarantee ideal safety conditions for machine operation.

LIST OF WORK AREAS:

• Outside the all-around guards, where the control panels used to manage the machine are located.
• Inside the all-around guards, after having implemented the access procedures.
• Electrical panels.

IMPORTANT

Complete information regarding the various work stations is provided in the chapters “Controls and
Signals” and “Use”.

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4.6 Adopted safety measures

This section contains information regarding the safety measures implemented to eliminate or reduce
machine risks.

Risks that have not been completely eliminated by the safety measures, but remain to a reduced extent,
are described in this manual as residual risks.

DANGER

VARIOUS RISKS DERIVING FROM INCORRECT USE OF SAFETY MEASURES

The safety measures adopted must be checked and kept efficient for the length of the machine’s service
life.
• Perform the periodical checks described in this manual.
• Do not remove or bypass the safety measures, even temporarily (for example, guards, photocell
barriers, etc.).

Time limits
The expected machine service life is 20 years. Command and control circuits with safety functions are
manufactured taking into account this limit.

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Emergency Stop
Emergency stop device located on every control panel, which may be activated in case of personal and
collective danger.

3 2 3 3

2 3 2 2 3 2 3 2

4 1

# Description
1 Emergency stop located on electrical panel
2 Emergency stop located outside the guards.
3 Emergency stop located inside the guards.

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Lock-out/Tag-out
Every energy source may be cut off and locked out in the OFF position using special clamps and padlocks.

# Description
1 Rewinder cut-off.

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Fixed Guard
Protection for moving parts composed of fixed panels that may be removed only using tools (wire fence
and/or plate).
4.6.4.1 Perimeter protections

1
1 1
1
1 1 1
1

# Description
1 All-around fixed guard.
2 Wall (the fixed guards are desgined for the specific installation; should the machine be moved, all
the guards must be newly assessed).

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4.6.4.2 Unwinders

2 1 1
2

# Description
1 Riparo fisso fiancata espulsore.
2 Riparo a protezione degli elementi di trasmissione.

4.6.4.3 Rewinder

# Description
1 Fixed guard on the walkway protecting the unwinder behind it.

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Movable guard (with guard lock)

Movable guard with interlocking devices that lock the guard. Opening the guard trips the safety function.

2
3

# Description
1 Door to access the unwinders area.
2 Door to access the rewinder area.
3 Door to access the carry drums / unloading table area.
4 Door to access the the extractor area.
5 Sliding door to access the extractor area.
6 Movable guard with manual opening mechanism for access to the cutting group.

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Notes

• The gates are controlled by interlocking devices with a guard lock.

The lock is mechanical and lock release is electrical (power to
release), in order to guaranty that the gates remain closed even in
the event of power failures.
• The gates may be opened only when the machine slows to zero
speed and dangerous machine components are in safety
conditions, before enabling unlocking of the gates.
• The interlocking device is fitted with a key release that unlocks the
device from the outside but that immediately stops the machine in
emergency mode if used. This device is not intended for use in
normal conditions, but the key must be made available to personnel
in order to allow releasing the guard in extraordinary circumstances
(for example, in case of power failures).
• The interlocking device is fitted with a release handle on the inside,
which may be activated should someone remain locked inside the
guard (personnel escape and rescue). If activated, this handle will
stop the machine in emergency mode.
• When any gate is closed, the reset control must be pressed to
reset and lock the gate.

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Hold-to-run device
Machine movement at reduced speed by pressing the hold-to-run control button to enable movement.
Releasing the button stops machine movement.

# Description
1 Unwinder 1 JOG button
2 Unwinder 2 JOG button

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Photoelectric barrier

Pressure sensitive device used to stop the machine or a part of the machine when it comes into contact
with any person entering beyond the safety limits.

# Description
1 Photoelectric barriers (Schmersal - 101216823).

Note

• The area near the unloading table is surrounded by photoelectric

barriers which, bhen crossed, must be reset to enable machine
movements.

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Signal tower
Tower with signal lights and warning horn to signal machine conditions.
.

# Description
1 Signal tower.

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Valvola di Check valve

Check valve fitted on the actuator. The valve is released to enable movement.

4.6.9.1 Rewinding head

Check valve fitted on the actuator. The valve is released to enable movement.

4
5
1
3
5 2
4

3
1

6 6

# Description
1 Pneumatic check valve for chuck closing.
2 Pneumatic check valve (blocks the air chamber for sideways movement of the blade and counter-
blade). The check valve used for the blades serves this operational purpose only.
3 Blade beam pneumatic check vavle (activates in the event of an emergency stop).
4 Shaft holding clamp pneumatic check valve.

5 Ejector pneumatic check valve (overcenter)

6 Unloading table hydraulic check valves.

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4.6.9.2 Extractor

# Description
1 Deflator pneumatic check valve.

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Blade protection
Protection device on the cutting elements of the blade, to be used when working close to the blade and
for maintenance operations.

# Description
1 Blade protection device.

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Fall prevention device

Mechanical device able to guarantee the stability of the load and the structure.

4
4 5
4
4

# Description
1 Rider roller blocking device
2 Blade beam mechanical safety hook
3 Unloading table mechanical safety pins.
4 Carton blocking system stem mechanical blocking device
5 Extractor rising/lowering movement negative action pneumatic brake

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Lock-out/Tag-out (valves)
Every source of energy supply may be locked out in the OFF position by means of special clamps and
locks.

# Description
1 Main pneumatic power supply cut-off valve.

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Keys to the electrical board

Lock with key to open the electrical board. The key must be handled only by skilled and qualified personnel.

# Description Description
1 Access keys Chiave di acces

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Protection against direct and indirect contacts

Creation/implementation of containers and sheaths capable of guarantying an appropriate level of isolation
of live parts.

# Description
1 Electrical board.

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4.7 Checking the safety measures

MEASURE INSPECTION METHOD FREQUENCY

Test A): preventing machine start
• Press the emergency pushbutton and check that it
remains blocked.
• Check that the emergency light turns on.
• Check that the machine will not start when the
emergency pushbutton has been pressed.
Emergency
SIX-MONTHLY
pushbutton Test B): reset the emergency pushbutton
• Turn the emergency pushbutton clockwise and check
that it releases.
• Check that it is possible to start-up the machine.

NOTE: Both tests must be repeated for every emergency

pushbutton on the machine.
• Check for leaks or damage to any part of the guard,
especially if it decreases the safety function (for
example, reduction of the resistance to bumps,
scratches on glass, etc.)
Fixed and/or • Replace the parts subject to wear, verifying the
deterioration of the couplings or anchor points. MONTHLY
movable guards
• Check that there is no deterioration due to corrosion,
temperature changes or chemicals.
• Check that the safety distances and sizes of the
openings have not changed.
• Check to make sure that the machine will not start if
the gate is open.
• Check to make sure that the gate remains blocked
after the safety device has been activated (for
example, when the machine is running).
Interlocking
• Check that the gate remains blocked in case of
devices (with SIX-MONTHLY
power failure.
door locks)
• For gates equipped with an internal release device
(for example, a pushbutton and/or handle), check to
make sure that the device effectively releases the
gate and simultaneously generates a safe machine
stop.
Warning lights • Regularly check that the lights and horns turn on
SIX-MONTHLY
and horns properly.
LOCK-OUT/TAG- • Check that locks and clamps are always on hand to
AT EACH USE
OUT cut off and lock out energy supply sources.
Hold-to-run • Check that movement occurs only when the control is
MONTHLY
control pressed and stops when the control is released.
• Check that the load supported by the cylinder
remains in position even in absence of a command or
Check valves power to the circuit. YEARLY
• Check the conditions of the pipes and make sure
there are no leaks or spillages.

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MEASURE INSPECTION METHOD FREQUENCY

• The keys must be used only for the time required to
carry out the intervention. Once the work has been
completed, they must be removed and stored by the
person in charge of the keys, or left inserted in the
Keys machine operation mode selector switches (for AT EACH USE
example JOG control, MANUAL mode, etc.).
• The keys may be used only by authorised and
qualified persons, identified in a written procedure.
• Do not duplicate the keys.
Perform the following procedures as described in the
paragraph "Electrical Maintenance":
Direct / indirect • Inspection of tightening of clamps.
YEARLY
contacts • Check the degree of protection of the casing.
• Inspect the conditions of the electrical conductors.
• Protection equipment.
Blade protection • Check that the blade protection device is intact.
SIX-MONTHLY
device • Return the protection guard to its housing after use.
Fall prevention • Check that the is in place.
mechanical • Check the correct tightening.
SIX-MONTHLY
device (structure /
person)

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4.8 Information and warnings on the machine

In conformity with paragraph 1.7.1 of European Machinery Directive 2006/42/EC, the machine bears the
information and warnings described in this section.

• Failure to abide by any safety prescription, due to deterioration, loss or failure to consult a safety
sticker may engender serious accidents.
• It is obligatory to know and abide by the information and warnings on the machine, in conformity
with the meaning and actions described in this instruction manual.
• The information and warnings on the machine must be kept intact for the entire service life of the
machine; for this purpose, instructions for specific scheduled checks are provided in the paragraphs
that follow.
• The manufacturer declines all responsibility deriving from failure to abide by the prescriptions
indicated on the machine and in the manuals provided.

T Summary table of information and warnings

STICKER
SYMBOL DESCRIPTION LOCATION
ID

Located on the door of the electri-

DANGER; ELECTRICITY: Warns of the presence of
W012 cal cabinet and on all boxes hous-
electrical tension
ing live parts.

DANGER; SLIPPERY SURFACE: Warns of the pres- Located on the slide and near the
W011
ence of slippery surfaces paper roller.

DANGER; HOT SURFACE: Warns of the presence Located near the unwinder brake,
W017
of a heated surface and the carry drum brakes

Located near the scrapers, the

DANGER; SHARP OBJECT: Warns of the presence
W022
of sharp objects
DANGER; CRUSHING OF HANDS: Warns of the
W024
closing motion of mechanical machine parts
DANGER; RESIDUAL PNEUMATIC PRESSURE:
C007 Warns of the presence of residual pneumatic
pressure in pipes and/or actuators
DANGER; RESIDUAL HYDRAULIC PRESSURE:
C008 Warns of the presence of residual hydraulic
pressure in pipes and/or actuators
knives and the width-wise cutting
blade.
Located near the knives
Located near the conduit inspec-
tion hatches
Located near all actuators that
may accumulate residual pneu-
matic pressure.
Located near all actuators that
may accumulate residual hydraulic
pressure.

DO NOT TOUCH: Warns that it is forbidden to - Located on the door of the elec-
P010
touch an object or parts of an object trical cabinet

DO NOT EXTINGUISH WITH WATER: Warns that Located on the door of the electri-
P011
it is forbidden to use water to put out fires cal cabinet

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STICKER
SYMBOL DESCRIPTION LOCATION
ID

DO NOT CLIMB: Warns that it is forbidden to

P019 Located near the paper roller
climb onto a surface

DO NOT CLOSE OTHERS INSIDE THE SAFETY

Located on all the all-around guard
C006 GUARDS: To prevent intentionally closing an ac-
access doors
cess door while someone is still inside the area.
DISCONNECT THE MACHINE BEFORE MAINTE-
NANCE OR REPAIRS: Indicates that it is obliga-
Located on the door to the electri-
tory to disconnect the machine, which is con-
M021 cal board and near the compressed
nected to the main electrical grid, from all power
air cut-off switch.
sources before carrying out maintenance or re-
pair work.
CHECK GUARDS: Indicates that it is obligatory to
Located near all the all-around
M027 check that all guards and safety devices are in
guard access doors.
place and working properly
DANGER OBSTACLE: Warns of the presence of an
Located near the unwinder guides
C005 obstacle at ground level (tripping hazard) or
and on the knife movable guard
overhead (impact hazard)

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4.8.1.1 EL – Electrical system

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4.8.1.2 General

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4.8.1.3 Unwinder area

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4.8.1.4 Rewinding head area

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4.8.1.5 Extractor area

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4.9 User safety measures

Type of personal protection equipment (P.P.E.)

Symbol Description Technical Standards

Protection for the entire body 1) UNI EN ISO13688 Safety
(1, 2, 3, 4, 5 6, 7) work wear general
Always wear safety work wear suited for the work requirements
to be carried out. 2) UNI EN ISO 342 Work wear
The column to the right specifies the reference for protection against the cold
standards, based on the relative safety 3) UNI EN ISO 11612 Work wear
requirements. for protection against heat and
flames
4) UNI EN 943-1-2
Work wear for protection
against chemical products
5) UNI EN 13034
Work wear for protection
against liquid chemical agents
6) UNI EN 1149
Safety work wear –
electrostatic properties
7) IEC EN 61482-1-2
Work wear against the thermal
effect of electric arcs
Head protection
Always wear a safety helmet while hoisting and
positioning the machine and whenever there is a UNI EN 397
risk of objects falling from above. Industrial safety helmets

Hand protection
1) UNI EN 374
(1, 2, 3)
Safety gloves against chemical
Always wear safety gloves for operations that products.
expose hands to various risk factors.
2) UNI EN 388
The column to the right specifies the reference
Safety gloves against
standards, based on the relative safety
mechanical and electrostatic
requirements.
risks.
3) UNI EN 407
Safety gloves against heat risks

Eye protection
Always wear eye protection during work that UNI EN 166
entails the risk of flying materials or exposure to Personal eye protection–
sprays. Specifications

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Symbol Description Technical Standards

Hearing protection
(1, 2)
Wear personal hearing protection equipment 1) UNI EN 352-1
based on an assessment of the noise risk in the Headphones
work environment and in compliance with laws
2) UNI EN 352-2
currently in force in the country of use.
Ear plugs
The column to the right specifies the reference
standards, based on the relative safety
requirements.

Foot protection
1) UNI EN ISO 20345
(1, 2, 3)
Safety boots
Always wear safety footwear.
2) UNI EN ISO 20346
The column to the right specifies the reference
Protective footwear
standards, based on the relative safety
requirements. 3) UNI EN ISO 20347
Work boots

Respiratory system protection 1) UNI EN 149

(1, 2, 3, 4) Anti-dust filtering half-mask
Always wear safety equipment to protect the 2) UNI EN 405
respiratory system when cleaning the machine Anti-dust and anti-gas filtering
using solvents or chemical products. half-mask
The column to the right specifies the reference 3) UNI EN 143
standards, based on the relative safety Anti-dust filters
requirements. 4) UNI EN 14387
Anti-gas filters and combined
filters

Protection against falling from high places 1) UNI EN 353-1-2

(1, 2, 3, 4, 5, 6, 7, 8) Guided-type fall protection
Always wear a safety belt and safety harnesses devices.
for height work. 2) UNI EN 354
Ropes
The column to the right specifies the reference 3) UNI EN 355
standards, based on the relative safety Energy dissipaters
requirements. 4) UNI EN 360
Retractile fall protection
devices
5) UNI EN 361
Body harnesses
6) UNI EN 363
Fall-arrest systems
7) UNI EN 795
Anchoring devices

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4.10 Warnings regarding residual risks

In conformity with paragraph 1.7.2 of the European Machinery Directive 2006/42/EC, residual risks that
persist despite the implementation of safety measures built into the design and guards and all additional
safety measures are described in this section.

The paragraphs in this section describe residual risks subdivided by stages of the machine’s service life.

NOTE: In compliance with current legislation, in the risk assessment, the manufacturer has not taken into
account (nor did the manufacturer have the information at his disposal to do so) the risks inherent to the
work environment and the specific work procedures of the user company.

RISK ID RISK ELEMENT CONSEQUENCES OF HOW TO AVOID THE RISK

THE RISK
1. Mechanical hazards
R1.1 UNEXPECTED Various consequences OBLIGATORY:
START-UP deriving from unexpected - cut-off power sources and discharge
start-up of machine move- residual energies.
ments.
R1.2 MOVING VEHI- Crushing and/or impact OBLIGATORY:
CLES AND with moving vehicles and - use the warning horn/buzzer to sig-
EQUIPMENT equipment nal the approach of the vehicle or
equipment.
- Keep pedestrian routs and vehicular
routes separate.
R1.3 HANDLING OF Crushing and/or impact OBLIGATORY:
LOADS with the load or between - Mark off the area and/or keep other
the load and parts of the persons away from the handling area.
machine or structures - Stay clear of the suspended load.

If necessary, use ropes to guide the

load.
Handle carefully.

PERSONAL PROTECTION EQUIP-

MENT:
- Safety helmet
R1.4 FALLING OF A Being crushed by and/or OBLIGATORY:
SUSPENDED impact with the falling - Make sure the load has been fas-
LOAD load tened correctly before starting to hoist
it
- Lift the load slowly.
- Stay at an appropriate safety dis-
tance.

FORBIDDEN:
- Standing in the hazard area.
- Walking under a suspended load.
- Leaving suspended loads unat-
tended.

PERSONAL PROTECTION EQUIP-

MENT:
- Safety helmet

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RISK ID RISK ELEMENT CONSEQUENCES OF HOW TO AVOID THE RISK

THE RISK
R1.5 SLIPPERY Slipping, tripping and fall- OBLIGATORY:
FLOOR AND/OR ing - Remove processing residues and
THE PRESENCE materials not required for production
OF PRO- from the floor.
CESSING RESI- - Mark off the area and clean up and
DUES OR MATE- liquid spills.
RIALS

R1.6 STAIRS AND/OR Slipping, tripping and fall- OBLIGATORY:

WALKWAYS ing - Move with caution and keep stairs
FOR ACCESS and walkways clean of processing
TO THE MA- residues and materials not required
CHINE for production.

FORBIDDEN:
- Climbing onto or leaning over para-
pets.

R1.7 STAIRS AND/OR Falling from heights OBLIGATORY:

MEANS OF TEM- and/or from above (higher - Use stairs and/or means of tempo-
PORARY AC- than 2 metres) rary access that are compliant with
CESS FOR regulations in force.
HEIGHT WORK
FORBIDDEN:
- climbing onto machine structures
and anywhere that is not intended to
be climbed onto.
R1.9 MANUAL CUT- Cutting of hands and/or OBLIGATORY:
TING TOOLS fingers - Check that the tool is intact.
- Grasp the tool firmly.
- Do not leave tools in passage ways
and tie them in to keep them from
falling from heights.

PERSONAL PROTECTION EQUIP-

MENT:
- Gloves for protection against me-
chanical risks

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RISK ID RISK ELEMENT CONSEQUENCES OF HOW TO AVOID THE RISK

THE RISK
R1.10 MANUAL HAN- Crushing under a falling OBLIGATORY:
DLING OF load - Do not lift a load that cannot be
LOADS grasped firmly and securely.

PERSONAL PROTECTION EQUIP-

MENT:
- Gloves for protection against me-
chanical risks
R1.11 PROTRUDING Bumping the head OBLIGATORY:
STRUCTURES - Move with caution.
AND/OR LOW
PASSAGE
WAYS

R1.12 ROTATING Entanglement in rotating OBLIGATORY:

PARTS parts - Stay clear of rotating parts during
machine operation.
- Wait for machine movements to
have come to a stop before ap-
proaching the machine.
- Wear appropriate clothing, without
loose parts that may get caught in the
machine.
- Do not wear bracelets, watches,
rings or chains and gather long hair in
caps or nets.

R1.13 ROTATING Dragging by and entan- OBLIGATORY:

PARTS glement in rotating parts - Stay clear of rotating parts during
machine operation.
- Wait for machine movements to
have come to a stop before ap-
proaching the machine.
- Wear appropriate clothing, without
loose parts that may get caught in the
machine.
- Do not wear bracelets, watches,
rings or chains and gather long hair in
caps or nets.

R1.14 SLIDES/CHUTES Slipping, tripping and fall- OBLIGATORY:

ing - Move with caution and keep the
slides clean of processing residues
and materials not required for produc-
tion.

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RISK ID RISK ELEMENT CONSEQUENCES OF HOW TO AVOID THE RISK

THE RISK
R1.15 CHUCKS Crushing of hands and/or OBLIGATORY:
fingers - Be careful when activating the con-
trol.
- Make sure the area is clear of other
persons.

R1.17 TRANSVERSAL Cutting of hands and/or OBLIGATORY:

CUTTING fingers - Be careful of the cutting edge when
BLADE AND handling the blade.
KNIVES
PERSONAL PROTECTION DEVI-
CES:
- Mechanical hazard safety gloves

R1.18 PAPER ROLLER Slipping, tripping and fall- OBLIGATORY:

ing - Move with caution around the paper
rollers.
R1.20 CONDUIT IN- Crushing of hands and/or OBLIGATORY:
SPECTION fingers - Open the inspection hatch only
HATCH when the dust removal system has
been turned off.

FORBIDDEN:
- Starting up the dust removal system
when the inspection hatches are
open.
R1.21 PAPER THREA- Slipping, tripping and fall- OBLIGATORY:
DING BELTS ing - Move with caution in the area

R1.25 PAPER REEL Crushing by the paper OBLIGATORY:

reel as it rolls after being
ejected
- Be careful during activation of the
control.
- Make sure nobody else is in the
area.
- Wait for the reel to have come to a
full stop before accessing the area.

2. Electrical hazards
R2.1 ELECTROCU- Electrocution / Burns due OBLIGATORY:
TION to direct or indirect con- - Work on electrical equipment, be it
tact with live parts live or not, may be carried out only
by skilled personnel (PES) and in-
structed personnel (PAV), according
to the definition provided in IEC 11-
27.

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RISK ID RISK ELEMENT CONSEQUENCES OF HOW TO AVOID THE RISK

THE RISK
R2.3 ELECTROCU- Electrocution due to direct FORBIDDEN:
TION contact with energized -Touching the active elements of the
parts of the anti-static bar anti-static bar.

3. Heat hazards
R3.2 HEATED PARTS Burning the hands and/or OBLIGATORY:
Heat (50°C < T < fingers - Follow the procedure for access to
100°C) the area and/or for work on hot ma-
chine parts.

PERSONAL PROTECTION EQUIP-

MENT:
- Heat-resistant safety gloves (50°C <
T < 100°C)

7. Hazards deriving from materials / substances

R7.1 FLAMMABLE Fire caused by mechani- OBLIGATORY:
SUBSTANCES cally and/or electrically - Keep the work place and the ma-
generated sparks and/or chine clean.
from the use of live flames - Provide fire extinguishers on site.
coming into contact with
flammable materials
R7.2 TOXIC AND/OR Poisoning and/or sensitis- OBLIGATORY:
NOXIOUS SUB- ing - Follow the instructions and precau-
STANCES tions on the product safety sheets.

PERSONAL PROTECTION EQUIP-

MENT:
- Consult the product safety sheets

R7.3 CELLULOSE Contact with the eyes or OBLIGATORY:

DUST inhalation of suspended - Abide by the dust removal proce-
dust dure.

PERSONAL PROTECTION EQUIP-

MENT:
- Safety mask (impact, sprays, dust)
- Mask for protection against dust,
fumes and mists
R7.4 DUST DEPOS- Fire caused by the brakes OBLIGATORY:
ITS ON THE activating due to a power - Keep the brakes clean and avoid
BRAKES failure, heating up and dust build-ups.
setting fire to accumulated
dust.

8. Ergonomic hazards

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RISK ID RISK ELEMENT CONSEQUENCES OF HOW TO AVOID THE RISK

THE RISK
R8.1 MANUAL HAN- Fatigue / muscle pains OBLIGATORY:
DLING OF - Assume ergonomically correct pos-
LOADS tures and positions to lift, drag, push
or move loads, in order to avoid inju-
ries to the spinal column, joints and
muscles.

FORBIDDEN:
- Lifting loads heavier than 25 Kg for
men and 15 kg for women (ISO
11228).
9. Hazards associated to the environment in which the
machine is used
R9.1 POLLUTANTS Environmental pollution. OBLIGATORY:
- Dispose of any kind of waste in ac-
cordance with laws currently in force.

PERSONAL PROTECTION EQUIP-

MENT:
- Consult the safety data sheet of the
product being used

12. Hazards due to: assembly and installation, adjustments, cleaning, troubleshooting, mainte-
nanc
R12.1 GETTING Various consequences FORBIDDEN :
TRAPPED IN- deriving from the start-up - Tampering with or bypassing safety
SIDE THE of machine movements devices and being voluntarily closed
GUARDS inside the guards.

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5 DESCRIPTION AND TECHNICAL DATA

5.1 Operating principle
The machine was designed and manufactured to unwind and rewind one or more paper reels, so as to
produce reels with different formats.
.

The work cycle for paper tissue entails unwinding the reels, coupling the paper plies and then rewinding.

The final reel may be the same size as the initial one, with the possibility of trimming the sides, or the paper
may be rewound into more than one reel, based on the knives fitted on the cutting unit.

The machine operating cycle may be summarised as shown in the table below:

Stage Description
Preparing the cores
Inserting the rewinding
shaft
Positioning the rewinding
shaft (shafted mode)
Positioning the knives
Loading the reels on the
unwinders
Threading the paper
Adjusting the position of
the knives
Starting the rewinding
cycle
End of the rewinding
cycle
Ejecting the reel
Slitting the paper
Positioning the rewinding
shaft
Starting the rewinding
cycle
Inserting the cores
Removing / inserting the
rewinding shaft
• The cores are inserted in the core loader and compacted.
• The extractor inserts the rewinding shaft inside the rewinding head;
the shaft will therefore be inserted inside the previously loaded
cores.
• The shaft, inclusive of the cores, is released by the ejector onto the
carry drums.
• The shaft is locked in place by the chucks.
• The knives and anvil knives are brought into position.
• The trim suction mouths are adjusted.
• Reels are loaded onto the unwinders using an overhead travelling
crane.
• The first ply is drawn through the machine completely.
• If necessary, additional plies are drawn through.
• The paper is smoothed out, cut, and positioned on the previously
loaded shaft.
• The machine is run in JOG mode to check the position of the strips
of paper with respect to the cores and, if necessary, the cores or
the knives are repositioned manually.
• The rewinding cycle is started from the main control panel.
• At the end of the rewinding cycle, the machine comes to a stop.
• The reel is ejected using the controls on the main control panel.
• The knife on the rewinding head lowers and slits the paper
crosswise.
• During reel ejection, the shaft, inclusive of the cores, is positioned
on the carry drums.
• The paper is positioned on the cores by air blowers.
• The operator starts the new rewinding cycle.
• The operator inserts the cores inside the ejector.
• The extractor removes the rewinding shaft from the completed reel
and re-inserts it in the extractor.

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Stage Description
• The operator makes sure that nobody and/or nothing is inside the
unloading area..
Unloading the reel
• The unloading table is lowered manually and the reel is unloaded
onto the ground.

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5.2 Identification of the main units

# Description
1 Unwinder 1
2 Unwinder 2
3 Rewinding head.
4 Estrattore.
- Electrical cabinet..

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5.3 Description main unit

Unwinder
The unwinder is composed of a motor (1), an unwinding arm (2), a linear motor (3) to move the arm, two
unwinding belts (4), two movable side panels (5), and two blocking flanges (6).

The frame supports the motor and the unwinding arms.

The unwinding arm is driven by a linear motor; the belts are driven by the motor and, as they are positioned
in contact with the paper reel, they are responsible for rotating and unwinding the reel. Two pneumatic
cylinders (7) keep the belts tensioned to allow for unwinding.

The shaft is unloaded by two flanges activated by pneumatic cylinders (8); the flanges lift the shaft from the
cradle in which it is positioned during the unwinding stage, and deposit it onto the guides from where it will
be retrieved using appropriate handling equipment.

The two movable side panels allow centering the mother reel, as they move together, driven by an electric
motor (9) located at the base of one of the two panels.
The paper roller (10) and the slide (11) allow the material to pass through and move towards the machine
winding area.

2
6
8
3
5

1
9

10
7

11

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Rewinding head
5.3.2.1 Machine head unit
The machine head is the unit inside which all the rewinding stages take place, from paper cutting up to
rewinding on the shaft.

The unit is composed of two side panels that contain the following components:

• Paper rollers,
• Walkway
• Cutting group,
• Carry drums,
• Chuck group,
• Rider roller group
• Ejector group

5.3.2.2 Paper rollers

The motorized paper roller (1) is positioned at rewinding area infeed, and allows threading the paper under
the walkway between the calender and the cutting group.

The spreader roller (2) located under the walkway is driven by the paper roller (1), and smoothens out the
paper before it enters the rewinding area.

2 1

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The paper rollers located at the infeed (3) (infeed roller) and outfeed (4) (outfeed roller) of the cutting group
are driven by an electric motor (5) with a belt drive system; the action of the rollers on the paper allows the
correct dragging of the same through the cutting unit.

The spreader roller (6) is driven by the outfeed roller; the rotation of the spreader roller spreads out the
paper before the rewinding stage.

3 4 6

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5.3.2.3 Walkway

The walkway (1) provides operator access to the knife group. Fixed guards are installed on the walkway to
prevent the operator from accessing the drive area or the unwinding area.

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5.3.2.4 Cutting unit

The cutting unit is composed of a set of knife holders (1) mounted on a moving upper beam (2) that is raised
by pneumatic cylinders (3), and the respective anvil blades (4) located below the upper beam.

When they are in the lowered position, the knife holders bring the knives into contact with the anvil blades,
and cut the paper.
The trims produced by the external knives are collected by the motorised vacuum trim removal ports (5)
that are to be connected to the vacuum system by the end customer.

The operator manually adjusts the transversal position of the knives and anvil blades, after having released
the pressure inside the linear expansion guides (6). The operator must position the knives before threading
the paper through the machine, based on the width of the reels to be produced.

The walkway may be accessed only for visual inspections to allow executing adjustments or regulations
from the machine’s touchscreen, or for interventions on the cutting group by maintenance personnel, with
the energy supply sources disconnected and locked out.

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5.3.2.5 Carry drums

The carry drums (1) are located in the front section of the machine and serve to set the reel turning, in order
to support it during the rewinding stage.

The motors (2) are connected directly to the roller by means of a coupling.

2
2

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5.3.2.6 Chucks group

The chucks (1) close and support the shaft during rewinding, following the increase in size of the reel.

The chucks are moved by a carriage (2) that shifts vertically by means of ball screws (3) (one per side).

The chucks close against the shaft by means of a linear actuator, ensuring that the reel is kept in position
as it is rewound.

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5.3.2.7 Rider roller group

The rider roller group is composed of a rider roller (1), mounted on a moving beam (2), and a pair of
recirculating ball screws (3), one on each side.

The rider roller is an idle roller, installed on a moving beam. The rider roller follows the reel as it increases
in size, varying the pressure exerted on the reel itself, based on the diameter.

The moving beam moved by two carriages (4), that are set into motion by a pair or recirculating ball screws

The rider roller can be blocked in any position by means of a system composed of two negative calliper
pneumatic brakes (5).

5 5

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5.3.2.8 Width-wise cutting group

The width-wise cutting group is composed of a moving bar (1) fitted with a blade (2).

This cutting group executes the final cut on the daughter reel/s.
On completion of the rewinding stage, the reel is positioned on the unloading table; the material is spread
out on the table, and two pneumatic cylinders (3) lower the moving bar onto the table to cut the material.

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5.3.2.9 Ejector group

The ejector (1) serves to eject the reel at the end of the rewinding cycle and place a new shaft on the carry
drums.

The new shaft is positioned by means of the pneumatic opening of the shaft storage area (2)..

The ejected reel comes to rest on the unloading table (3) which rotates on its anchoring axis, thanks to the
action of two pneumatic cylinders, thereby releasing the reel onto the ground, where it can be retrieved by
the designated operator, using appropriate handling equipment.

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Extractor
The extraction system extracts the shaft from the reel at rewinding head outfeed and then transfers the
shaft to the carry drum area.

The deflation unit (1) releases the pressure of the shaft inserted in the reel that is on the shuttle.

The handling system (2) approaches the shaft, the wheels close and the system comes to a stop to pick up
the shaft.
At this point, the wheels activate again to transfer the shaft onto the cradle (3).

As the shaft is being transferred to the cradle, the cardboard cores that were previously loaded by the
operator, are inserted inside the shaft itself.

The shaft is unloaded and allowed to roll until it reaches the transfer unit (5); this latter unit pusher the shaft
away from the rewinding head fixed guards.

The shaft is deposited on the chain table (6), which is fitted with porters that accompany that shaft onto
the feeder (7).

The feeder is equipped with a swinging pusher (8) that positions the shaft inside the rewinding head.

4
6

1 7

2 8

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Hydraulic control unit

The machine is equipped with an hydraulic control unit (1) that manages machine movements.

For the characteristics of this control unit, please consult the manual provided by the manufacturer of the
control unit.

Electrical cabinet
The electrical cabinet is composed of an electrical cabinet (1) installed outside the machine’s all-around
safety guards. The cabinet houses all the elements required to manage the machine’s command and
control logic and safety logic.

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5.4 Additional groups

Trim removal
The machine is designed to allow installing a trim removal system. For the characteristics of the vacuum
system, please consult the system manufacturer’s instruction manual.

Unwinders – rewinder paper threading system

The unwinders - rewinder paper threading system is designed and constructed to allow threading paper
plies through the unwinding area and up to the rewinding section.

The paper threading system is composed of two passages that use belts to fully thread the ply between the
unwinders and the rewinder.

The system is composed of a series of pullies on which a flat belt with special slits runs.
The operator inserts the paper inside the slits and then starts the machine in slow speed from the outside,
to thread the paper inside the area.

Rewinding head paper threading system

The rewinding head paper threading system is designed and constructed to thread the paper plies from the
rewinding area to the front section of the carry drums.

The system is composed of a series of pulleys on which a slitted flat belt runs.
The operator inserts the paper inside the slits, and when the machine is started running from the outside,
the paper is threaded inside the area.

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Automatic lubrication system

Where possible, an automatic lubrication system may be provided, managed through a dedicated control
unit (1). The manual lubrication points are equipped with special greasing nipples that are easy to reach.

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5.5 Technical data

General characteristics

Data Value Units

Drive side (as per layout) right -
MAXIMUM design speed 1600 (shafted configuration) m/min
Varies based on the machine
Actual operating speed configuration, paper quality, number -
of knives, etc.
Acceleration 16 m/min/s
Fast stop 45 m/min/s
Emergency stop 100 m/min/s

Product characteristics

Data Value Units

Type of product Paper tissue mother reel
Grammage (per ply) 15 -35 g/m2
Crepe ratio 5 - 12 %
Maximum width of untrimmed mother reel 3640 mm
Minimum width of untrimmed mother reel 3300 mm

System characteristics
5.5.3.1 Electrical system

Data Value Units

Rated tension 440 Vac
Auxiliaries tension 24 Vdc
Number of phases 3 Nr
Frequency 60 Hz
Circuit breaking power of the safety device 50 kA
Electrical board protection IP 54 -

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5.5.3.2 Pneumatic system

Data Value Units
Air characteristics Dry, filtered air -
Working pressure 6 Bar

5.5.3.3 Oil-hydraulic system

Consult the characteristics contained in the oil-hydraulic control unit manual, annexed to this use and
maintenance manual.

Characteristics of the work environment

Data Value Units

Light industrial environments,
Work environment -
indoors, well-aired and well-lit
Ambient temperature 15 ÷ 55 °C
Humidity at 40 °C 95 %
Storing temperature See note (1) -

NOTE (1): If the machine is stored idle, the storing temperature may vary between -10 °C ÷ +55 °C (with
peaks of up to 70 °C for a period no longer than 24 hours), provided that all other precautions are taken.

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Overall size and space requirements

NOTA: dimensioni in mm.

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5.6 Noise
The machine is designed and manufactured so as to minimise air noise emissions at source (Machine
Directive 2006/42/EC, Annex I, par. 1.5.8.).

IMPORTANT

NOISE RISK ASSESSMENT

To assess noise risk, please pay particular attention to the following points:
• The type of product being machined and the environment where the machine is installed may affect
the noise levels indicated.
• Permitted exposure levels may vary from one country to another; the instructions provided in this
manual refer to current standards within European Union member states.
• The factors that determine the exposure level to which the labour force is subjected include the
duration of the exposure, the characteristics of the work place and other sources of noise (number of
machines, adjacent processes, etc.).

The environment in which the rewinder is to be installed is foreseeably a noisy environment due to the
proximity of the paper converting machine. The noise generated by the paper making machine is generally
louder than that generated by the rewinder.

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6 TRANSPORTATION AND UNLOADING

6.1 Shipping information
The machine is shipped in perfect working order, after having been tested at the manufacturer’s plant.

The manufacturer will use suitable packing based on the type and size of the components to be shipped,
in order to guaranty protection against damage during shipment and up to delivery to the customer.

Depending on the distance to the place of delivery, customer instructions and the time that the machine will
remain packaged, the manufacturer will decide whether to transport the machine directly on the truck
platform or inside a container. The number and type of truck and/or container may vary based on the load
units to be shipped.

In view of a long stay in packaging or sea freight, appropriate precautions will be taken as required to
prevent oxidation and rusting of metal parts and the formation of humidity and condensation in the electrical
equipment.

DANGER

VARIOUS HAZARDS DERIVING FROM LOAD HANDLING

Load handling may entail various risks (crushing, shearing, etc.) for persons present in the areas where
machine handling is taking place.
• Machine unloading and handling must be carried out only by skilled technicians trained and informed
on load handling activities.
• Load unloading and handling areas must be marked off and accessible only to designated personnel.

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6.2 Equipment required for unloading

The customer receiving the machine must have all the unloading and handling equipment listed below. The
equipment must be appropriate for the mass of the various load units and suited to the characteristics of
the unloading area.

Equipment Required
YES

Crane and/or overhead

travelling crane

YES

Lift-truck

YES

Hoisting straps

YES

Eyebolt

YES

Adjustable chains

YES
Balancing rod

Ladders and scaffolding YES

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6.3 Preparing the unloading area

Follow the instructions provided below to prepare a specific area for unloading.

Procedure:

1. Reserve a work area large enough to allow for easy and convenient machine unloading. The haulage
truck and unloading and hoisting equipment must be able to manoeuvre easily in the area.
2. Mark off the area and forbid access to persons not authorised to carry out unloading operations.
3. If unloading in a closed environment, hoisting equipment must be selected taking into account the
minimum ceiling height (h) that may limit manoeuvres.

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6.4 Unloading from the means of transportation

Follow the instructions provided to correctly upload the machine from the means of transportation.

Procedure:

1. Use ladders and scaffolding to climb up and down the means of transportation. Do not climb onto the
means of transportation or the load units.
2. Check that the load units have not shifted during transportation; otherwise, immediately inform the
carrier and the manufacturer.
3. Always start unloading the load units that are easiest to reach, unloading one unit at a time.
4. Find the hook-up points on the load units and anchor the hoisting equipment before removing the straps
and beams blocking the load.
5. Reach the hook-up points on the load units. Anchor the hoisting devices and tension them slightly
without lifting the load.
6. Remove the blocks and straps used to stabilise the load units during transportation, to allow lifting.
7. Move away from the loads and begin unloading.

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6.5 Handling the load units

Follow the instructions provided below to correctly handle the load units.

Procedure:

1. Load units may bear illustrations that specify the type of hoisting required or other useful information.
Abide by these warnings and always follow the instructions provided. The table below describes the
meaning of the symbols that may appear on the load units.

SYMBOL DESCRIPTION

ISO 780 symbol 6.

Harnessing point on which to attach the hoisting equipment (straps, chains, etc.).

ISO 780 symbol 1.

Fragile. Load and unload with caution.

ISO 780 symbol 7.

Keep the pack dry and protect it against inclement weather.

ISO 780 symbol 3.

Keep this end up. Do not turn the pack upside down.

ISO 780 symbol 8.

Barycenter. Centre of gravity of the pack.

ISO 780 Symbol 2.

Do not use hoisting hooks.

DIN 30600 N.02903

Do not use lift-trucks.

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6.6 General notes for lifting and handling

The load units may be lifted and then handled in two different ways:

LIFTING FROM BELOW Use the forks of a lift-truck or transpallet appropriately inserted in
the special slots with which the load unit is provided.
HOISTING FROM ABOVE Use chains, ropes, harnesses, etc. connected to eyebolts (where
present) or passed around the load unit, at the hoisting points
provided.

To lift the load unit correctly, use lifting equipment with a load capacity that is sufficient for the weight to be
lifted.

Procedure:

1. Make sure that the lifting equipment is centred with respect to the barycentre of the units
2. Lift and handle the load unit keeping it level and avoiding bumps and jolts.
3. Unload carefully, placing the load unit as close as possible to the point of installation, and lowering it to
the ground very slowly to avoid damaging fragile parts.
4. Loading equipment must be run and operated by trained personnel, assisted on the ground by a
signalman, seeing as the size of the machine does not allow for sufficient manoeuvring visibility.

WARNING

VARIOUS HAZARDS DERIVING FROM LOAD HANDLING

During load lifting and handling there is a risk of colliding with the load and of remaining crushed between
the load and fixed structures (machines, building structures, etc.).
• Lifting and handling work must be carried out by specialised personnel (crane slingers, crane
operators, lift-truck operators, etc.), coordinated as required by a skilled signalman.
• Hoisting equipment must be adequate to the weight of the load units to be handled. This equipment
must also be in excellent condition and certified to lift the weight of the machine safely.
• While lifting and handling the various load units, only personnel designated to unloading and handling
should be present in the work area, in compliance with general safety rules that call for a safety area
around suspended loads, moving lift-trucks and/or travelling cranes.
• Do not stand or walk under suspended loads.
• Authorised operators must be provided with the personal protection equipment required for hoisting
work.

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6.7 Unpacking
On delivery of the supply, follow the instructions provided below to correctly unpack the load units.

Procedure:

1. Open the pack protecting each module.

2. Check that the contents are in perfect conditions and correspond to the description present on the bill
of lading.
3. Once the packaging has been removed, no inconveniences or tampering should be found; otherwise,
immediately inform the carrier and the manufacturer.

IMPORTANT

Packaging materials must be disposed of by the addressee, who must do so in compliance with current
laws in force in the country where the machine is to be used.
• Unpack the load units taking care to separate and select waste material deriving from packaging
elements.

4. For some machines, mechanical parts are blocked by using wood wedges to keep components from
moving and/or avoid damage to the various units during transportation.
5. Generally, this method is not adopted for our machines; however, if necessary, the points on the
machine where the wedges are inserted will be well marked.

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6.8 Lifting the machine

Identification of load units
For transportation purposes, the machine is subdivided into various load units, which are univocally
identified by the numbering on each case (1).

The numbering of the cases is specified in the packing list (2), which provides all the information required
to correctly identify each case.

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Examples of lifting of load units

6.8.2.1 General

# Description Type of hoisting

1 Cage From above
2 Case From below
3 Electrical panel From above
4 Supplementary units From below

2
1

3 4

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6.8.2.2 Unwinder

# Description Type of hoisting

1 Unwinder arm From above
2 Base From above
3 Side frame From above

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6.8.2.3 Rewinding head

# Description Type of hoisting

1 Rewinding head part 1 From above
2 Rewinding head part 2 From above

1 1

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6.8.2.4 Extractor

# Description Tipo di sollevamento

1 Main frame Alto

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6.9 Temporary storage

If the machine must be stored for a given period of time while waiting to be installed, follow the instruction
provided below.

Procedure:

1. Prepare a covered area protected against atmospheric agents and large enough to store the machine.
2. Leave the load units in the original packaging used to ship the machine.
3. Cover the load units with sheets to avoid dust deposits.
4. Always check that storing temperatures remain within the range defined in the technical data.

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7 INSTALLATION AND START-UP

7.1 Floor requirements
As regards the required civil engineering work and levelling of the surface on which the machine is to stand,
the machine must be positioned on an industrial floor, perfectly designed and constructed in accordance
with current legislation and technical standards in force in the country of installation and start-up (for
example, for Italy, the Standards are UNI 11146-2005 Concrete floors for industrial use – criteria for design,
construction and testing).

The floor must also be tested and must undergo scheduled maintenance to ensure functionality for the
entire foreseen service life.

Rheological and mechanical properties of the cement conglomerate, necessary to ensure that the floor
maintains its functionality unaltered for the entire service life of the project, must be defined taking into
account:

• Requirements tied to execution issues during construction.

• Static and dynamic loads during work.
• Possible aggressive conditions.
• Whether or not an anti-slip finish is required

The flat surface must not present irregularities, either convex or concave, and maximum deformation,
measured at a distance of 2 metres, must be ± 3 mm (1.5%), and never greater than ± 5 mm (2.5%).
Definitions according to classes A and B of UNI 11146 Standards.

Civil engineering work

Where not otherwise agreed upon, all civil engineering work required to prepare the installation is the
customer’s responsibility and at customer’s expense. Required civil engineering work is described in the
specific layout.

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Preparation of flooring and machine bases

For information regarding how to prepare the flooring and the foundation bases on which to rest the
machine, consult the layout diagrams attached to this manual and/or transmitted during the order stage.

Reference layouts
• “GV.260240 General View CFD”
• “CW260240 - Civil works CFD”
• “FL260240 - Foundation and Load CFD”

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7.2 Mechanical assembly

Requirements for mechanical assembly
The customer to whom the machine is delivered must prepare for mechanical assembly of the machine as
described in the procedure below.

Procedure:

1. Check the size and load capacity of the floor based on the size and load capacity of the weight it must
bear, beforehand.
2. Reserve a work area large enough to allow for easy machine assembly. The hoisting equipment
required for assembly must be able to easily manoeuvre in the area.
3. Mark off the work area and forbid access to unauthorised persons not involved in assembly work.
4. To choose the hoisting means, take into account the minimum structure height (h), which may limit
manoeuvres.
5. Provide for suitable raceways and pipes to connect the machine to energy supplies (electrical,
pneumatic, etc.)

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Assembly and positioning

The specific assembly and positioning procedures must be evaluated directly at the installation site, based
on the actual conditions of the plant, layout of the machines already present and the equipment and tools
provided by the final customer.

IMPORTANT

All the RED structures are used exclusively for transport and assembly, and must be removed before
commissioning the machine.

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7.3 Installation and assembly instructions to reduce noise

In working conditions that are conformant to the conditions for proper machine use, the noise generated
does not generate hazard conditions.

7.4 Installation and assembly instructions to reduce

vibrations
In working conditions that are conformant to the conditions for proper machine use, the vibrations generated
does not generate hazard conditions.

7.5 Illumination
The lighting of the site where the machine is installed must comply with laws currently in force in the country
where the machine is installed and must in any event guarantee good visibility of all points, must not create
dangerous glares and must allow for easy reading of the control panels and easy identification of the
emergency pushbuttons.

The machine is fitted with separate lighting system, and the work environment must also provide overall
illumination of the work space such as to guarantee lighting values between 200 and 300 lux at every
machine point.
The lights inside the electrical cabinets and/or in the shunt boxes are always powered. They may be turned
on and off from inside the electrical cabinet.

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7.6 System connections

Electrical connections

IMPORTANT

The electrical equipment must be assembled in compliance with laws currently in force regarding
electrical circuit safety.
• The manufacturer of the final machine is responsible for assessing compliance to applicable directives
and standards.

The customer and end-user must prepare for machine electrical work and connections as follows:

• Prepare the raceway between the machine’s electrical board and the main power board.
• All "connection" work must be performed by specialised personnel and is always responsibility of
the customer and end-user.

DANGER

ELECTROCUTION HAZARD
Poor electrical connections and wiring may engender electrical hazards.
• Make sure that the machine’s electrical board is actually suited to grid electrical tension. If the supply
tension needs to be modified, contact the Manufacturer.
• If work is required on the electrical plant upstream of the main switch (for example, inversion of phases),
the main line switch must be blocked in the OFF position so that only the maintenance technician can
reset it (for example, using a lock).

Procedure:

1. The electrical system and the earth line must be conformant to the provisions of regulations and laws
currently in force in the country where the machine is installed.
2. If the machine power line does not have an over-current safety switch, the customer must install this
safety device. The wiring diagram contains the data regarding: type of device, rated current, adjustment
or calibration against over-currents and short circuits. If there is a neutral conductor, the over-current
safety device is not necessary, if the conductor cross section is the same as that of the phase
conductors.
3. Check that the grid tension corresponds to that specified on the wiring diagrams.
4. Connection to the electrical grid must be executed only through the specific terminal board inside the
electrical cabinet and the ground connection provided.
5. It is important that there are no tension drops and peaks on the “lines”, and it is indispensable that the
connection cables have a cross section that is sufficient for the installed electrical power.

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7.6.1.1 Notes for the correct connection of the power line or earth line
The connections must be performed in full respect of the section and the colour of the connection cables
as stated in standard EN60204-1:2006.

Procedure:

6. Connect phases L1 L2 L3 to the main switch of the electrical plant.

7. Connect the protective equipotential conductor (PE) to the earth bar.

Note: When there is a neutral [N] cable in addition to the three phases, please refer to the instructions
provided in the wire diagram.

DANGER

ELECTROCUTION HAZARD
Poorly executed electrical connections or wiring can cause electrical hazards.
• It is forbidden to connect more than one protective conductor to a single point.
• It is forbidden to connect more than one cable a single conductor.

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7.6.1.2 Connection to the equipotential protection circuit

Prerequisites:

• All the connection work must be executed by specialised personnel as is the responsibility of the
end customer of the machine.

Procedure:

1. Connect the masses to the equipotential protection circuit (PE) of the machine.
The connection points are identified by the presence of a screw (1), to which the connector must be
attached, and the earth symbol (2).

For details regarding the connection point, please consult the attached diagrams:
“GC.260232.00_GroundConnection_CFA”:

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7.6.1.3 Pneumatic panel (main disconnector)

2 3

# Description
1 Line air connection
2 Lockable cut-off valve
3 Pressure regulator
4 Manometer

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Hydraulic system connections

To connect the hydraulic system, consult the instructions contained in the hydraulic control unit (1) manual,
following the diagrams accompanying this use and maintenance manual..

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7.7 Commissioning (first start-up)

DANGER

VARIOUS MECHANICAL RISKS DERIVING FROM THE ABSENCE OR TEMPORARY DISABLING

OF MACHINE SAFETY DEVICES
During initial machine start-up, safety devices may be removed or disabled for technical reasons.
• Only expert personnel (maintenance technicians and/or manufacturer technicians), trained and
instructed regarding the risks entailed are authorised to work on the machine when safety devices
have been removed or temporarily disabled.
• Personnel designated to run the machine (machine operator) must be informed of the risks present
during this stage and must keep away from danger areas.
• It is obligatory to place a warning sign in the area and stay away from machine danger areas.

Checks required prior to first start-up

Please perform the following checks before testing machine movements.

Procedure:

1. Check that mechanical and electrical assembly work, as described in the previous paragraphs, has
been fully completed.
2. Power the machine and check that all power sources work properly.
3. Check that all machine controls and signals from detection and control devices (sensors, photocells,
etc.) are correctly transmitted to and received by the PLC input.

Testing machine movements

Follow the procedure described below to test machine movements.

Procedure:

1. Power every single motor and check the direction of rotation.

2. Test all machine movements that may be controlled manually.
3. Test all the work cycles.

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First machine start-up

The first machine start-up must be performed by our assistance service or by the maintenance technician,
after having been duly trained. The procedure for first machine start-up may be executed without the
product, to check that all machine units are in working order, and subsequently with the product to be
machined, to check proper machine functioning.

DANGER

MECHANICAL RISKS CAUSED BY MACHINE START-UP

Untimely machine start-up while personnel are still working on moving parts or power circuits engenders
risks for any “exposed” person".

7.8 Start-up after a long idle period

If the machine has been left idle for a long period of time, the procedure described for the first machine
start-up must be repeated.

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8 CONTROLS AND WARNING SIGNS

8.1 Position of the control panels and warning signs

20

12 5 10

19

18

14

13

17 15 1 16 11 3 2 7 6 8
4 9
# Description
1 Rewinder pushbutton control panel– 151JB630
2 Unwinder 1 pushbutton control panel - CB122
3 Unwinder 2 pushbutton control panel – CB124
4 Unwinder 1 pushbutton control panel – CB120
5 Unwinder 1 pushbutton control panel – CB121
6 Unwinder 2 pushbutton control panel – CB222
7 Unwinder 2 pushbutton control panel – CB225
8 Unwinder 2 pushbutton control panel – CB224
9 Unwinder 2 pushbutton control panel – CB220
10 Unwinder 2 pushbutton control panel – CB221
11 Walkway pushbutton control panel – 151CB620
12 Walkway pushbutton control panel – 151CB621
13 Rewinder pushbutton control panel – 151CB616
14 Rewinder pushbutton control panel – 151CB614
15 Rewinder pushbutton control panel – 151CB612
16 Rewinder pushbutton control panel – 151CB618
17 Unloading table pushbutton control panel – 151CB775
18 Extractor pushbutton control panel – 151CB831
19 Extractor pushbutton control panel – CB824
20 Extractor pushbutton control panel –CB826
- Pulsantiera centralina idraulica –151JB670
- Quadro elettrico.

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8.2 Main control panel – 151JB630

1 2

3 4 5

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
EMERGENCY RESET
2 Press to check and reset safety devices. Machine controls are enabled only if all the safety devices
and functions have been correctly reset.
FAST STOP
3
Press to command a fast machine stop.
TH BELT ON/OFF
4
Ruotare per attivare o disattivare la cinghia di passaggio carta.
CRAWL SPEED
5
Premere per attivare la marcia lenta autoritenuta.

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8.3 Pushbutton Unwinder 1 - CB 122

2 3 4 5
6

# Function
TOUCH SCREEN
1
For all touch screen functions and features, see the software manual.
POWER SUPPLY PRESENCE
2
Pilot light that signals the presence of power.
STOP REWINDER
3 Press to stop the work cycle. After the work cycle has been stopped, power to the drives is not cut
off and the machine is ready to be restarted.
FAST STOP REWINDER
4
Press to execute a fast machine stop.
UNW AREA THREADING
5 Press to activate slow speed operation for threading (enabled unwinders and paper threading
belt).
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
6 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.

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8.4 Pushbutton Unwinder 1 – CB120

2 2
4 1 3

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
JOG
2 Press the two buttons simultaneously to start the unwinder in JOG mode.
• Release to stop movement
JOG REVERSE
3
Use the selector to select reverse JOG mode.
4 NON IN USE

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8.5 Pushbutton Unwinder 2 - CB 222

2 3 4 5
6

# Function
TOUCH SCREEN
1
For all touch screen functions and features, see the software manual.
POWER SUPPLY PRESENCE
2
Pilot light that signals the presence of power.
STOP REWINDER
3 Press to stop the work cycle. After the work cycle has been stopped, power to the drives is not cut
off and the machine is ready to be restarted.
FAST STOP REWINDER
4
Press to execute a fast machine stop.
UNW AREA THREADING
5 Press to activate slow speed operation for threading (enabled unwinders and paper threading
belt).
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
6 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.

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8.6 Pushbutton Unwinder 2 – CB220

2 2
4 1 3

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
JOG
2 Press the two buttons simultaneously to start the unwinder in JOG mode.
• Release to stop movement.
JOG REVERSE
3
Use the selector to select reverse JOG mode.
4 NON IN USE

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8.7 Pushbutton Unwinder 1/2 – CB121 – CB 221

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.

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8.8 Walkway pushbutton control panel– 151CB620

1 2

3 4 5 6

7 8 9 10

11 12 13 14

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
UNWINDER SELECT
2
Turn to select the unwinder to be moved.
CRAWL SPEED
3
Press to activate continuous slow speed.
KNIVES BEAM
4 Press to position the knives in the low position (cutting position) or in the high position (paper
threading position).

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# Function
MIDDLE KNIVES
5
Press to activate / deactivate the middle knives.
TRIM KNIVES
6
Press to activate / deactivate the side trim knives.
TRIM CUT
7
Press to activate / deactivate the side trim cut.
STOP REWINDER
8 Press to stop the work cycle. When the work cycle has been stopped, power to the drives is
maintained and the machine is ready to be restarted.
FAST STOP REWINDER
9
Press to execute a fast machine stop.
10 NOT ENABLED
KNIVES FENCE UNLOCK
11
Press to enable opening the movable guard on the knife group.
UNWINDER CENTERING
Turn and hold in position:
12 • “LEFT”, to move the selected unwinder to the left.
• “RIGHT”, to move the selected unwinder to the right
Release to stop movement.
IN SPREAD
Turn and hold in position:
13
• “CW”, to rotate the calander spreader roller clockwise.
• “CCW”, to rotate the calander spreader roller counter-clockwise.
TRIM SUCTION
Turn and hold in position:
14
• “DS”, to shift the trim suction mouths towards the drive side.
• “TS”, to shift the trim suction mouths towards the operator (tender) side.

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8.9 Walkway pushbutton control panel – 151CB621

2 3

4 5

6 7

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
STOP REWINDER
2 Press to stop the work cycle. When the work cycle has been stopped, power to the drives is
maintained and the machine is ready to be restarted.
FAST STOP REWINDER
3
Press to execute a fast machine stop.
MIDDLE KNIVES
4
Press to activate / deactivate the middle knives.

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# Function
TRIM KNIVES
5
Press to activate / deactivate the side trim knives.
TRIM SUCTION
Turn and hold in position:
6
• “DS”, to shift the trim suction mouths towards the drive side.
• “TS”, to shift the trim suction mouths towards the operator (tender) side.
KNIVES FENCE UNLOCK
7
Press to enable opening the movable guard on the knife group.

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8.10 Rewinder pushbutton control panel– 151CB616

2 3 4

5 6 7

8 9

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
TH BELT ON/OFF
2
Turn to activate or deactivate the paper threading belt.
OUT SPREAD
3
Turn the selector to orient the spreader roller arrow (clockwise CW and counter-clockwise CCW)
RIDER ROLL UP/DOWN
4
Turn to raise or lower the rider roller.

124/226 Rev: A
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# Function
STOP REWINDER
5 Press to stop the work cycle. When the work cycle has been stopped, power to the drives is
maintained and the machine is ready to be restarted.
CRAWL SPEED
6
Press to activate continuous slow speed.
FAST STOP REWINDER
7
Press to execute a fast machine stop.
MIDDLE KNIVES
8
Press to activate / deactivate the middle knives.
TRIM KNIVES
9
Press to activate / deactivate the side trim knives.

Rev: A 125/226
8 CONTROLS AND WARNING SIGNS

REELITE | 15 T

8.11 Rewinder pushbutton control panel – 151CB614

2 3 4

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
CHUCKS OPEN / CLOSE
Turn to the position:
2
• “OPEN” to open the chucks.
• “CLOSE” to close them.
CHUCKS UP / DOWN
Turn to the position:
3
• “UP” to raise the chucks.
• “DOWN” to lower them.
TAIL BLOW
4
Press to flip the plies over on the shaft using a blow of air.
5 BYPASS

126/226 Rev: A
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8.12 Unloading table pushbutton control panel – 151CB775

3 4

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
PLANE DELIVERING/RECEVING
2
Turn the selector to start rotation of the unloading table in the delivering or receiving position.
BARRIER RESET
3
Press this button to reset the safety barrier.
BARRIER TRIPPED
4 Photoelectrical barrier status pilot light. When the light is on, the barrier has been tripped and
must be reset.

Rev: A 127/226
8 CONTROLS AND WARNING SIGNS

REELITE | 15 T

8.13 Extractor pushbutton control panel – 151CB831

3 2

# Function
TOUCH SCREEN
1
For the functions and features of the touchscreen, consul the software manual.
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
2 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
STOP OPERATION
3
Press to stop the extractor operating sequence.

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8.14 Hydraulic control unit pushbutton control panel –

151JB670

2 1

# Function
EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
1 machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
• Once pressed, turn to release.
POWER SUPPLY PRESENCE
2
Power supply present pilot light.

Rev: A 129/226
8 CONTROLS AND WARNING SIGNS

REELITE | 15 T

8.15 Access request pushbutton control panels – CB124 –

CB 224 – CB 225 - CB121 - 151CB612 - 151CB618 –
CB824 – CB826

# Function
GATE UNLOCK REQUEST TO ENTER
1
Press to request access to the rewinder area.
GATE LOCK RESET
2
Press to reset the rewinder area.

130/226 Rev: A
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8.16 Signal tower

# Function
RED LIGHT
1
Emergency stop signal light.
YELLOW LIGHT
Process error signal light.
2 • “ON”, persistent error that blocks the process.
• “OFF”, no error.
• “FLASHING”, error detected; intervene before the process is blocked.
GREEN LIGHT
Normal process running signal light.
3
• “ON”, work cycle started.
• “OFF”, standby for reset and start-up.
WARNING HORN
4
Sounds to signal machine start-up.

Rev: A 131/226
8 CONTROLS AND WARNING SIGNS

REELITE | 15 T

8.17 Electrical cabinet

# Function
1 MAIN SWITCH
Turn the switch to:
• “ON”, to power the machine.
• “OFF” to cut off power to the machine.
• The switch may be locked in the OFF position using special clamps and/or padlocks.
2 EMERGENCY STOP
Press in the event of imminent personal danger. The emergency stop has priority over all other
machine controls. Once the machine or hazardous machine functions have come to a stop, power
to the respective drives is cut off.
Once pressed, turn to release.

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9 USE
9.1 Turning on the machine
Prerequisites:

• The machine must be in condition to be powered. Powering the machine must not generate
unforeseen risks.
• If maintenance has been carried out on the machine, check that all dismantled parts have been
properly replaced.
• All machine guards and safety devices must be assembled and functioning.
• Doors to the electrical cabinet and all the boxes containing live parts must be closed.

Procedure:

1. Check that no one is in the machine hazard areas.

2. Turn the MAIN SWITCH to the “ON” position to power the machine electrically.
3. Turn all the valves to the “OPEN” position to provide pneumatic power to the various machine areas.

Rev: A 133/226
 9 USE

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9.2 Resetting safety devices

Prerequisites:

• The machine must be powered.

• All emergency pushbuttons must be released.

Procedure:

1. Check to make sure no one is inside the areas protected by guards and close all the access gates.
2. Press the GENERAL RESET pushbutton (Main control panel 151JB630 > #2), and check that the
safety logic resets.
3. If the safety logic does not reset, check for active alarms. Identify and clear the causes and press the
reset pushbutton again.

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9.3 Access procedures

IMPORTANT

NUMBER OF OPERATORS PERMITTED

Where not explicitly otherwise indicated, the machine may be accessed by ONLY ONE operator at a
time. If the presence of a second operator is required, follow the instructions provided in the specific
procedures.

Access to the unwinders

Prerequisites:

• The machine must be stopped.

Procedure:

1. Open the door (1) through which you want to enter the area.
2. Enter the area and perform the necessary tasks.
3. Exit the area.
4. Make sure no one else is inside the machine.
5. Close the door.

1 1 1

Rev: A 135/226
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Access to the cutting area

ATTENTION

CUTTING HAZARD
Be careful of the cutting edge of the knives and anvil knives.
• It is OBLIGATORY to wear appropriate PPE (cut-proof gloves) for any kind of work on the cutting
unit.
• Whenever it is necessary to handle the knives and/or anvil knives, the starting point and
destination must be clearly known and the space between the two must be clean and cleared of
any obstacles.
• Make sure the knives and/or anvil knives are temporarily placed in a location that ensures they
are stable and is indicated by a cutting hazard warning sign.

9.3.2.1 Access from the walkway

Prerequisites:

• The machine must be stopped.

Procedure:

1. Access the machine from the walkway (1).

2. Raise the knife guard.
3. Carry out the required tasks.
4. Close the knife guard.

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9.3.2.2 Access from the ground

Prerequisites:

• The machine must be stopped.

Procedure:

1. Access the walkway (1).

2. Raise the guard on the knife group.

3. Step off the walkway.
4. Manually open the walkway.
5. Execute all the interventions required inside the cutting group.
6. Make sure that no one and/or nothing is inside the area.
7. Manually close the walkway.
8. Access the walkway (1).
9. Lower the knife guard.

Rev: A 137/226
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Access to the area inside the rewinding head

Prerequisites:

• The machine must be stopped.

• All the doors must be closed.

Procedure:

1. If necessary, raise the rider roller using the RIDER ROLLER control (1).

2. Open the access door on the operator side (2).

3. Access the area and carry out the required tasks.
4. Exit the area.
5. Make sure no one is inside the machine.
6. Close the door.

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Access to the reel outfeed area

Prerequisites:

• The machine must be stopped.

Procedure:

1. Open the door (1).

2. Access the area and carry out the required tasks.
3. Exit the area.
4. Make sure no one is inside the machine.
5. Close the door.

Rev: A 139/226
 9 USE

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Access to the core feeder area

Prerequisites:

• The machine must be stopped.

Procedure:

1. Open the door (1) o to the sliding door (2).

2. Access the area and carry out the required tasks.
3. Exit the area.
4. Make sure no one is inside the machine.
5. Close the door.

1
2

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9.4 Operating adjustments and procedures

Preparing the mother reel
Preparation of the mother reel entails a series of operations that must be carried out outside the machine
before loading the reel onto the unwinders, in accordance with the internal procedures set forth by the end
customer.

Operations to be carried out:

6. Clean the reel: Remove a certain number of layers of paper to even out the surface of the reel and
make sure there are no imperfections.
7. Braid the paper: The paper must be braided (1) so that when the reel is loaded into the machine, the
of the braid is positioned on the OPERATOR SIDE, based on the unwinding direction of rotation.

Rev: A 141/226
 9 USE

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Unwinder enabling / disabling

Prerequisites:

• The machine must be stopped.

• The doors to the unwinding area must be closed.

ENABLING

Procedure:

• Press the REEL CENTERING control (1) (HMI-UNW>MAIN PAGE), to bring the unwinding
belts into contact with the mother reel and ENABLE the unwinder.
• When the unwinder is enabled, the message “Unwinder ready” appears on the main HMI page
of the unwinder in question (2)

1. Engage the AXIAL BRAKE by pressing the AXIAL BRAKE control (2) (HMI-UNW>SECONDARY
PAGE); and wait for the command to be executed, checking that the green pilot light next to the control
turns on.

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DISENABLING

Procedure:

2. Press the REEL CENTRING control (4) (HMI-UNW>MAIN PAGE), to move the unwinding belts away
from the mother reel and DISABLE the unwinder.
• When the unwinder is disabled, the paper reel is not present on the main HMI page of the
unwinder in question (5).

3. Press the AXIAL BRAKE control (6) (HMI-UNW> SECONDARY PAGE) to disengage the axial brake.

Rev: A 143/226
 9 USE

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Loading the mother reel

Prerequisites:

• The machine must be stopped.

• The unwinder must be empty of shafts and/or reels.
• The area must be free of persons and objects.
• The doors to the unwinding area must be closed.
• Axial transmissions of the unwinders disinserted.
• Carry out the procedure to prepare the mother reel.

Procedure:

1. Pick-up the reel from the storage area (1), using appropriate hoisting equipment.
2. Move the reel slowly until it is above the unwinder, taking care not to bump into surrounding structures.

1
1

3. Check the unwinding direction of the reel and rotate is as required, so that the braid made during the
preparation stage (to be executed before inserting the reel in the machine) is on the OPERATOR SIDE.
4. Slowly lower the reel, making sure that ends of the unwinding shaft (2) insert correctly in their seats (3)
on both sides of the unwinder.

2
3

144/226 Rev: A
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5. Once the mother reel has been positioned, remove the hoisting equipment from the shaft and move it
away from the machine.
6. Block the shaft using the HOLD SHAFT control (4) (HMI-UNW>PAGINA PRINCIPALE)
7. wait for the pilot light to turn green.

IMPORTANT

POSITIONING THE MOTHER REEL

The mother reel must be positioned so that the braid on the reel is on the OPERATOR SIDE, so that in
order to thread the paper through the machine the operator does not need to climb onto the machine
frames and unwinder slides to reach the braid on the mother reel.

Rev: A 145/226
 9 USE

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Paper splicing
Number of operators required:

• N. 1 Operator (necessary)
• N. 2 Operators (recommended).

IMPORTANT

ACCESS OF THE SECOND OPERATOR

Access of the second operator to the machine area is permitted only for those operations where it is
specified that “n. 2 operators are permitted”.

The unwinding area may be accessed and the required operations may be executed only after having
opened and blocked the lock of a second door, up-line or down-line of the area where the work
procedures are to be carried out.

Opening two doors in the unwinding area prevents unexpected machine movements in the entire
unwinding area.

Prerequisites:

• The machine must be stopped.

• The mother reel must be loaded on the unwinder.
• The mother reel must be “clean”
• The unwinder where the splice is to be executed must be enabled.

Procedure:

1. Access the unwinding area.

2. Position the end of the paper on the mother reel (1), on top of the paper present on the paper slides
(2).
• “If necessary”, accumulate paper by pressing the JOG run control on the pushbutton panel near
the unwinder controls.

3
2

3. Apply double-sided tape (3) to the paper on the slides (n. 2 operators permitted),
4. Attach the tail end of the paper from the mother reel to the double-sided tape (n. 2 operators permitted).
5. Exit the area, making sure no one and nothing is in the area inside the guards, and close the door..

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Replacing the mother reel

Prerequisites:

• The machine must be stopped.

Procedure:

1. Access the unwinding area.

2. Cut the paper directly on the unwinding shaft, so as to guaranty a certain tail length for splicing.
3. Exit the area, making sure no one and nothing is in the area inside the guards, and close the door.
4. Wait for the “Air pressure” pilot light (1) to turn green (pneumatic circuit pressurised)..

1
1

5. Select manual operating mode by pressing the control: Combiner MANUAL MODE (2).
6. Move the unwinding arm away using the UNWINDING ARM command (HMI-UNW>PAGINA and wait
until the light next to the control turns green.

3
2

Rev: A 147/226
 9 USE

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7. Disengage the axial brake, by pressing the AXIAL BRAKE control (4) (HMI-UNW>SECONDARY
PAGE)

8. Eject the shaft by pressing the SHAT BLOCK/EJECT control (5) (HMI-UNW>MAIN PAGE),

9. Remove the shaft using the hoisting equipment.

10. Carry out the procedure to load the mother reel.
11. Carry out the paper splicing procedure.

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9.5 Operating procedures in the rewinding and doffing

area
Cleaning the reel

Prerequisites:

• The machine must be stopped.

• The paper must have been threaded and/or spliced on the unwinders.

Procedure:

1. Access the doffing – carry drum area (consult the specific procedure).
2. Cut any paper not suitable for processing (1).

3. Start the machine at slow speed.

4. Remove the previously cut paper and spread the ply out on the carry drums (2).

5. Carry out the paper splicing procedure.

6. Exit the area, making sure no one and nothing is in the area inside the guards, and close the door..

Rev: A 149/226
 9 USE

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Restarting the work cycle:

7. Lower the rider roller using the RIDER ROLLER control (3) (HMI>COMANDI MOVIMENTI), so that it
comes into light contact with the reel being rewound.

8. Return to the PROCESS page (4) and select PRODUCTION mode (5).
9. Set the speed to approximately 50 m/min (6).
10. Press WORK SPEED (7) to start the work cycle.
11. Gradually increase the speed until the desired production speed is reached.

4
5

150/226 Rev: A
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Paper splicing

Number of operators required:

• N. 1 Operator (necessary)
• N. 2 Operators (recommended).

Prerequisites:

• The machine must be stopped.

Procedure:

1. If necessary, clean the reel on the rewinding head (consult the specific procedure).
2. Feed the paper forwards in JOG mode until the end of the paper on the carry drums is fit for processing,
then stop the forward feed.
3. Place double-sided tape (1) along the entire length of the paper reel (n. 2 operators permitted).

Rev: A 151/226
 9 USE

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4. Take the ply on the carry drums and attach it to the double-sided tape strip on the reel (2). (n. 2
operators permitted).

5. Remove any excess paper (n. 2 operators permitted).

6. Clean the area, removing any paper residues.

7. Exit the area, making sure no one and nothing is in the area inside the guards, and close the door.

152/226 Rev: A
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9.6 Cutting group setup procedures

The cutting group is manufactured by Mario Cotta. For procedures regarding the adjustment and/or
maintenance of the cutting group, please consult the manufacturer’s documentation attached to this man-
ual.

The conditions for access to the cutting group are controlled by the machine safety command and control
logic. Please consult the specific procedures for safe access to the cutting group.

IMPORTANT

MAGNETIC TOOL (“AM”)

The cutting group is equipped with a “magnetic tool” that is designed and manufactured by Mario Cotta,
and which allows the operator to handle the knives without coming directly into contact with the cutting
blades.

ATTENTION

CUTTING HAZARD
Be careful of the cutting edge of the knives and anvil knives.
• It is OBLIGATORY to wear appropriate PPE (cut-proof gloves) for any kind of work on the cutting
unit.
• Whenever it is necessary to handle the knives and/or anvil knives, the starting point and
destination must be clearly known and the space between the two must be clean and cleared of
any obstacles.
• Make sure the knives and/or anvil knives are temporarily placed in a location that ensures they
are stable and is indicated by a cutting hazard warning sign.

IMPORTANT

HANDRAIL
There is a handrail (2) inside the cutting group, which is designed and constructed to aid the operator
during execution of required operating procedures, where necessary.

Rev: A 153/226
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Activating the knives

Prerequisites:

• The machine must be stopped.

Procedure:

1. Access the walkway.

2. Disengage the middle and trim knives, using the respective controls: MIDDLE KNIVES (Pulsantiere
151CB620>#5, 151CB621>#5, 151CB616>#8), TRIM KNIVES (Pulsantiere 151CB620>#6,
151CB621>#6, 151CB616>#9).
3. Open the guard.
4. Enable / disable the knife using the pneumatic valve (1).

NOTE: the knife is enabled when the circuit is pressurised.

154/226 Rev: A
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Replacing the knives

Prerequisites:

• The machine must be stopped.

Procedure:

1. Open the walkway.

2. Disengage the middle and trim knives, if engaged, using the respective controls: MIDDLE KNIVES
(Pulsantiere 151CB620>#5, 151CB621>#5, 151CB616>#8), TRIM KNIVES (Pulsantiere
151CB620>#6, 151CB621>#6, 151CB616>#9).
3. Raise the beam using the control KNIVES BEAM TOGGLE (Pulsantiera 151CB620>#4).
4. Raise the cutting unit guard.
5. Align the dowel (1) with the hole on the guard (2).
6. Loosen the dowel using a 2.5mm hex wrench.
7. Block the knife by inserting the hex wrench inside the hole (3).

2
3

Rev: A 155/226
 9 USE

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8. Manually remove the lock ring (4).

9. Use the “AM” magnetic tool (5) to remove the knife and place it on an appropriate support.

4 5

10. Perform the above procedure backwards to assemble the new knife. Take care not to tighten the lock
ring with excessive force.

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Adjusting the position of the knives

Prerequisites:

• The machine must be stopped.

Procedure:

1. Enter the walkway.

2. Disengage the middle and trim knives, if engaged, using the respective controls: MIDDLE KNIVES
(Pulsantiere 151CB620>#5, 151CB621>#5, 151CB616>#8), TRIM KNIVES (Pulsantiere
151CB620>#6, 151CB621>#6, 151CB616>#9).
3. Block the knife group using the control LOCK KNIVES TOGGLE (Pulsantiera 151CB620>#11,
151CB620>#7),
4. Raise the guard.
5. Release the knife that needs to be adjusted by means of the lock/release lever (1).
6. Turn the knob (2) to adjust the position of the knife, checking the distance from the reference knife.

7. Tighten the lever.

8. Enable the knife by means of the pneumatic valve (3).

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9. Repeat steps from #5 to #8 for each knife that needs to be adjusted.

10. Close the knife group safety guard.
11. Release the knife group, using the control LOCK KNIVES TOGGLE.(Pulsantiera 151CB620>#11,
151CB620>#7),

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9.7 General operating procedures

JOG mode
Information required to run the machine in JOG mode in each machine area is provided in this chapter.

ATTENTION

OPERATORS REQUIRED
The machine may be run in JOG mode only when there is ONLY ONE operator in the area.

9.7.1.1 JOG in unwinding area

Prerequisites:

• The machine must be on and must have been reset.

• Mother reel loaded.
• All the doors to the unwinding area must be closed.

Procedure:

12. Enable the unwinder that is to be run in JOG mode.

13. Access the unwinding are of the enabled unwinder.
14. Start JOG mode using the pushbutton panel near the access door.
• JOG mode enables rotation at 10 [m/min] of only the unwinder present in the area that has been
accessed.

IMPORTANT

SIMULTANEOUS ACCESS TO MORE THAN ONE UNWINDING AREA

Simultaneous access to various unwinding areas disables all the controls in the unwinding area.

Unwinding areas where JOG mode may be operated:

2 1

# Aree di svolgimento
1 Unwinder 1 area.
2 Unwinder 2 area.

Rev: A 159/226
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Paper threading

IMPORTANT

PAPER THREADING DIAGRAM

For paper threading operations, always consult the threading diagram provided in the following sections
and/or attached to this manual.

IMPORTANT

MOTHER REEL CLEANING AND BRAID POSITIONING

Before threading the paper through the machine, check that all the reels present on the unwinders have
been correctly prepared (the reel has been cleaned and the paper braid is on the operator side); to the
contrary, carry out the procedure to prepare the mother reel (outside the machine) and re position the
reels on the unwinders, following the procedure described in the paragraph “Loading the mother reel”.

9.7.2.1 Threading the first ply

Prerequisites:

• The machine is reset.

• The shuttle is in the extraction position.
• The shaft, including the cores, is correctly positioned on the carry drums.
• The mother reel/s are loaded on the unwinders.
• All the unwinders are disabled.

Procedure:
1. Enable the unwinder that is the “farthest away” with respect to the rewinding head, to be used for the
work cycle.
2. Enter the unwinding area of the enabled unwinder.
3. Start JOG mode using the joystick near the access door, and accumulate enough paper to reach the
paper threading belt.
4. Grasp the paper braid (1) on the mother reel.
5. Draw the braid under the paper roller (2) near the reel .
6. Insert the end of the braid into one of the slits (3) on the paper threading belt.

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7. Start JOG mode only from the JOG pushbutton control panel (4) (Pulsantiera CB120 >#2).
8. Stop the machine when the paper reaches the slide of the first unwinder (5)

4 5

9. to start the paper threading belt of the rewinding head (7).

10. Remove the paper from the belt system of the unwinding area (8).
11. Insert the paper on the belt system of the rewinding area (7)

6
7 8

12. Exit the area, making sure no one and nothing is in the area inside the guards, and close the door.

Rev: A 161/226
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13. Access the carrying roller area (9)

14. Execute JOG from the buttons (10), JOG (Pulsantiera 151JB630>#5).
15. Stop JOG operation as soon as the paper is near the carry drums.

9 10

16. Remove the paper from the paper threading system.

17. Start JOG operation using the JOG control JOG (Pushbutton control panel151JB630>#5), and spread
out the paper on the carry drums.

18. Stop the machine as soon as the paper has been fully spread out (11).

11

19. If the material to be produced is single ply, execute the procedure to position the ply on the cores;
otherwise, continue on to the next step.
20. Exit the area, making sure nobody and/or nothing is inside the area, and close the door.

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9.7.2.2 Threading all subsequent plies

Prerequisites:

• The machine must be stopped.

• The mother reel must be loaded on the unwinder.
• The mother reel must have been “cleaned” (consult the procedure for preparation of the mother
reel).
• The first ply must already have been threaded.

Procedure:

1. Access the unwinding area.

2. Start the machine running in JOG mode to accumulate paper on the slide under the mother reel.
3. Position the tail end of the mother reel (1) on the paper present on the slides (2).

4. Apply double-sided tape to the paper on the slides.

5. Attach the tail end of the paper from the mother reel to the double-sided tape.
6. Exit the area, making sure no one and nothing is in the area inside the guards, and close the door.
7. Repeat steps 1 to 6 for each ply to be added to the production, according to the threading diagram
(consult the “Paper threading diagram” section).
8. Thread the paper up to the carry drums (3).
9. Start JOG operation using the Joystick JOG (Pulsantiera 151JB630>#5),

9 10

10. Stop travel as soon as the joint made in the unwinding area completely comes out of the carrying rollers.
11. Perform the positioning of the paper on the cores.

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9.7.2.3 Paper threading after the ply breaks

Prerequisites:

• The machine must be stopped.

Procedure:

CHECKING THE REEL:

1. Access the unwinding area.

2. Inspect the reel and assess the general conditions of the reel, deciding whether to remove the reel for
cleaning or simply re-thread the paper.

REMOVING THE MOTHER REEL FOR CLEANING:

3. Exit the area, making sure no one and nothing is in the area inside the guards, and close the door.
4. Select manual operating mode by pressing the control (2) MACCHINA Modo manuale (HMI-
UNW>PAGINA PRINCIPALE).
5. Allontanare il braccio di svolgimento, mediante il comando (3) BRACCIO SVOLGITORE (HMI-
UNW>PAGINA PRINCIPALE) e attendere che la spia in corrispondenza del comando diventi verde.

2 3

6. Move the unwinding arm away, by pressing the UNWINDING ARM control (3) (HMI-UNW>MAIN
PAGE) and wait for the pilot light next to the control to turn green.

2 3

7. Disengage the axial brake by pressing the AXIAL BRAKE control (4).

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8. Using appropriate hoisting equipment, position the hoisting hooks in the special seats on the unwinding
shaft.
9. Press (5) BLOCK/EJECT SHAFT (HMI-UNW>MAIN PAGE), in order to release the reel unwinding shaft
and allow hoisting it.

10. Slowly hoist the mother reel and move it outside the machine, positioning it on supports (not part of this
supply).
11. Execute the mother reel preparation procedure.
12. Execute the mother reel loading procedure.

PAPER THREADING:

Depending on the position of the unwinder where the paper break occurred, executed the procedure to
thread the first ply, or the procedure to thread plies subsequent to the first one.

13. Execute the paper threading procedure.

14. Execute the procedure to clean the reel on the rewinding head.
15. Execute the mill splice – rewinding area procedure.

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9.7.2.4 Positioning the plies on the cores

Prerequisites:

• The machine must be stopped.

• All the paper plies must have been threaded through the machine.

Procedure:

1. Access the carry drum area.

2. Engage the middle and trim knives, using the respective controls: MIDDLE KNIVES (Pulsantiere
151CB620>#5, 151CB621>#5, 151CB616>#8), TRIM KNIVES (Pulsantiere 151CB620>#6,
151CB621>#6, 151CB616>#9).
3. A Start the machine running at low speed JOG (Pulsantiera 151JB630>#5)
4. Stop the machine as soon as the strips on the carry drums are long enough to be positioned on the
cores.
5. Tear off the excess paper and position the paper web on the cores.

6. Manually remove the trim on both ends and drop it into the trim removal suction mouths (if trim cutting
is not required, skip this step and go directly to the next one).
7. Exit the area, making sure no one and nothing is in the area inside the guards, and close the door.

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9.7.2.5 Paper threading diagram

All the paper threading procedures described in the previous paragraphs refer to this diagram

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Changing type of rewinding Shafted - Shaftless

Prerequisites:

• The machine has been stopped.

• There must be no rewinding shafts and/or reels on the carry drums.

Procedure:

FROM SHAFTED TO SHAFTLESS:

8. Carry out the procedure to access the rewinding area.

9. Block rotation of the chuck by inserting an appropriately sized dowel into the hole (1),
10. Support the chuck (2) and remove the n. 4 screws (3),
11. Remove the chuck,
12. Mount the appropriate adapter (4) for the processing to be carried out (either 3”, 6” or 10”).
13. Insert the n.4 screws in the adapter and tighten them (5) (TCEI M12x200).
14. Insert the pin in the hole (6) and tighten the screws.
15. Perform this procedure on both chucks.

2
3

5 4 6 5 4 6

FROM SHAFTLESS TO SHAFTED

To return to “SHAFTED” mode, execute the above procedure inversely.

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9.8 Work cycle

Preparing for start-up

Prerequisites:

• The machine is stopped.

• All the machine access doors/gates are closed.

Procedure:

1. Execute the procedure for CORE LOADING.

2. Execute the procedure for INITIAL INSERTION OF THE SHAFT.
3. Execute the procedure for cutting group settings (consult the manufacturer’s documentation).
4. Execute the procedure for LOADING THE MOTHER REEL/S.
5. Execute the procedure to ENABLE/DISABLE THE UNWINDERS.
6. If necessary, press the ROTATION SENSE control (1) (HMI-UNW>PAGINA PRINCIPALE), to vary the
direction of rotation of the reel.
7. .

8. Repeat steps from #1 to #3 for each unwinder to be enabled and prepared for the work cycle.

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NOTA: The correct activation of the individual unwinders can be verified from the individual control panels,
where the wording “Unwinder Ready” will appear, and from the main control panel, where a “WHITE REEL”
will be displayed (2).

9. Execute the PAPER THREADING procedure for all the unwinders required for the work cycle.

NOTE: The first ply to be threaded through the machine must be the one relative to the (“enabled”) unwinder
farthest away from the rewinding head.

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Starting the rewinding cycle

Prerequisites:

• The machine is prepared for start-up.

• The machine has been reset and all the doors are closed.
• Initial paper threading has been completed or the finished roll has been unloaded.

Procedure:

1. Lower the rider roller using the RIDER ROLLER control (1) (HMI>MOVEMENT CONTROLS
MOVIMENTI), so that it comes into light contact with the cores on the carry drums.

2. Select PRODUCTION mode (2) (HMI > Process Page),

3. Set the operating speed to about 50 m/min (3).
4. Press WORK SPEED (4) to start the work cycle.
5. Gradually increase the speed until the desired operating speed is reached.

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Loading the cardboard cores

Prerequisites:

• There must be no cores and/or rewinding shaft inside the ejector.

Procedure:

6. Enter the ejector area.

7. Place the cores on the tray (1).
8. Compact the cores up to the moving stopper (2).

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Adjusting the height of the inflator

Prerequisites:

• None

Procedure:

9. Enter the ejector area.

10. Turn the flywheel (1) to adjust the height of the inflator based on the diameter of the reel.

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Adjusting the moving stopper

Prerequisites:

• The cardboard cores have been loaded

Procedure:

11. Enter the ejector area.

12. Turn the flywheel (1) to adjust the moving stopper (2) based on the position of the cutting knives.

NOTE: A reference scale (3) is installed near the stopper to aid the operator during the adjustment.

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End of the rewinding cycle – doffing and starting a new cycle

Prerequisites:

• The machine has been reset, all the doors are closed and the doffing table is raised.
• Reel rewinding has been completed.
• The barriers have been reset.
• The cores are positioned on the extractor tray.

Procedure:

13. Wait for the work cycle to be completed; the machine automatically comes to a stop,

REEL DOFFING

14. Enable DOTTING (1) (HMI > PROCESS PAGE) .

15. Start the REEL DOFFING sequence (2) (HMI > PROCESS PAGE);

NO NOTE: The above procedure entails the automatic execution of the following operations:
• Daughter reel/reels are unloaded on the doffing table.
• The new shaft with the cores is loaded onto the carry drums.
• The plies are cut
• The plies are positioned on the cores.

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RESTARTING THE WORK CYCLE (OPTIONAL)

1. Select PRODUCTION mode (3) (HMI > PROCESS PAGE);

2. the operating speed to about 50 m/min (4).
3. Press WORK SPEED (5) to start the work cycle.
4. Gradually increase the speed until the desired production speed is reached.

5
4

LOADING THE CORES

5. Execute the core loading procedure.

EXTRACTING / INSERTING THE SHAFT

6. Execute the “shaft extraction” procedure.

UNLOADING THE REEL

7. Make sure that nobody is in proximity of the area where the reel is going to roll.
8. Execute the daughter reel unloading procedure.

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9.9 Machine stop

Working stop
Prerequisites:

• The machine is running.

Procedure:

9. Press the STOP pushbutton (HMI > Main control panel), The machine will begin its deceleration ramp
until all moving parts reach zero speed.

FAST STOP working stop

Prerequisites:

• The machine is running.

Procedure:

Press the FAST STOP pushbutton (Main control panel > #8). The machine will begin its deceleration
ramp, about 50% faster than the working stop, until all moving parts reach zero speed

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Emergency stop and restart

9.9.3.1 Emergency pushbutton

Prerequisites:

• The emergency stop is a machine safety stop procedure and must be used only in the event of
danger for the operator or exposed persons.
• When this procedure is started, priority is given to stopping all machine movements as quickly as
possible, in order to reduce risks for exposed persons to a minimum.
• The emergency stop does not guaranty that the material being processed will remain intact.

Procedure:

10. Press the emergency pushbutton (1) if the machine in an imminent risk condition. The machine will
stop in the shortest time possible.
11. After an emergency stop has been executed, the causes that have generated the stop must be
identified and cleared, and normal operating conditions must be restored.
12. Release the emergency stop pushbutton by turning it clockwise (2), in order to reset the safety function.
13. Reset the safety functions and devices.

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9.10 Operating instructions to be followed in case of an

accident or malfunction
Procedure to unlock the doors from the outside
In the event of an electrical power failure, the doors will remain locked. In these circumstances, the
mechanical release key (1), with which the interlocking device is fitted, may be used to access the machine.

Procedure:

14. Open the plastic cover (1).

15. Turn the triangle clockwise to release the locking mechanism (2).
16. The normal locking function is reset by returning the triangle to the starting position (3).

NOTE: do not go beyond the stopping point. After commissioning, the auxiliary manual release must be
sealed using the special plastic cover (1) and the special seal provided.

2 3

IMPORTANT

The external door release key is a mechanical device that works even in case of power shortages.
• This release key must not be used as the normal system to unlock the door.
• The key must be stored by authorised personnel, so it remains available in case of need.
• Designated personnel must be trained on correct use of the handle in order to avoid improper
use.
• Periodically check (at least once a year) that the release key works properly.

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Procedure to release the door from the inside

If someone gets trapped inside the machine hazard areas, proceed as described following.

Procedure:

17. If the machine is starting up, move away from the moving elements and reach the closest emergency
push-button. Machine start-up is always preceded by an acoustic warning.
18. Press the emergency push-button to interrupt the start-up procedure.
19. Go the door that accesses the area, identify the release handle and turn it to open the door.
20. Push the door open and exit the area.

IMPORTANT

The release handle is a mechanical device that works even in case of power shortages.
• The handle must not be used as a machine emergency stop device.
• The handle is located in a such way that it cannot be reached and turned from the outside. Turn
the handle only in case of need.
• Designated personnel must be trained on correct use of the handle in order to avoid improper
use.
• Do not place objects in front of the handle that make it difficult to locate and reach the handle
(e.g., hanging garments).
• Periodically check (at least once a year) that the handle works properly.

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9.11 Turning off the machine

WARNING

VARIOUS RISKS DERIVING FROM TURNING OFF THE MACHINE INCORRECTLY

Turning off the machine in a way different from that described may lead to damage or risks for exposed
persons.
• Follow the machine shut down procedure.

Prerequisites:

• Based on the work shifts and scheduled machine stops, if the machine must remain idle or if it is
necessary to access the machine for maintenance, the machine must first be turned off.

Procedure:

21. Complete the work cycle, feeding all the material through the machine, and stop the machine using the
operating stop procedure.
22. Turn all the air valves to the “CLOSED” position, to disconnect the pneumatic power.
23. Turn the main disconnector switch on the electrical board to the “OFF” position, to disconnect the
electrical power supply.

WARNING

ACCESS FOR MAINTENANCE

If the machine needs to be accessed for maintenance, powering the machine may create risks for
exposed persons.
• Cut off the power supplies and lock them with clamps and padlocks, in compliance with
LockOut/TagOut procedures.

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10 MAINTENANCE
10.1 Introduction to maintenance
This chapter contains information regarding maintenance interventions that must carried out to keep the
machine working efficiently, and in compliance with the machine’s intended use.

By definition, MAINTENANCE is the combination of all the technical and administrative actions, including
supervision, aimed and keeping or restoring an entity to a condition in which it can perform the functions
required.

This information is divided based on the types of maintenance:

• Inspections
• Cleaning
• Lubrication and greasing
• Mechanical maintenance
• Electric maintenance

IMPORTANT

It is OBLIGATORY that maintenance personnel be trained and instructed regarding residual risks during
maintenance operations.
• A complete list of the relative safety measures is described in the chapter “Safety”.
• Being familiar with the contents of the chapter “Safety” is an indispensable prerequisite for machine
maintenance.
• For all maintenance not described in this chapter, it is OBLIGATORY to always contact the
manufacturer for the required support.

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LockOut/TagOut concept (LOTO)

IMPORTANT

The procedure below describes the minimum requirements for the implementation of LockOut/TagOut
type procedures used for safe access to the machine for maintenance.
• The machine is fitted with devices that permit cutting it off from each of its power supplies.
• The creation and application of LockOut/TagOut type access procedures and personnel training
and supervision are employer responsibilities.
• Integrate the instructions provided below with the procedures in use in the specific workplace.

Procedure:

1. Every person authorised to carry out servicing and maintenance must be provided with a sufficient
number of personal padlocks and clamps to lock all the energy and power cut-off points.
2. Every person authorised to carry out servicing and maintenance must lock every power cut-off point
using his/her own padlocks.
3. In case of simultaneous interventions by more than one authorised person, each must lock every power
cut-off point using his/her own padlock, even if there are other padlocks already locking the power cut-
off points.
4. The presence of authorised personnel carrying out servicing or maintenance must be signalled using
warning signs.
5. Padlocks may be removed only when the maintenance has been completed. Make sure that no one in
the machine hazard areas without having locked off all the power cut-off points with personal padlocks.

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10.2 Access procedures for maintenance

Access to the machine with isolation of power supplies

IMPORTANT

The machine is designed so that all power and energy sources may be cut off and locked out.
It is OBLIGATORY to cut-off the machine from all energy and power supplies before carrying out
maintenance in order to prevent unexpected start-up during maintenance.
• Padlocks and clamps are not provided and the customer/employer is responsible for providing
this equipment to operating personnel.
• Please also consult the contents of the paragraph “The LockOut/TagOut (LOTO) concept”.

Prerequisites:

• Knowledge and implementation of the LockOut/TagOut procedures.

• Clamps and padlocks available for personnel designated to maintenance work.

Procedure:

1. Turn off the machine.

2. Block the power switch on the electrical board in the “OFF” position.
3. Block all other power supplies (for example, pneumatic, hydraulic, etc.) in the “CLOSED” position.
4. The switches must be blocked using a padlock or special clamps for contemporary access of more than
one person (LockOut/TagOut – LOTO procedure).

NOTE: the figure shows and example of a clamp (1) on which more than one padlock may be placed (2) to
lock the switch on the electrical board. Other types of devices suited to this purpose may be used on the
other power switches.

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Location of cut-off and lock-out devices

10.2.2.1 Electrical board

# Description Modalità

LOCKOUT/TAGOUT (ELECTRICAL BOARD CUT-OFF SWITCH)

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10.2.2.2 Area pneumatic cut-off valves

# Description Modalità

LOCKOUT/TAGOUT (AREA PNEUMATIC )

DANGER

RISK OF RESIDUAL PRESSURE

Some elements may remain pressurized. Consult the paragraphs that follow and the pneumatic diagram,
and discharge any residual pressure safely, with the actuators empty of potential energy, before working
on the components.

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Access to the electrical board

DANGER

RISK OF ELECTROCUTION
The key to the electrical board allows keeping the doors to live parts closed and locked.
• The key must be used for as long as required to complete the maintenance. Once maintenance
has been completed, it must be removed and stored by the designated person.
• The key may be used only by authorised and qualified persons, designated in a written
procedure.
• Duplicating the key is forbidden.

10.2.3.1 Access for maintenance work with the power on

In the event of work on the electrical board with the power on, proceed as described below.

Prerequisites:

• Use of qualified/skilled personnel (PES) or instructed/informed personnel (PAV).

• Use of qualified personnel (PEI).

Procedure:

5. Turn off the machine.

6. Insert and turn the key to open the door to the electrical board.
7. Repower the electrical board by turning the main switch.
8. When servicing has been completed, close the door and lock it. Remove the key and store it in a safe
place.

DANGER

RISK OF ELECTROCUTION
The procedure that allows repowering the electrical board when the doors are open is voluntary and may
create electrocution hazards deriving from contact with live parts.
• Only personnel qualified and authorised to carry out work on live parts, aware of the specific
risks that this type of work entails may turn the power switch; this is forbidden to all other persons.

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10.2.3.2 Access for maintenance work with the power cut off
In the event of work on the electrical board with the power cut off, proceed as described below.

Prerequisites:

• Use qualified/skilled personnel (PES) or instructed/informed personnel (PAV).

Procedure:

1. Turn off the machine.

2. Cut off the main switch located up-line of the electrical board cut-off switch (customer power grid). Lock
the cut-off switch in the open position using the special clamps and padlocks and placing signs warning
of the presence of maintenance personnel.
3. Cut off and lock the switches on the electrical boards of machines and/or devices that exchange
interface signals with the machine.
4. Insert and turn the key to open the electrical board door.
5. When servicing has been completed, close the door and turn the key. Remove the key and store it in
a safe place.

IMPORTANT

LOCKOUT/TAGOUT PROCEDURE (LOTO)

Accessing the electrical board does not allow blocking the board’s main switch.
• Do not perform maintenance on other machine points for which this switch must be cut-off and
locked, in compliance with the LockOut/TagOut procedures described in this manual.

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Bleeding off residual pressure

This paragraph illustrates the various points and procedures to safely bleed residual pressure present in
the various machine actuators.

10.2.4.1 Procedure to bleed pneumatic pressure.

Prerequisites:

• The access door to the maintenance area have been opened in advance.
• The machine is turned off and cut off from power.
• The Lock-Out procedures for all power sources have been carried out.

Procedure:

1. Access the maintenance area.

2. Find the residual pressure relief device.
3. Using a tool, press the button (1) or turn the valve (2), opening the pneumatic circuit, and wait for all
the residual pressure inside the actuator to bleed off completely.

1 2

4. Carry out the required maintenance.

5. Mae sure no one and nothing is present in the area.
6. Exit the area and close the door.

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Blocking the doffing table

The doffing table may be blocked in place for interventions on the hydraulic cylinders.

Prerequisites:

• The doffing table is either in the high position.

Procedure:

1. Access inside the unloading area.

2. Insert the pin to block the table.
3. Release pressure from the hydraulic circuit.
4. Carry out the required intervention.
5. Once the intervention has been completed, re-pressurize the hydraulic circuit.
6. Remove the blocking pin.
7. Exit and reset the emergency devices from the main control panel.

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10.3 Inspections

Purpose
To prevent anomalous operating
conditions through a visual inspection of
the components/work cycle carried out
by both operating personnel during
machine operation and by maintenance
personnel.
Actions
During the work cycle, visually inspect the machine and
signal any anomalies that must be cleared by maintenance
personnel.
Avoid that long-lasting anomalies lead to a malfunction, and
consequently damage the machine or a break down that may
compromise machine efficiency.
Carry out the programmed inspections described in the
maintenance schedule.

WHAT HOW FREQUENCY

• Before each machine use, check that the
Check the safety guards, alarm devices and safety devices
DAILY
devices are in place and working efficiently. Consult
the “Safety” chapter.
• Visually inspect that all information and
Check information and
warning signs on the machine are intact and
warnings on the SIX-MONTHLY
legible; if necessary, replace them. Consult
machine
the “Safety” chapter.
• Visually inspect that there are no oil leaks
Check for oil leaks from from the gear motors. If leaks are detected,
DAILY
gear motors have maintenance personnel intervene to
repair the leaks before using the machine.
• Visually inspect that there are no fluid leaks
from the pipes, flanges and couplings of
machine circuits. If necessary, supply the
Check for fluid leaks circuits before inspecting. If leaks are DAILY
detected, have maintenance personnel
intervene to repair the leaks before using the
machine.
• Check that the ampoules of the compressed
air treatment unit are free of condensation
Check the pneumatic
and that the condensation is discharged SIX-MONTHLY
system
automatically every time the tap up-line of
the machine is closed.
• Check the integrity of the rotary joint of each
Check the rotary joint of spreader roller on the machine. Consult the
QUARTERLY
the spreader rollers manufacturer’s manual attached to this
manual.
• Check knife wear and sharpness. Replace
Check the cutting group WEEKLY
as required.

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WHAT HOW FREQUENCY

• Check that the wear on the brake pads is
even on both sides. In case of excessive
wear, maintenance personnel must replace
the pads before the machine can be used.
• Check the mobility of the brake clamp. If the
clamp jams or does not move smoothly,
Check the brake clamp
maintenance personnel must intervene to SIX-MONTHLY
and pads
clear the inconvenience.
• NOTE: The clamps installed on the machine
are designed so that they are “self-centring”
with respect to the brake disk. Poor mobility
of the clamps may create a continuous
rubbing of the brake pad on the disk.
• Check the wear and lubrication of the linear
guides and supports inside the machine.
• In case of excessive wear, schedule a
Check the linear guides
component replacement. QUARTERLY
and supports
• If the lubricant inside the guides / supports is
not sufficient, lubricate the component before
the planned lubrication interval.

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10.4 Cleaning
Finalità Azioni
To eliminate anything that is superfluous
from the work area and keep all Define what is important and what is not.
necessary materials and tools in order.
After the initial clearing, eliminate sources of dirt (dust,
To keep the work area and the machine
machining waste, etc.), keeping the workstation and the
clean.
machine perfectly clean.

WHAT HOW FREQUENCY

• Quickly eliminate dirt deposits (dust
residues, oil, grease) that may alter machine
General machine and
and component efficiency. DAILY
work station cleaning
• Remove machining residues from the
machine and work areas.
• Clean the control panels using an
Clean the control panels appropriate cloth. Do not use aggressive WEEKLY
detergents.
• Keep dust from accumulating on the
machine by removing it with a specific device
(vacuum) or rags.
Remove dust WEEKLY
• If suspended particles risk creating a risk of
explosion, remove it only using vacuums that
are classified for use in ATEX environments.
• Clean the photocells using an appropriate
cloth, removing process residues and any
Clean the photocells DAILY
other dirt that may compromise device
efficiency.
• Clean the pinions (upper and lower), on the
drive side and tender side of the removable
Clean the cutting group
guard on the cutting group.
safety guard pinions and WEEKLY
chain • Clean the chain, on the drive side and tender
side of the removable guard on the cutting
group; lubricate as required.
• Eliminate accumulated dust, removing it from
Clean the cutting group WEEKLY
the cutting group using the special vacuum.
• Eliminate accumulated dust in the unwinding
Clean the unwinding area using appropriate bins and vacuums.
WEEKLY
area • Consult the procedure described here
following.
• Clean and vacuum the dust from the radiator
Clean the hydraulic of the hydraulic control unit.
MONTHLY
control unit radiator • Consult the procedure described here
following.
Cleaning the upper • Carry out the procedure to access the
CONDITION-
pulleys of the unwinding unwinding area to clean the upper pulleys.
BASED
arms • Manually remove excess paper.

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Cleaning the hydraulic control unit radiator.

Prerequisites:

• The machine must be turned off and disconnected from energy and power supplies.
• The electrical board must be padlocked.

Procedure:

8. Using a portable vacuum (not part of this supply), vacuum the dust from inside the radiator (1).

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10.5 Lubrication and greasing

Purpose
Rotating parts, bearings, axes, etc. that
require lubrication to reduce possible
friction.
Actions
Grease the manual greasing points according to the
scheduled greasing frequency or whenever necessary.
Check the grease level in the automatic greasing systems
(where provided) and top-up as required. Check the greasing
pipes and make sure the pump starts properly.
Check and top-up the oil as scheduled or whenever
necessary.

WHAT HOW FREQUENCY

• Where not specified, grease using the
specific greasers shown in the figures.
• After greasing, immediately start-up the
machine and let it run for a few minutes, to
Greasing NOTE 1
guaranty thorough and proper greasing.
• Do not top-up grease excessively (about one
third of the volume of grease already present
in the housing is sufficient).
• The first time an equivalent oil is used, drain
all the old oil from the system and clean it
thoroughly. Mixing different brands of oil may
lead to malfunctions and should be avoided.
Lubrication NOTE 1
• Top-up the oil in the tanks without exceeding
the maximum oil level.
• If the oil is contaminated or exhausted it must
be replaced.

NOTE 1: details regarding greasing interventions and related frequencies are provided in the paragraphs
that follow

IMPORTANT

Improper use of lubricants may lead to injury or machine malfunctions.

• Use only the type of lubricant provided for or one with equivalent characteristics.
• Before using any lubricant, request the “product safety sheet” from the lubricant producer. In
case of need, follow the instructions provided on the specific product safety sheet.
• Clean lubricant spillages appropriately.
• In general, oils and lubricant substances are highly pollutant and damaging for the environment.
Always dispose of waste lubricants through special waste oil treatment organisations.

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Lubrication and greasing

Type Characteristics Use

Multi-use grease for general industrial
Grade: NLGI 2
G1 GREASE applications to protect against wear,
Type: Lithium soap
rust and wash-out
Total Ceran CA
G2 GREASE DIN51502: OGPON-25 ISO6743-9:L- Grease for high temperatures
XBDIB 0
Grease for heavy loads and extreme
G3 GREASE LGEP 2
pressures
C.L 68 DIN 51517 p.e
01 OIL Lubricant oil for circulation systems
DTE PM Heavy medium
CLP ISO PG 220
02 OIL Total CARTER XEP 220 Lubricating oil for gears
Total CARTER EP 220

Rev: A 197/226
 10 MAINTENANCE

REELITE | 15 T

Lubrication and greasing

10.5.2.1 Unwinder

198/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

Ref Type of
Pos. Component Frequency Image
. lubricant
1 -D.S. Unwinder N. 8 HIWIN G01
-T.S. centring guides lubrication grease or
points equivalent

Relubricati Use manual

on with 3.8 pump
cc of
grease
every year

2 -D.S. Unwinder N. 1 UNIMEC Mark

centring chuck lubrication CA grease or
point equivalent
Relubricati
on with Use manual
grease pump
every 6
months

3 -Centro Unwinder N. 2 NLGI 2 or

electric- lubrication equivalent
mechancial points
actuator Use pneumatic
Add grease pump
at least
every year.
Check
every 2
months.

Rev: A 199/226
10 MAINTENANCE

REELITE | 15 T

Ref Type of
Pos. Component Frequency Image
. lubricant
4 -Centro Unwinder N. NLGI 2 or
mechanical lubrication equivalent
actuator bearing point
Use pneumatic
Add grease pump
at least
every year.
Check
every 2
months.

200/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

10.5.2.2 Rewinding head

Rev: A 201/226
10 MAINTENANCE

REELITE | 15 T

202/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

Re Type of
Pos. Component Frequency Image
f. lubricant
1 -T.S Carry drum N°2 -LGEP 2
-D.S bearings Lubrication grease or
points per side equivalent

Relubricate
every year

2 -T.S Spreader N°2 -LGEP 2

-D.S roller bearings Lubrication grease or
points for roll equivalent

Relubricate Use manual

every year pump

3 -T.S Cutting beam N°2 -HIWIN G01

-D.S linear guides Lubrication grease or
points equivalent

Relubrication Use manual

with 3,8 cm³ of pump
grease every
year

Rev: A 203/226
10 MAINTENANCE

REELITE | 15 T

Re Type of
Pos. Component Frequency Image
f. lubricant
4 -T.S Moving N°2 - HIWIN G01
-D.S walkway Lubrication grease or
linear guides points per side equivalent

Use manual
Add fat pump
monthly as
needed

5 -T.S Blade guard N°2 HIWIN G01

-D.S linear guides Lubrication grease or
points per side equivalent

Use manual
Relubrication pump
with 0.5 cm³ of
grease every
year

6 -T.S Chucks and N°8 - HIWIN G01

-D.S rider roll linear Lubrication grease or
guides points per side equivalent

Use manual
Relubrication pump
with 3,8 cm³
of grease
every year

204/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

Re Type of
Pos. Component Frequency Image
f. lubricant
7 -T.S Width-wise N°2 - HIWIN G01
-D.S cut linear Lubrication grease or
guides points per side equivalent

Use manual
Relubrication pump
with 1,3 cm³ of
grease every
year

8 -T.S Internal side N°2 -LGEP 2

-D.S chuck Lubrication grease or
bearings points per side equivalent

-Use
Relubricate pneumatic
every year pump

Rev: A 205/226
10 MAINTENANCE

REELITE | 15 T

Re Type of
Pos. Component Frequency Image
f. lubricant
9 -T.S Core loader N°1 -LGEP 2
-D.S moving Lubrication grease or
support point per side equivalent

Relubricate Use manual

every year pump

10 -T.S Ejector side N°1 - LGEP 2

-D.S panel Lubrication grease or
supports point per side equivalent

Relubricate Use manual

every year pump

11 -T.S Cuscinetti N°1 - LGEP 2

-D.S cilindro Lubrication grease or
espulsore point per side equivalent
idraulico
Relubricate Use manual
every year pump

206/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

Re Type of
Pos. Component Frequency Image
f. lubricant
12 -T.S Ejector N°4 - LGEP 2
-D.S hydraulic Lubrication grease or
cylinders point per side equivalent
Supports
Relubricate Use manual
every year pump

13 -D.S Cutting group N°3 - LGEP 2

outfeed paper Lubrication grease or
roller point per side equivalent
transmission
supports Relubricate Use manual
every 6 pump
months

14 -D.S Cutting group N°2 - LGEP 2

outfeed paper Lubrication grease or
roller point per side equivalent
transmission
supports Relubricate Use manual
every 6 pump
months

15 -D.S Trim suction N°2 - LGEP 2

-T.S mouths Lubrication grease or
points per side equivalent

Relubricate Use manual

every year pump

Rev: A 207/226
10 MAINTENANCE

REELITE | 15 T

Re Type of
Pos. Component Frequency Image
f. lubricant
16 -D.S Trim suction N°4 - HIWIN G01
-T.S. mouth linear Lubrication grease or
guides points per side equivalent

Relubrication Use manual

with 3,8 cm³ pump
of grease
every year

17 -D.S Rider roll N°2 - LGEP 2

-T.S brakes Lubrication grease or
Supports points per side equivalent

Add grease Use manual

every year, if pump
required

18 -T.S Unloading -N°1 -LGEP 2

-D.S table rotation Lubrication grease or
bearings points per side equivalent

Use
Add grease pneumatic
every month, if pump
required

-N°1
Lubrication
points per side -LGEP 2
grease or
-T.S Unloading
equivalent
19 -D.S floor bearings
Add grease
-Use manual
every month, if
pump
required

208/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

Re Type of
Pos. Component Frequency Image
f. lubricant

N°2
-HIWIN G01
Rider roll and Lubrication
or equal
-D.S chucks points per side
20
-T.S Ball screw
- Use manual
Relubricate 15
pump
g every year

N°2 -Grease
Lubrication HIWIN G01
Trim suction points per side or equal
-D.S
21 mouths ball
-T.S
screw - Use
Relubricate manual
every year pump

Rev: A 209/226
10 MAINTENANCE

REELITE | 15 T

Re Type of
Pos. Component Frequency Image
f. lubricant
Rider roll and N. 2
chucks Lubrication
Translation points per side
Relubrication
with grease UNIMEC
every 6 ATIR SH 150
months o equivalente
22 -T.S
Use manual
pump

210/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

10.5.2.3 Shaft Handler

Rev: A 211/226
10 MAINTENANCE

REELITE | 15 T

Type of
Ref. Pos. Component Frequency Image
lubricant
1 -Front Bevel Gearbox N°2 Unimec Atir
-Back lubrication SH150
points

Completely 0.9 l
replace the
oil after
3.000 h of
operations
Add oil
every year
if
necessary
2 -Center Torsion Rod N°2 Grade:
Supports lubrication NLGI 2
points Type:
Relubricati Lithium
on of soap
grease
every year Use
manual
pump

3 -Front Ball Screw N°2 Grade:

-Back Supports lubrication NLGI 2
points Type:
Lithium
Relubricati soap
on of
grease Use
every manual
month pump

212/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

Type of
Ref. Pos. Component Frequency Image
lubricant
4 -Front Vertical N°4 Grease
-Back Translation Linear lubrication HIWIN G01
Guides points or equal

Use
Relubricati manual
on of pump
grease
every year

5 -Front Ball Nut and N°2 Grade:

-Back Screw lubrication NLGI 2
points Type:
Lithium
soap
Relubricati
on of Use
grease manual
every pump
month

6 -Front Feeler Linear N°1 Grease

Guide lubrication HIWIN G01
point or equal

Use
Relubricati manual
on of pump
grease
every year

Rev: A 213/226
10 MAINTENANCE

REELITE | 15 T

Type of
Ref. Pos. Component Frequency Image
lubricant
7 -Front Inflator and N°2 Grade:
- Deflator Guides lubrication NLGI 2
Rewind points Type:
er Lithium
Tender soap
Side Keep them
regularly
clean and
lubricated

8 -Back Introducer N°1 Synthetic

Gearbox lubrication oil SHELL
point Omala S4
Lubricated WE 220
for Life
(In pollution 0.9 l
free
environme
nt)

Check level
every year

9 -Front Linear Unit N°4 Linear Grade:

-Back Guide NLGI 2
Block Type:
inside the Lithium
unit soap

Use
Relubricati manual
on of pump
grease
every year

214/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

Type of
Ref. Pos. Component Frequency Image
lubricant
10 -Back Porter Gearbox Lubricated Synthetic
for Life oil SHELL
(In pollution Omala S4
free WE 220
environme
nt) 0.45 l

Check level
every year

11 -Front Porter Chain N°4 Grade:

-Back Bearings lubrication NLGI 2
points Type:
Lithium
soap
Relubricati
on of Use
grease manual
every year pump

12 -Front Porter Chains and N°4 Grade:

-Back Pinions lubrication NLGI 2
points Type:
Lithium
soap
Relubricati
on of Use
grease manual
every pump
month

13 -Front Front Carriage N°4 Grease

Horizontal lubrication HIWIN G01
Translation Linear points or equal
Guides
Use
Relubricati manual
on of pump
grease
every year

Rev: A 215/226
10 MAINTENANCE

REELITE | 15 T

Type of
Ref. Pos. Component Frequency Image
lubricant
14 -Front Deflator/Pusher N°4 Grease
Vertical Linear lubrication HIWIN G01
Guide points or equal

Use
Relubricati manual
on of pump
grease
every year

15 -Front Front Carriage N°6 Grease

Wheels Linear lubrication HIWIN G01
Guides points or equal

Use
Relubricati manual
on of pump
grease
every year

16 -Front Driving Wheel N°1 Grade:

Chain and Pinions lubrication NLGI 2
point Type:
Lithium
soap
Relubricati
on of Use
grease manual
every pump
month

216/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

Type of
Ref. Pos. Component Frequency Image
lubricant
17 -Front Front Carriage N°1 Synthetic
Wheels lubrication oil SHELL
Transmission point Omala S4
Gearbox Lubricated WE 220
for Life
(In pollution 0.9 l
free
environme
nt)

Check level
every year

18 -Front Front Carriage N°1 Synthetic

Translation lubrication oil SHELL
Gearbox point Omala S4
Lubricated WE 220
for Life
(In pollution 0.45 l
free
environme
nt)

Check level
every year

19 -Front Front Carriage N°1 Grade:

Translation Pinion lubrication NLGI 2
and Rack point Type:
Lithium
soap
Relubricati
on of
grease
every
month

Rev: A 217/226
10 MAINTENANCE

REELITE | 15 T

Type of
Ref. Pos. Component Frequency Image
lubricant
20 -Back Vertical Lubrificated -
Translation for life
Planetary Gear

218/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

10.6 Mechanical maintenance

Purpose
To avoid accidents and unwanted
machine breakdowns.
Perform maintenance before the
component shows signs of breakage or
when a malfunction occurs (condition-
based).
Actions
Accurately check that all belts, chains, bolts, couplings,
wires, plugs, locks, connections, etc. are tight.
Perform all “replacement”, “overhaul” or “repair” operations
in accordance with the procedures described in this manual
or in the specific component documents.

WHAT HOW FREQUENCY

• Check for loss of or damage to any part of
the guard, especially if this reduces the
safety function (for example, reduction of
resistance against bumps, scratches on
glass panels, etc.)
Fixed and removable • Replace parts subject to wear, taking
SIX-MONTHLY
guards particular care to inspect deterioration of
couplings or anchor points.
• Check for deterioration due to corrosion,
temperature changes or chemical effects.
• Check that there are no changes in the
safety distances and the size of openings.
• Check that all fastening nuts and bolts are
Frames YEARLY
tight.
Brake pads
Brake disks • Consult the use and maintenance manual CONDITION-
Knife replacement provided by the manufacturer. BASED
Hydraulic control unit

Rev: A 219/226
 10 MAINTENANCE

REELITE | 15 T

Replacing the reel unwinding belts

Prerequisites:

• The machine must be stopped.

• The unwinding area doors must be closed.

Procedure:

1. Remove the mother reel (if one is present) and completely lower the unwinding arms.
2. Turn off the machine and cut off all power sources.
3. Access the internal machine area.
4. For safety purposes, connect the unwinding arm to the hook of a travelling crane using a hoisting
harness.

2 2 1

5. Remove the safety guard (1) and the couplings under the transmission shaft.

NOTE: Always change one belt at a time, so that the unwinding arm is never completely disconnected from
the unwinder structure.

6. Slide the belt (2) off the pulleys and insert a new belt.
7. Replace the transmission shaft and the respective safety guard.
8. If necessary, repeat the procedure for the second belt.
9. Remove the hoisting harness.

220/226 Rev: A
 MAINTENANCE 10
REELITE | 15 T

10.7 Electrical maintenance

Purpose
Preserve the initial performance and
safety level, limiting normal wear and
aging of components.
Respect law provisions.
Actions
Do not allow persistent anomalies to cause a malfunction and
damage the machine, or a breakage that compromises
normal machine functions.
Inspect the machine regularly as per the maintenance
schedule.
Perform the maintenance foreseen by applicable technical
safety standards and current legislation in the country where
the machine is installed and run.

WHAT HOW FREQUENCY

• Check that the equipment and various
Inspect components
devices inside and outside the electrical SIX-MONTHLY
visually
board are in good working condition.
• Check that the wiring diagram is present and
Wiring diagram. YEARLY
updated.
• Replace illegible plates.
Controls,
• Replace controls and instrumentation that no
instrumentation, pilot YEARLY
longer guaranty normal operating efficiency.
lights.
• Replace the lights on signalling devices.
• Make sure there are absolutely no water
infiltrations or dangerous condensation
Inspect for water
formation. Check the sealing systems
infiltrations and SIX-MONTHLY
(gaskets) and internal conditioning systems
condensation.
for the equipment itself. Immediately remove
water and repair.
• Remove dust from the electrical board filters
using a vacuum. If the filters are too dirty,
they may be cleaned using water and neutral
Clean the electrical soap, leaving them to dry completely before
re-installing them. Excessively worn filters SIX-MONTHLY
board
must be replaced.
• Use a vacuum to remove dust from inside the
electrical cabinet.
Inspect that all • Check that sensors, the encoder and
components on the photocells on the machine are tightly
YEARLY
machine are fastened fastened.
properly
• Check that power wires and connections
bars are tight.
Inspect terminals YEARLY
• Check the wires on the terminal boards by
pulling on them lightly.
• Check that the cable glands are tight by
pulling on the lightly; tighten as required.
• Check that seals are intact and check sealing
Check the degree of
of the covers or junction boxes and terminal
protection of the YEARLY
board boxes on the machine.
casings.
• Check that the seals of the electrical cabinet
doors are intact and that the doors close
properly.

Rev: A 221/226
10 MAINTENANCE

REELITE | 15 T

WHAT HOW FREQUENCY

• Check locks, hinges and paint and repair or
restore as required.
• Check the wear of electrical cables on board
the machine and replace them if optimal
insulation and flexibility conditions are
Inspect the condition of altered.
electrical conductors • Take special care to check dynamic laying YEARLY
cables and those near the passage of the
paper/boards or located in unfavourable
environments (e.g. where there are high
temperatures, water oil, acid, etc.).
• Check the characteristics of the safety
Safety equipment equipment with respect to over-currents, YEARLY
conductor loads and indirect contacts.
• Check the wear conditions of all protection
cables, ground cables and equipotential
cables on the main collector as well as on
secondary collectors, where present.
• Check the identification plate and replace if
illegible or missing. BIANNUALLY OR
Check continuity of the • Check that the lead-in wires and junction AFTER
equipotential protection terminals are tight. DISASSEMBLY
circuit • Check the colouring of the insulation sheath. AND REASSEMBLY
• Check cable sizes. OF PARTS
• Check connections to earth cables and
external conduction cables.
• Check the continuity of both main and
secondary protection cables, earth cables
and equipotential cables.

222/226 Rev: A
 DISMANTLING AND SCRAPPING 11
REELITE | 15 T

11 DISMANTLING AND SCRAPPING

11.1 General information
All the interventions described in this chapter are to be performed only by technical personnel specialised
in load handling and waste disposal.
• Final decommissioning and scrapping must be carried out by technical personnel from a centre
specialised in waste disposal to which the machine must be delivered or by whom the machine must be
picked up.
• The machine must not be abandoned in the environment, neither intact nor partially dismantled, and
scrapped.
• Always contact the manufacturer for necessary support.

11.2 Decommissioning for prolonged periods

If the machine is to remain idle for prolonged periods, carry out the procedure described below to ensure
correct storage and conservation.

Prerequisites:

• Regardless of whether the machine is dismantled or left intact and idle, it is important that the
storage area temperature and humidity characteristics are conformant to the technical data.
• The storage area must be clean and not exposed to dust and dirt deposits.
• Always store the machine in a closed environment, protected against inclement weather conditions.

Procedure:

1. Always contact the manufacturer for machine disassembly and handling.

2. Disconnect all energy sources and power supplies.
3. Clean the machine and remove machining residues and dust.
4. Grease and lubricate all components.
5. If the machine will remain idle for more than 3 months, protect parts subject to rust with a suitable
protective product. Protect electrical and electronic equipment by placing anti-humidity sachets in the
electrical cabinets.
6. Cover the machine with plastic sheets to avoid dust.

Rev: A 223/226
 11 DISMANTLING AND SCRAPPING

REELITE | 15 T

11.3 Decommissioning and scrapping

Procedure:

1. Thoroughly consult laws currently in force in the country of use regarding environmental safeguarding
and safety procedures. Implement the inspection procedure of the authorised body, as provided for by
law, and report scrapping as required.
2. Disconnect all power supplies.
3. Disassemble the electrical board and all plastic components, such as covers and pipes for recycling.
Electrical cabinets and control panels must be completely dismantled, separating electrical components
from wires. Electrical wires on board the machine must be collected along with the wires from the
cabinets.
4. Disassemble the various machine components and then break down and divide the parts based on the
type of metal or alloy, making sure to eliminate oil or grease residues.
5. After the initial separation has been made, separate plastic pipes and tubes from rubber pipes and
seals.
6. Pile electrical motors separately, without reducers. Reducers must be emptied of oil and the oil must
be gathered in drums and stored, and not disposed of in the environment. The same is true for waste
grease.

separation, classification and disposal

Waste is any substance or object that is the product of human activities or natural cycles, which is
abandoned or destined to be abandoned.

Special waste includes the following categories of waste:

• Deteriorated or obsolete machines and equipment.

• Motor vehicles and vehicle components that are no longer in use.

European Community directive 2008/98/EC sets forth a law frame work for waste treatment within the
Community.

Waste electrical and electronic equipment may contain dangerous substances

with potentially noxious effects for the environment and for the health of persons.
Therefore, we recommend disposing of such waste correctly, using appropriate
measures. With reference to the WEEE Directive (Waste Electrical and
Electronic Equipment – WEEE 2012/19/UE Directive), during decommissioning,
the user must separate electrical and electronic components and dispose of
them in authorised collection centres.

224/226 Rev: A
 DISMANTLING AND SCRAPPING 11
REELITE | 15 T

Types of waste produced by machine demolition

The table below summarises and classifies the types of waste produced by machine demolition.
• Request information from competent authorities regarding current waste storage and disposal
methods.
• Always contact the manufacturer for the necessary support.
•
Component / material Location
Electrical wires Electrical equipment wiring
Iron and bronze materials Structure
Stainless steel Structure
Lubricants Reducers

Rev: A 225/226
 11 DISMANTLING AND SCRAPPING

REELITE | 15 T

VALMET S.p.a.
Via delle Molina, 69
51017 Veneri di Pescia (PT)
Url: www.valmet.com E-mail: -

226/226 Rev: A