Flexa CWT GALAXY, Use And Maintenance Manual

Page 1: ...MANUAL EN GALAXY HOT ROLLER LAMINATOR FOR HIGH QUALITY PRODUCTION MODEL CWT GALAXY YEAR OF CONSTRUCTION 2019 MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 Translated from original language Read...

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Page 3: ...7 Marking date 6 1 8 Directives and reference standards 7 1 9 Declaration of conformity 8 1 10 Warranty 9 1 11 Assistance 9 2 Machine presentation 11 2 1 Machine parts 11 2 1 1 Self locking spindle s...

Page 4: ...structions 29 5 1 Environmental conditions and preparation for installation 29 5 2 Checks before installation 29 5 3 Unpacking 30 5 3 1 Removing the machine from the pallet with a forklift 31 5 3 2 Re...

Page 5: ...y reset procedure 45 7 10 Quick roller heating procedure 46 7 11 Soft roller heating procedure 46 7 12 Foot pedal control activation procedure 48 7 13 Roller backwards movement activation procedure 48...

Page 6: ...mination on sheets 65 7 21 7 Mounting of image on panel already made adhesive 66 7 21 8 Mounting adhesive images on panels 67 7 21 9 Hot film lamination on sheets and rewinding the finished product 68...

Page 7: ...roubleshooting 79 10 Dismantling and disposal 81 11 Attachments 83 GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduction pr...

Page 8: ...GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduction prohibited without authorisation...

Page 9: ...manual in question is addressed to the operator responsible for operation of the machine and to the technicians authorised for installation and maintenance This document and or its parts cannot be re...

Page 10: ...anical operations regarding the adjustment maintenance and ordinary repairs described in this manual It is not authorised to perform operations on electrical systems in the presence of voltage Qualifi...

Page 11: ...tation in good conditions legible and complete in all its parts Store documentation near the machine in an accessible location known to all operators and maintenance personnel and more generally to al...

Page 12: ...ay indicate a HIGH LEVEL of hazard which if not avoided could result in serious injury or death Warning The risks described in this way indicate a MEDIUM LEVEL of hazard which if not avoided could res...

Page 13: ...0438 38565 Fax 0438 38767 1 6 Ownership of information Icon used Description Mechanical type intervention Electrical type intervention Specifies the frequency of interventions This document and or it...

Page 14: ...e model D Serial number E Supply voltage F Nominal power G Frequency H Year of manufacture I Mass J Caution Request a new identification plate whenever the one applied on the machine becomes illegible...

Page 15: ...2010 Safety of machinery General principles of design Risk assessment and risk reduction UNI ISO TR 14121 2 2013 Safety of machinery Risk assessment Part 2 Practical guide and examples of methods UNI...

Page 16: ...y The original document is supplied separately to this manual GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduction prohibi...

Page 17: ...ust directly contact the manufacturer whose contacts are as follows The warranty is supplied separately or with the contract TELEPHONE 469 758 2288 EMAIL sales cwtworktoolsusa com ASSISTANCE DEPARTMEN...

Page 18: ...GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduction prohibited without authorisation 10...

Page 19: ...asing G Recovery clutch adjustment H Brake adjustment I Foot pedal control J Storage compartment K Print storage tray optional L Recovery clutch adjustment optional M Material trimming blades optional...

Page 20: ...spindles nominal and are perfectly symmetrical not polarised thus allowing for easy placement on the machine The shafts are equipped with two cords A for easy insertion of the core of the roll B on t...

Page 21: ...in the technical data tables see par 2 4 Machining is carried out by passing the material on a pair of rollers The upper roller is heated The machine equipped with 3 spindle shafts works with great p...

Page 22: ...of the machinable products are reported in the technical data Cold lamination is intended as when the roller temperature does not exceed 50 C Danger The machine has not been designed to operate in po...

Page 23: ...c variation m min 0 5 Upper roller temperature C 0 50 Mass of machine parts that require frequent handling Description U M Data Spindle shaft weight empty kg 3 Characteristics of treated product Descr...

Page 24: ...t Description U M Data A mm 1270 B mm 2000 C mm 820 Machine weight kg 215 GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduc...

Page 25: ...machine in order to obtain performance other than that for which it was designed and built unless authorised to do so by the manufacturer Warning Do not neutralise remove modify or otherwise render t...

Page 26: ...as been built in compliance with the technical safety standards in force at the time of its design The instructions and safety warnings in this manual have been written taking into account that the us...

Page 27: ...nce with the machine manufacturing specifications Safety devices must be maintained in efficient conditions Use original spare parts only for the replacement of any safety components Fixed protective...

Page 28: ...le plastic rivets Safety photocell composed of emitter and receiver The machine is equipped with a safety light curtain to safeguard hands from possible crushing The light curtain is active during the...

Page 29: ...used as ordinary stop commands To restart after an emergency stop see par 7 5 In the event of an emergency stop with the rollers hot restart roller rotation as soon as possible If the machine remains...

Page 30: ...rface of the rollers is hot Keep hands away from rollers risk of burns Caution Labels must be replaced if worn or illegible GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DAT...

Page 31: ...rol and if the work so requires manual unloading of the product Machine direction of work Operator intervention area dimensions U M Dimensions D mm 1250 E mm 2460 Descriptions of the direction way and...

Page 32: ...ution The assigned PPE cannot be changed The manufacturer declines all responsibility for any damage to persons caused by failure to use the PPE Caution Operators and maintenance personnel must not we...

Page 33: ...hand protection Warning Risk of abrasion Keep hands away from the two rollers If the safety photocells are not working promptly press the emergency stop button then manually raise the upper roller Wa...

Page 34: ...e and wear gloves Warning Coils with weight less than 50 kg must be handled by two operators Coils with weight exceeding 50 kg must be handled using lifting equipment GALAXY USE AND MAINTENANCE MANUAL...

Page 35: ...ling the packaging at the customer s site Warning Lift the machine following the instructions provided in this chapter Warning Use appropriate tested and certified lifting equipment Warning Lifting an...

Page 36: ...erify the weight to be lifted and the pre set hooking points on the packaging or on the documentation attached to it Use suitable lifting equipment Description U M Data A mm 1450 B mm 2100 C mm 950 Pa...

Page 37: ...ighting system is adequate Check that flooring meets the agreed specifications Installation operations and the first machine start up are carried out by FLEXA S r l Caution The machine must not be ins...

Page 38: ...ber roller lining must be perfectly smooth free of fingerprints bubbles grooves missing portions or cuts Drive pedal no cracks or damaged cable Spindle axes must be intact positioned on their supports...

Page 39: ...he pallet using a forklift Place the forks as shown in the figure Fork positioning point in order to lift the machine GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 0...

Page 40: ...ps A Lower the slides B and have them rest on the ground Slowly move the machine down the slides until it rests on the ground Caution The machine descent must be carried out by two persons one on each...

Page 41: ...the components i e Metals plastic rubber etc and dispose of the various parts in compliance with the local regulations in force To move the machine Release the locks A to release the wheels B 1 After...

Page 42: ...stances indicated in the following image The flooring on which the machine will be positioned must be flat and free of bumps The flooring must be suitable for the mass of the machine including accesso...

Page 43: ...must comply with the regulatory characteristics of the country of installation The electrical connection must only be carried out when positioning fixing has been completed and when all the parts pos...

Page 44: ...ctioning of the safety devices Verify that the machine is completely free of assembly equipment and materials Verify that a general cleaning of the machine has been performed FLEXA S r l Is responsibl...

Page 45: ...witch Par 6 2 B Control panel Par 6 3 C Foot pedal control Par 6 4 D Emergency buttons Par 6 5 E Material tension adjustment knobs Par 6 6 F Adjustment hand wheel lifts and lowers the upper roller Par...

Page 46: ...oller pressure indicator LED B Roller speed adjustment knob C Roller rotation activation button D Roller rotation deactivation button E Roller backwards movement activation button F Vacuum feed table...

Page 47: ...button Press this button to activate roller rotation The roller speed adjustment knob must be positioned between zero and max Roller rotation deactivation button Press this button to deactivate roller...

Page 48: ...r roller heating activation button Press this button to activate deactivate roller heating The lit LED indicates roller heating activation During heating cooling operation the rubber rollers must be i...

Page 49: ...activation of the functional processes immediate stop of all machine movements and equipment dependent on it To reset operation turn it clockwise and the button automatically comes back up The emergen...

Page 50: ...ept slightly taut For material tension adjustment mode see par 7 17 Adjustment hand wheel The adjustment hand wheel lifts and lowers the upper roller Turn clockwise to lift the upper roller Turn count...

Page 51: ...tly to the processing that must be performed Load the material to be processed into the machine Press the roller rotation start button to begin processing See par 6 3 7 3 Cycle pause Warning Remove an...

Page 52: ...they are hot the rollers can deform if left stationary for prolonged periods of time They must always be kept in rotation for cooling If they need to be stopped for example for an emergency stop resta...

Page 53: ...is cycle will be carried out after the machine has been switched on via the main switch If the self diagnosis cycle is positive put the following procedure into effect The LED flashes and there is no...

Page 54: ...wound Perform the following operations to start processing after putting the machine into service The approximate times for reaching the selected working temperatures are as follows About 20 minutes f...

Page 55: ...ng is not required Before activating quick heating of the rollers make sure that there is no material being processing between the rollers and that the protective liner recovery clutch is not excessiv...

Page 56: ...safety light curtain is not engaged 3 Roller backwards movement will activate with a fixed speed pre set by the manufacturer 4 Release the roller backwards movement button B to stop roller rotation 5...

Page 57: ...responding LED will switch off 2 Leave the rollers in rotation and in close contact for at least 20 minutes from when heating is deactivated 3 Press button B to deactivate roller rotation 4 Lift the u...

Page 58: ...e lamination with respect to the image to be laminated An extra area of maximum 2 cm is permitted With extra areas over 2 cm the adhesive lamination can stick to the worktops and make feeding of the m...

Page 59: ...f the working pressure is carried out for example with material scraps or rather of the sandwich of the materials to be laminated In this way it is possible to calibrate the working pressure on the ac...

Page 60: ...e 2 View roller pressure by how the LEDs light up 3 Green LED ideal pressure Orange LED high pressure Red LED pressure too high Turn the hand wheel clockwise to decrease roller pressure The image show...

Page 61: ...ke 2 Start up the work cycle at low speed 3 Gradually increase the clutch brake to start shaft rotation 4 The recovery speed increases as the diameter of the roll increases Decrease the clutch brake t...

Page 62: ...the worktop D 4 Completely lower the upper roller R1 and adjust pressure 5 Detach the adhesive film B from the rear worktop 6 Start the work cycle 7 Stretch the adhesive film evenly during film applic...

Page 63: ...on the support to be processed D on the worktop E 6 Completely lower the upper roller R1 and adjust pressure 7 Detach the adhesive film C from the rear worktop 8 Start the work cycle 9 Stretch the adh...

Page 64: ...n the panel B 3 Have the image C adhere uniformly on the adhesive D 4 Position the panel B between the upper roller R1 and the lower roller R2 5 Completely lower the upper roller R1 and adjust pressur...

Page 65: ...The movement of the axes is greatly facilitated if performed at the rear of the machine Manually rotate the spindle shaft A until the locking pin B is in a horizontal position Lift and tilt the spindl...

Page 66: ...ng pin E Orient the pivot pin D in parallel with the locking pin E Move the pivot pin D closer and engage it in the locking pin E Connection is made on the clutch side At the opposite end of the spind...

Page 67: ...Necessary equipment Screwdriver To adjust the cutting unit Loosen the knob A to move the cutting unit B along the guide 1 Tighten the knob A to lock the cutting unit B in a desired position 2 Cut the...

Page 68: ...ing shaft optional F1 F2 Unwinding shafts idler F3 Unwinding shaft idler optional R1 Upper rubber and heated roller idler R2 Lower motorised rubber roller G1 G2 Guide rollers GALAXY USE AND MAINTENANC...

Page 69: ...irection of rotation of the roll with external liner B Direction of rotation of the roll with internal liner C Liner D Images to be laminated arranged on a sheet GALAXY USE AND MAINTENANCE MANUAL EN M...

Page 70: ...l liner A Direction of rotation of the roll with external liner B Direction of rotation of the roll with internal liner C Liner D Panel to be laminated GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE...

Page 71: ...s F1 Roll with double sided adhesive A Images to be laminated arranged on a sheet GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole...

Page 72: ...n on panels F1 Roll with double sided adhesive A Panel to be laminated GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproductio...

Page 73: ...rection of rotation of the roll with external liner B Direction of rotation of the roll with internal liner C Liner D Images to be laminated arranged on a sheet F2 Roll with double sided adhesive GALA...

Page 74: ...B Double sided adhesive C Liner to be removed manually D Images arranged on a sheet to be applied to the panel GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019...

Page 75: ...sive images arranged on a sheet to be applied to the panel C Liner to be removed manually GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial o...

Page 76: ...tation of the roll with glue on the external side B Direction of rotation of the roll with glue on the internal side C Images to be laminated arranged on a sheet M2 Rewinding the finished product GALA...

Page 77: ...ct F3 Roll with double sided adhesive A Images to be laminated arranged on a sheet M2 Rewinding the finished product GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03...

Page 78: ...GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduction prohibited without authorisation 70...

Page 79: ...ntenance cleaning or repair operation carried out with the electrical system live can cause serious accidents to people including death Warning Always disconnect the machine from energy sources before...

Page 80: ...precision and at the frequency indicated by the manufacturer The table reported in the paragraph 8 3 1 Routine maintenance summary table indicates all the recommended interventions indicates the freq...

Page 81: ...he panel B Type of intervention Performed by Frequency When needed PPE to be used Materials and equipment Common workshop tools Warning Set the machine in safe conditions see par 7 8 GALAXY USE AND MA...

Page 82: ...ide Tighten the screws B Type of intervention Performed by Frequency When needed PPE to be used Materials and equipment Common workshop tools Caution This maintenance must only be performed by an elec...

Page 83: ...Industrial vacuum cleaner Warning Set the machine in safe conditions see par 7 8 Caution If the machine operates in dusty environments clean more frequently Danger Before using any flammable substanc...

Page 84: ...ths PPE to be used Materials and equipment Common workshop tools 10 g of grease for screw A and B 20 g of grease for screw C For lubricant type see par 8 5 Warning Set the machine in safe conditions s...

Page 85: ...ency Every year PPE to be used Materials and equipment Common workshop tools Brush 20 g of grease for chain A Warning Set the machine in safe conditions see par 7 8 To remove the protective casings se...

Page 86: ...r improvements 8 5 Oils and lubricants These maintenance operations are entrusted directly to the manufacturer s specialised technicians Use Quantity Brand kg Grease for lifting screw Arexons GC300 Gr...

Page 87: ...e light curtain interruption and press the safety reset button 6 3 Pedal operation has been activated Deactivate pedal operation 6 3 The roll on the unwinding shaft is turning with difficulty Excessiv...

Page 88: ...GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduction prohibited without authorisation 80...

Page 89: ...ent nature of the components i e metals plastic parts rubber oils etc Hire specialised disposal companies and in any case observe the laws in force concerning waste disposal GALAXY USE AND MAINTENANCE...

Page 90: ...GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduction prohibited without authorisation 82...

Page 91: ...iring diagram 711039020 110V 711039040 230V Spare parts catalogue GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduction pro...

Page 92: ...GALAXY USE AND MAINTENANCE MANUAL EN MANUAL CODE 756100330_EN REVISION 0 DATE 07 03 2019 FLEXA S r l Partial or whole reproduction prohibited without authorisation 84...

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Page 94: ...FLEXA Sr l reserves the right to make technical changes to this manual without prior notice...