ROLLMATIC

User manual
ENGLISH

Serial Number Edition Rev

03

IMPORTANT
Keep this manual for the entire life
of the machine in a known and
easily accessible place
IDM C043600103.fm

The reproduction, even partial, of this document is prohibited without authorization from the builder. The builder is engaged in a program of continuous improvement and reserves the right to modify this document without any
obligation to provide advance notice so long as it is no safety risk. © 2002 - IDM technical communication experts - Forlì - Author of the text, the illustrations and the pagination. The text is registered and the intellectual property of
IDM and may be reproduced, in whole or in part, so long as the author is cited.

P.E. LABELLERS S.p.A

Via Europa, 25 - 46047 Porto Mantovano (Mantova) - Italy
Tel. +39 0376 389311 - Fax +39 0376 389411 - E-mail:[email protected]
http://www.pelabellers.com
The reproduction, even partial, of this document is prohibited without authorization from the builder. The builder is engaged in a program of continuous improvement and reserves the right to
modify this document without any obligation to provide advance notice so long as it is no safety risk. © 2002 - IDM technical communication experts - Forlì - Author of the text, the illustrations
and the pagination. The text is registered and the intellectual property of IDM and may be reproduced, in whole or in part, so long as the author is cited.
 SUMMARY 1

GENERAL INFORMATION ......................................................................from page 3 to page 5

TECHNICAL INFORMATIONS...............................................................from page 6 to page 21
SAFETY INFORMATION .....................................................................from page 22 to page 26
INFORMATION ON HANDLING AND INSTALLATION .......................from page 27 to page 33
ADJUSTMENT INFORMATION ...........................................................from page 34 to page 38
INFORMATION ON USE......................................................................from page 39 to page 65
MAINTENANCE INFORMATION .......................................................from page 66 to page 102
BREAKDOWN INFORMATION........................................................from page 103 to page 105
REPLACEMENT INFORMATION ....................................................from page 106 to page 117

ANALYTICAL INDEX 2

A Clean oil filter (79)

Adjustment of additional aligner (37) Clean the vacuum distributor (78)
Adjustment of glue distribution (38) Cleaning the air filters (78)
Adjustment recommendations (34) Cleaning the cutting shells (77)
Adjustments and maintenance norms (24) Cleaning the glue filter (80)
Aim of the manual (3) Cleaning the labeling unit (72)
Alignment and levelling (30) Cleaning the opening blower device (83)
Attached documentation (5) Container support disk change (50)
Auger drive oil change (94) Control description (39)
Automatic cycle stop (44) Conveyor belt guide positioning (58)
- Final stop of the automatic cycle (44) Conveyor change (49)
- Temporary stop of the automatic cycle (44)
Automatic lubrication oil change (92) D
"Automatic mode" operations (44) Description of accessories (optional) (17)

B E
Belt feeding roller cleaning (84) Electrical connections (31)
Electrical devices (14)
C Emergency stop and restart (45)
Central turntable encoder replacement (110)
Erroneous use (18)
Change automatic joiner pins (57)
Exiting star change (50)
Change contrast device (57)
Change label application roller (52) F
Change label cutter shells (53) Feeding block device positioning (48)
Change label reel format (54) Feeding star change (48)
Change lubrication cartridge (90) Format change (46)
Change value of label held (54) Fume exhaust hook-up (33)
Check cutting blade efficiency (100) G
Check for plate drive wear (S machine version) (98) General norms (22)
Check glue uniformity and distribution (95) Glossary and terminology (4)
Check head drive device bearings (100) Glue supply (64)
Check head rotation (97) Glue tank cleaning (82)
Check idle roller rotation (96) H
Check of the plate rotation belt (machine version N) (99) Handling and installation norms (22)
Check transmission chain tension (102) Handling and lifting (28)
Clean brake reel (81) How to replace the glue doser (114)
IDM C043600103.fm

Clean cutting roller (74)

I
Clean glue roller (75)
Information and safety signals (25)
Clean label application roller (73)
Installation of dismounted parts (29)
Clean label application roller slides (76)

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 L R
List of residual risks (17) Recommendations for connections (31)
Lobe cam change (S machine version) (51) Recommendations for handling and loading (27)
Lubricant table (71) Recommendations for use (65)
- Table Features of the lubricants (71) Recommendations for use and functioning (39)
Lubricate head drive device (87) Recommended spare parts (106)
Lubricating the glue roller (85) Reel brake adjustment (35)
Lubricating the plates (86) Reel ch’ange (62)
Lubrication of the labelling unit chain (88) Reel insertion (with automatic joiner) (61)
Lubrication of the main transmission chain (88) Reel insertion (without automatic joiner) (60)
Lubrication point diagram (70) Replacement instructions (106)
M Replacement of the axis encoder (112)
Machine cleaning (71) Replacing "FR unit" air filter (107)
Machine demolition (117) Replacing air filters (106)
Machine disposal (117) Replacing electrical heating elements (110)
Machine general description (6) Replacing label application roller slides (109)
Machine installation (29) Replacing oil filter (108)
Machine reset button (65) S
Machine start (42) Safety devices (12)
Machine testing (33) Safety regulations for environmental impact (25)
Main organs (8) Signal position (21)
Maintenance instructions (66) Spacer auger change (46)
Maintenance period table (66)
T
- Table Maintenance intervals (67)
Technical specifications (19)
Manufacturer and machine identification (4)
- Table Container technical characteristics (19)
Modes of requesting for assistance (5)
- Table Label technical characteristics (19)
O - Table Machine technical characteristics (19)
Oil change of main drive reduction gear (91) Transmission belt adjustment (36)
Operating malfunctions (66), (103) Transmission belt replacement (N machine version) (113)
Operation and use norms (23) Transmission chain adjustment (34)
Operation in "manual mode" (43) Transmission gear lubrication (89)
Transport (28)
P
Troubleshooting (103)
Packaging and unpacking (27)
- Table Operation irregularities of the machine (103)
Plate roller lubrication oil change (93)
Pneumatic connections (32) W
Pneumatic devices (16) Work perimeter areas (20)
Positioning of the label presence check photocell (58) Working cycle (10)
Positioning of the labelling unit (59) - Container feeding (10)
- Container outlet (11)
Positioning of the spiral conveyor spacer (47)
- Labelling stage (10)
IDM C043600103.fm

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GENERAL INFORMATION
1

AIM OF THE MANUAL 1

– This manual is an integral part of the machine and has been produced by the man-
ufacturer in order to furnish necessary information to those that are authorised to
interact with it.

– In addition to adopting good use techniques, the recipients must carefully read and
strictly apply this information.

– This information has been produced by the manufacturer in his own original lan-
guage (Italian) and can be translated into other languages to satisfy legal and/or
commercial requirements.

– Time dedicated to reading this information will avoid personal safety and health risks
and economic damages.

– In the event that supplementary information to the actual machine set up is found in
this manual it will not interfere with reading.

– Keep this manual for the full machine life in a known and easily accessible place in
order to have it ready available in the event consultation is required.

– The manufacturer reserves the right to carry out modifications without obligation of
prior notice.

– To better stress the importance of some passages or to indicate important specifica-

tions, symbols, whose meanings are described as follows, have been adopted.

Danger - Warning
Indicates critically dangerous situations that if neglected can result in serious
personal safety and health hazards.

Caution - Precaution
Indicates that suitable actions must be employed in order to avoid personal
safety and health hazards and economic damages.

Important
Indicates particularly important technical information that should not be ne-
glected.
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MANUFACTURER AND MACHINE IDENTIFICATION 2

The illustrated identification plate is applied directly on the machine. It contains refer-
ences and indispensable operating safety indications.

A B

C
D
G F
Q P
R H
L M
E N

IDM-45500200100.tif

A)Builder identification (also see the title page of this manual).

B)Space reserved for CE compliance marking
C)Model
D)Serial number
E)Manufacturing year
F) Power supply voltage
G)Absorbed power.
H)Power supply frequency.
L) Air consumption
M)Air pressure
N)Machine weight
P)Maximum short circuit current
Q)Absorbed current
R)Power supply phases

GLOSSARY AND TERMINOLOGY 3

Some recurring terms found within the manual are described in order to provide a
more complete image of their meanings.
– Installation technician: a technician authorised by the Manufacturer or his agent,
chosen among those who have the requirements, skills and information necessary
to perform machine installation and testing.
– Ordinary maintenance: group of functions necessary to maintain suitable machine
operations and efficiency. Normally the manufacturer, who defines the necessary
skills and intervention procedures, plans these operations.
IDM C143600103.fm

– Unscheduled maintenance: set of operations necessary to keep the convenient

functionality and efficiency of the machine.

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GENERAL INFORMATION
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– Operator: a person trained, authorised and chosen among those who have the
requirements, skills and information necessary for machine use and supervision.
– System supervisor: a technician authorised and chosen to supervise all the organ-
isational and operative aspects of the personnel assigned to the system and produc-
tion activities.

MODES OF REQUESTING FOR ASSISTANCE 4

For any information, contact the manufacturer’s service centre.

For every technical service request regarding the machine, please indicate the data
found on the identification plate, the approximate hours of use and the type of fault
detected.

ATTACHED DOCUMENTATION 5

The indicated documentation is given to the customer along with this manual.
– Electric diagram
– Pneumatic circuit diagram
– Manual of operating terminal
– Equipment chart (format change)
– Documentation of commercial components installed
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MACHINE GENERAL DESCRIPTION 1

– The Rollmatic automatic rotary labeling machine is designed and constructed for ap-
plying wrap-around labels with hot-melt glue (distributed on its two ends) on cylindri-
cal and/or shaped containers, complete and product and sealed closed.

– Upon request, the machine can be supplied with a pressurization system for labeling
empty containers.The machine is produced in S and N versions.

– Machine version S: can label cylindrical or shaped containers. The plates are rotat-
ed by the lobe cam.

– Machine version N: can only label cylindrical containers. The plates are rotated by
pulley transmission.

– The application of the labels is extremely precise thanks to the use of an aligner that
automatically corrects the slightest movement and keeps the film perfectly horizontal.

– The machine is provided with four levers, from which it is possible to set and to con-
trol all the operation functions of the working cycle.

– The starting and stopping of the machine can be either manual or programmed. In
the latter case, the machine is preheated, starts and stops production automatically
according to a preset schedule.

– The machine can be constructed in various configurations so as to adapt to various

plant layouts and satisfy a wide variety of labeling needs.

– The machine may be provided with various parts in order to adapt it to the different
container and label formats.

Important
Unless specified otherwise, the information in this manual (text, tables and il-
lustrations) refers to the version to the left.

– This machine does not require the constant presence of the operator.

– It is sufficient for the employee selected by the line manger check its operation and,
when necessary, resupply the reels and glue.
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The drawing shows some configurations relating to the various container feeding
(inlet/outlet) procedures.

SX DX SX DX
IDM C243600103.fm

IDM-43600100201.tif

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MAIN ORGANS 2

A)Conveyor belt: it feeds the machine and conveys the exiting containers.

B)Feeding block device: it adjusts the container feeding flow to the machine.

C)Spacer auger: it places the containers at a distance.

D)Feeding star: it conveys the containers to the central carousel.

E)Central carousel: it conveys the containers during the labelling stage.

F) Disk: it holds and rotates the container during labelling stage.

G)Container holding head: it stops the container during the labelling stage.

H)Head control device: it lifts and lowers the head.

J) Contrast device: presses the label on the container to smooth it and apply it cor-
rectly. Device installed on the machines that do not perform the "slide to slide"
smoothing of the labels.

L) Glue tank: it contains and melts the glue.

M)Glue roller: it applies the glue on the labels.

N)Film feed roller: motorized and feeds the film to the cutting roller.

P)Aligner device: centers and aligns the film to the container.

P1)Additional aligner device: it keeps the film centred and aligned with the contain-
er if wrong reels are produced (non uniform print, wrong joint, etc.).

Q)Support reel : supports and maintains the film under tension.

R)Automatic joiner: for automatically joining spools and eliminating idle time
changing spools.

S)Cutting roller: cuts the labels in correspondence with the notices of reference.

T)Label application roller: takes the cut label and applies it to the container after it
is spread with glue.

U)Conveyor: it acts as support to the containers in the conveying stage of the feeding
and exiting stars.

V)Exiting star: it transfers the containers from the central carousel to the exiting
conveyor belt.

X)Automatic lubrication system: lubricates the plate operating rollers (only for
version S).

Y)Automatic lubrication system: lubricates the labelling unit components.

Z)Control panel: it contains the devices to start and control all the operation
functions.
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(X) Automatic lubrication system

(H) Head operating device

(G) Container stopping head
(F) Container support bottom

(A) Conveyor
(D) Container feeding star
(B) Container feeding block device
(C) Spacer auger

(M) Glue application roller (V) Container exit star

(E) Central turntable (U) Container conveyor

(T) Label application roller

(Z) Control panel

(L) Glue tank (Q) Reel support

(Y) Automatic lubrication system
(N) Label belt feeding roller
(R) Label automatic joiner
(P) Label belt aligner device
(J) Contrast device
(S) Cutting roller
(Q) Reel support
(P1) Label film aligner device (additional)
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IDM-43600100303.tif

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WORKING CYCLE 3

Container feeding

– The lever (B) is unlocked by means of the operating terminal, the containers are
transferred from the conveyor belt (A) and spaced by the spiral conveyor (C) to adapt
them to the machine's pace.
– The containers are picked up by the feeding star (D) and transferred on the disks (F).
– The heads (G) lower to block the containers, which are rotated at a constant speed
by the carousel (E).

(D) Container feeding star

(C) Spacer auger

(A) Conveyor

(B) Lever
(G) Container stopping head

(F) Container
support bottom

(E) Central turntable

IDM-00000000000.tif

Labelling stage

– Feed roller (N) unwinds the film and transfers it to roller (T) for cutting.
– The cut label is sucked by roller (U) and transferred to roller (M) for the application
of the glue.
– The container is correctly positioned in front of roller (U) for the application of the
label.
IDM C243600103.fm

– During the labeling phases, container (Q) rotates so as to allow the definative
smoothing of label (P).

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(Q) Container

(P) Label

(F) Container support

bottom
Label film
(P) Label

(T) Cutting roller

(M) Glue application roller

(U) Label application roller

(N) Label belt feeding roller

IDM-43600800401.tif

Container outlet

– Upon the completion of the labeling phase, the containers are picked by star (Z) and
transferred to the exit by conveyor belt (A).

(A) Conveyor

(Z) Container exit star

IDM C243600103.fm

IDM-43600800501.tif

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SAFETY DEVICES 4

The figure shows the positioning of the devices on board of the machine.

(C) Emergency stop button (B) Main switch

(A) Mobile guard (E) Mobile guard
(C) Emergency stop button
(C) Emergency stop button (E) Mobile guard
(H) Selector
(L) (G) Key

(L)

(F) Mobile push-button pad

(H) Selector

(L) (L)

(D) Fixed safety guard

(E) Mobile guard (D) Fixed safety guard

(C) Emergency stop button
(P) Key (C) Emergency stop button
(M) Mobile push-button pad
(N1) Key
(N) Key

IDM-43600100902.tif

A)Mobile guard: prevents access to the electrical panel. It is fitted with a lock with
removable key.
B)Main disconnector (lockable): it is used to isolate the machine from the energy
source.
C)Emergency stop button with key unlocking device: quickly stops each machine
IDM C243600103.fm

parts. After normalising the working conditions, unlock the button with the key in
order restart the machine.

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D)Fixed guard: it prevents from accessing the dangerous areas of the machine.
E)Mobile guard: it prevents the access to the hazardous areas of the machine.
The guard is combined with a safety microswitch. When it opens, the machine
stops in safe conditions. The new start is subject to the closing of the guard and to
the restoration of the operating cycle.
F) Mobile push-button pad: it is used to start the machine in safe conditions, as well
as to make the machine operate in "manual mode" during format change, mainte-
nance phases, etc.
The mobile push-button pad is equipped with the emergency stop button (C), the
button (G) to start the machine in "manual mode", which must be pressed together
with the buttons (L), and a key selector (H) to disable the operation of the buttons
(L).
M)Mobile push-button pad: it is used to start, in "manual mode" and in safe condi-
tions, only the labelling unit during format change, maintenance phases, etc.
The mobile push-button pad is equipped with the buttons (N-N1) to start the belt
feeding roller in "manual mode", the button (P) to start the label application roller in
"manual mode" and a key selector (H) to disable the operation of the buttons (L).
The buttons (L) in the push-button pad must be disabled only when it is necessary
to replace the cutting blades.
When the buttons (L) are disabled, all safety conditions are cancelled, with subse-
quent increase in the risks for people. Therefore, the key to disable the selector (H)
must be kept by the system manager, who has to personally disable the control.
The person in charge of the system must authorise only the properly skilled person-
nel to replace the cutting blades. Moreover, he/she must make sure that no improp-
er operations are carried out in order to prevent any risks to people’s safety.
When the cutting blades are replaced, the person in charge of the system must re-
set the operation of push-button panel (F-M) by means of key selector (H), must
check the resetting of the safety conditions, remove the key from selector (H) and
retain it in a place unknown to his/her colleagues.
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ELECTRICAL DEVICES 5

The figure shows all the necessary devices for the activation and control of the ma-
chine operating functions.

20
16
2
22
14

21
16
7
18
13 19
6 16
24

25
11
8 17
12
5
9 23
4 1
15
3
12
10
17

IDM-43600100403.tif

1) Gearmotor: it starts the main drive.

2) Gearmotor: it adjusts the height of the upper carousel.
3) Gear motor reducer: regulates the height of the labeling unit.
4) BRUSHLESS motor: drives the film feed roller.
5) Gear motor reducer: starts the rotation of the labelling unit.
6) Gear motor reducer: drives the glue feed pump.
7) Gear motor reducer: starts the central automatic lubrication pump.
IDM C243600103.fm

8) Suction unit: creates suction to hold the label.

9) Photocell: detects the correct position of the label tape.

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10)Photocell: detects the passage of the label film notches and synchronises the cut-
ting and pull rollers.
11)Sensor: detects the quantity of glue on the tub.
12)Sensor: detects the quantity of label tape on the spools.
13)Sensor: detects the correct functioning of the distributor of the central automatic
lubrication.
14)Sensor: it detects the presence of containers and enables the labelling unit.
15)BRUSHLESS motor (only version N): starts the rotation of the plates.
16)Microswitch: it detects the jamming of the auger and stops the machine.
17)Electric clutch brake: acts on tensioner roller device to adapt the tension of the
label film.
18)Encoder: detects and control the phase of the central turntable.
19)Encoder: detects and controls the operational phases of the machine's functional
units.
20)Electric clutch brake: intervenes on the spiral conveyor spacer in order to stop
the flow of containers to the machine.
21)Photocell: detects that the label has been applied on the container.
22)Sensors: detect the accumulation of containers in the entry area and determine
the speed of the machine.
23)Sensor: detects the position of the tensioner roller and enables the activation of
the clutch brake.
24)Sensor: detects the accumulation of containers in the exit area and enables the
closing of container entry blocking device.
25)Sensor: it detects the accumulation of containers in the exiting area and deter-
mines the speed of the machine.
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PNEUMATIC DEVICES 6

The illustration shows all the necessary pneumatic devices for actuating and control-
ling the machine's functions.

Pressure switch
Air treatment unit Solenoid valve
Pneumatic manifold Solenoid valve unit

Pressure regulator

IDM-43600100503.tif

- Air treatment unit

- Pressure switch: detects the working pressure value when it lowers to minimum.
- Solenoid valve: controls the start of the pneumatic system.
- Regulator: regulates the operating pressure of the "opening blower".
Rotate the handle in order to vary the levels of pressure indicated on the pressure
gauge.
- Regulator: regulates the operating pressure of the "cutting blower".
Rotate the handle in order to vary the levels of pressure indicated on the pressure
gauge.
- Regulator: regulates the operating pressure of the tensioner.
Rotate the handle in order to vary the levels of pressure indicated on the pressure
gauge.
- Regulator: regulates the operating pressure of the "transfer blower".
Rotate the handle in order to vary the levels of pressure indicated on the pressure
gauge.
- Regulator: regulates the operating pressure of the label film feed roller.
Rotate the handle in order to vary the levels of pressure indicated on the pressure
gauge.
- Solenoid valves unit: it controls the pneumatic actuators of the machine.
- Pneumatic manifold: it connects the label application roller to the suction system.
- Regulator: adjusts the operating pressure of the "inlet blower" device.
Rotate the handle in order to vary the levels of pressure indicated on the pressure
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gauge.

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DESCRIPTION OF ACCESSORIES (OPTIONAL) 7

The following accessories, which are intended to enhance the machine performance
and versatility, are available from the Manufacturer.
– Automatic joiner: for automatically joining spools and eliminating idle time changing
spools.
– Container pressurization system: fills the containers with pressurized air for labe-
ling.
– Conveyor belt motor drive: synchronizes the speed of the belt to that of central
turntable through an inverter. This is installed when the machine is not directly con-
nected to the production line.
– Electrical panel conditioner: for maintaining the temperature and moisture inside
the electrical panel within an adequate value.
– Ink-jet stamper: for stamping products.
– Missing plug control: for checking products on the turntable and discarding those
that do not have a closing plug.
– Tipped container control: for checking the correct positioning of the products on
the conveyor belt.
– Automatic reject device: it rejects the containers in which the label has not been
applied during the labelling phase.

LIST OF RESIDUAL RISKS 8

Although during machine design and manufacturing phases all safety solutions were
used, the listed residual risks still remain.
– Risk of burns close to the glue tank: when you access the labelling unit (area (A))
and the protective covers open, all moving parts will stop. The risk of burns, which is
specified by the proper signal, still remains.
– Risk of cutting or crushing close to the cutting roller: if it is necessary to replace the
cutting blades, the authorized staff for this operation must disable the buttons in the
mobile push-button pad. In these conditions, there is a risk of cutting or crushing and
the authorised staff must take the correct precautions.
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IDM-43600114000.tif

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– Risk of entanglement and crushing close to product input (B) and output (C) areas:
do not approach the areas that are equipped with the moving parts. In particular, pay
attention to the reject device.
– Risk of collision close to the idle roller (D): when the staff replaces the reels, it is nec-
essary to pay attention to the idle roller, as it could activate in a sudden way, and then
move abruptly. The area is signalled by means of a band with inclined stripes.

IDM-43600114000.tif

ERRONEOUS USE 9

– The machine must be exclusively used to apply wrap-around labels to containers

having an appropriate size and shape (see technical specifications).
– Non wrap-around labelling (partial labelling) must not be performed and is therefore
considered improper use.
– The products to be labelled must not contain dangerous materials in order to avoid
the accumulation of gases that may provoke fires and explosions.
– The replacement of the cutting blades, if not performed according to the instructions,
is to be considered as improper use of the machine.
- The buttons (L) in the push-button pad must be disabled only when it is
necessary to replace the cutting blades.
- When the buttons (L) are disabled, all safety conditions are cancelled, with
subsequent increase in the risks for people. Therefore, the key to disable the
selector must be kept by the system manager, who has to personally disable
the control.
- The person in charge of the system must authorise only the properly skilled
personnel to replace the cutting blades. Moreover, he/she must make sure that
no improper operations are carried out in order to prevent any risks to peo-
ple’s safety.
- When the cutting blades are replaced, the person in charge of the system
must reset the operation of push-button panel by means of key selector , must
IDM C243600103.fm

check the resetting of the safety conditions, remove the key from selector and
retain it in a place unknown to his/her colleagues.

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TECHNICAL SPECIFICATIONS 10

Important
Consult the layout to identify the actual machine configuration.
Table 2.1: Machine technical characteristics
Description 720 - 16T 810 - 18T 960 - 24T 1420 - 35T 1420 - 40T

Installed power 20 Kw 24 Kw 27 Kw 35 Kw 35 Kw
Electric current voltage (standard) 380V 3 N / 380V 3
Electrical frequency 50/60 Hz
Operating pressure 7 bar
Pneumatic supply tube diameter ½“
Air consumption at operating pressure 900 Nl/min

Table 2.2: Container technical characteristics

1-2-375
Description 2-3-375 2-4-250
2-4-375

Minimum diameter 55 mm 40 mm
Maximum diameter 110 mm 75 mm
Minimum height 170 mm 170 mm
Maximum height 370 mm 370 mm

IDM-43600107000.tif

Table 2.3: Label technical characteristics

1-2-375
Description 2-3-375 2-4-250
2-4-375

Minimum length (L) 180 mm 135 mm

Maximum length (L) 360 mm 250 mm
Minimum height (H) 40 mm 40 mm
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Maximum height (H) 180 mm 180 mm

Internal diameter minimum spool (D1) 600 mm 600 mm

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Table 2.3: Label technical characteristics
1-2-375
Description 2-3-375 2-4-250
2-4-375

External diameter maximum spool (D2) 7 mm 7 mm

Minimum application height from bottom 245 mm 245 mm
(H1)
Standard label overlap (S) 11÷12 mm 11÷12 mm

Glue technical characteristics

Leuenberger Termomelt NK 827/825
Swift h 625/96
Fuller Clarity HL 4167 / HL 1195
Henkel Euromelt 357/362/377

Noise level
During operation the machine generates noise levels lower than 85 Db, in conformity
with the current law.

WORK PERIMETER AREAS 11

The drawing shows the operation areas.

A E

C B

IDM-43600100800.tif

A)Operator command and glue resupply area

B)Product feeding area
C)Product exiting area
IDM C243600103.fm

D)Spool replacement area

E)Boundary area

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TECHNICAL INFORMATIONS
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SIGNAL POSITION 12

The figure shows the position of the safety plates. Their meaning is described in
paragraph "Information and safety signals".

Important
Check that the plates are clearly readable, and, if necessary, replace them with
new ones that shall be positioned in the same places as previously.

IDM-43600112200.tif
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GENERAL NORMS 1

– During design and construction, the manufacturer has carefully considered the pos-
sible hazards and personal risks that may result from interaction with the machine.
In addition to observing the specific laws in force, the manufacturer has adopted all
"exemplary construction technique principles". The purpose of this information is to
advise the users to use extreme caution to avoid risks. However, discretion is inval-
uable. Safety is also in the hands of all the operators who interact with the machine.
– Carefully read the instructions published in the supplied manual and found directly
on the machine while strictly observing those concerning safety. Time dedicated to
reading will prevent unfortunate accidents; remembering what one was supposed to
do when the damage is already done is always too late.
– The insertion of this machine to a system requires a complex design that takes into
consideration all the "exemplary technique" requirements, the legislative and regula-
tion aspects. Careful attention must be paid to all instructions and technological in-
formation indicated by the Manufacturer.
– Pay attention to the meanings of the symbols on the applied stickers; their shape and
colour are significant to safety ends. Keep them legible and observe the indicated in-
formation.
– Never tamper, dodge, eliminate or by-pass the safety devices installed on the ma-
chine. Neglect to respect this requirement may cause serious risk to personal safety
and health.
– Personnel who are to perform any type of work on the machine during its lifetime
must possess specific technical skills, abilities and have acquired certified experi-
ence in the specific field. Neglect to observe these requirements may prove hazard-
ous to personal safety and health.
– Only wear and use the protective clothing and/or devices indicated in the instructions
provided by the manufacturer or work safety laws in force when operating the machine.
– Keep the area surrounding the machine, especially areas of control access, in suit-
able conditions during machine operations or intervention to avoid personal safety
and health risks.
– The aid of one or more helpers may be necessary during some stages. In these cas-
es it is advisable to adequately train and inform them on the type of activity to be car-
ried out, in order to avoid damages to the safety and health of personnel.

HANDLING AND INSTALLATION NORMS 2

– Observe the information found directly on the packaging and in the instructions pro-
vided by the manufacturer to move the machine.
– Personnel who load, unload and transport the machine must possess skills and ac-
quired certified experience in the specific field and have command of the lifting vehi-
cles utilised.
– Loading and transportation must be carried out with equipment having adequate ca-
pacity by anchoring the machine in the points foreseen by the manufacturer. The per-
sonnel authorized in accomplishing these operations must have specific capacity
and experience as to safeguard proper safety and that of the persons involved.
IDM C343600103.fm

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– Before loading the machine on transportation vehicles, make sure the machine and
its components are well centred and that the proportions do not exceed the foreseen
maximum dimensions. If necessary, arrange appropriate signals.
– All the installation stages must be considered, starting from the general project im-
plementation. Before proceeding to such stages, besides defining the installation ar-
ea, the operator who is authorized to carry out these operations must, in case of
need, perform a "safety plan" to preserve the security of the people directly involved
and strictly apply all the laws, with special reference to those concerning mobile
sites.
– The staff that is authorised by the manufacturer to perform the installation must
check that the premises are sufficiently lighted, that the connections to the power
supplies (electric, pneumatic, etc.) meet all legislative and prescriptive requirements,
and that the flooring of the area is stable and levelled in order to assure the correct
support of the machine.
– When installing, comply with the requested surrounding spaces required by the man-
ufacturer, including all other surrounding operations. This requirement must be exe-
cuted in order to keep the instalment in line with workplace safety laws.
– The installation and connections must be carried out according to the instructions
provided by the manufacturer. The person in charge must also comply with all nor-
mative and legislative requirements and execute all parts of the installation and con-
nection process to perfection. When the installation is complete and before use
commences, the person in charge must carry out a general check in order to verify
that all requirements have been complied with.

OPERATION AND USE NORMS 3

– In addition to being informed and trained on machine use, the operator must possess
the skills and acquired proficiency suited to the type of work to be accomplished.
– Even after an opportune documentation, at first utilisation, if necessary, simulate
some tests to identify command and their main functions, in particular those concern-
ing the starting and stopping operations.
– Only use the machine for the purposes specified by the manufacturer. Use of the ma-
chine for other purposes may be hazardous to personal safety and health and pro-
voke economic loss.
– The machine is designed and constructed to satisfy all the operating conditions indi-
cated by the manufacturer. Tampering with any device to achieve services other than
those may be hazardous to personal safety and health and provoke economic loss.
– Do not use the machine if the safety devices are not correctly installed and efficient.
Neglect to observe this requirement may be hazardous to personal safety and health.
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ADJUSTMENTS AND MAINTENANCE NORMS 4

– Keep the machine in maximum working conditions and perform the programmed
maintenance operations advised by the manufacturer. Good maintenance achieves
the best machine performance, longer machine life and constant observance of the
safety regulations.
– Before performing any maintenance and adjustment, activate all foreseen safety de-
vices and evaluate the need to warn operating personnel and those in the near vicin-
ity. In particular, adequately mark the surrounding areas and prevent access to all
devices that could, if activated, cause unexpected personal safety hazards.

Important
During adjustments and maintenance in machine areas where it was necessary
to deactivate some of the protections and where several components remain in
motion, do not bring parts of your body close to the area to avoid risks to your
safety and health.
– Maintenance and adjustments should be performed by authorised personnel who
must establish all the necessary safety conditions according to the indicated proce-
dures.
– All maintenance procedures that require precise technical competence or specific
skills must be exclusively performed by qualified personnel with acquired certified ex-
perience in the specific field.
– In order to carry out maintenance work in areas which are not easily accessible or
dangerous, adequate safety conditions must be imposed for oneself and others, in
full accordance with the laws in force on workplace safety.
– When operations requesting the use of the mobile push-button panel with disabled
safety functions must be performed, these functions must be disabled by the person
in charge of the system.
– The person in charge of the system must authorise only the properly skilled person-
nel to replace the cutting blades. Moreover, he/she must make sure that no improper
operations are carried out in order to prevent any risks to people’s safety.
– After completing these operations, the person in charge of the system must reset the
operation of push-button panel by means of key selector , must check the resetting
of the safety conditions, remove the key from selector and retain it in a place un-
known to his/her colleagues.
– Replace worn out components with original spare parts. Use oils and greases sug-
gested by the manufacturer. All this can ensure plant functionality and foreseen safe-
ty level.
– Do not litter the environment with polluting material; perform disposal according to
the pertinent laws in force.
IDM C343600103.fm

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SAFETY REGULATIONS FOR ENVIRONMENTAL IMPACT 5

– Every organisation is required to apply procedures to identify, evaluate and control

the influence of its activities (products, services, etc.) on the environment.
– The procedures to be followed to identify significant environmental impacts must
take the following factors into account:
- Emissions in the atmosphere
- Liquid drainage
- Waste management
- Ground contamination
- Utilization of raw materials and natural resources
- Local problems concerning environmental impact
– In order to minimize environmental impact, the manufacturer provides hereinafter
some indications that must be taken into account by all those who interact for any
purpose with the machine during its expected life.
– All packaging components should be disposed of in accordance with the legislation
in force in the country where disposal takes place.
– During installation, make sure there is suitable ventilation to avoid concentration of
unhealthy air for operators.
– During operation and maintenance, do not throw away polluting products (oils,
greases, etc) in the environment and carry out the differentiated waste disposal ac-
cording to the composition of the different materials and in compliance with the leg-
islation in force. Electric and electronic components should be carried out as special
waste.
– Keep noise levels at a minimum to reduce noise pollution.
– In dismantling stage, select all the parts in relation to their chemical features and car-
ry out separate disposal.

INFORMATION AND SAFETY SIGNALS 6

The illustrations depict the safety and information signs affixed on the machine. Their
relevant meanings are listed next to each sign.
Danger of burns: beware of hot surfaces. >>>

Removal prohibited: removing guards and safety device with parts

in motion is prohibited. >>>
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Danger of entanglement: stay away from moving parts. >>>

Shock hazard: do not touch live parts. >>>

Danger of burning: beware of hot surfaces. >>>

Gloves are compulsory: and must be worn in order to protect hands

from abrasions. >>>

Signal of residual risk next to the idle roller: keep off the area where
the machine is operating. >>>
IDM C343600103.fm

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INFORMATION ON HANDLING AND INSTALLATION
4

RECOMMENDATIONS FOR HANDLING AND LOADING 1

Lift and handle observing the information provided by the manufacturer and
found directly on the packaging, on the machine and in the instructions for use.
Personnel authorised to perform these operations must, if necessary, organise
a “safety plan” to protect those directly involved.

PACKAGING AND UNPACKING 2

Limiting the machine dimensions, packaging is also made according to the type of
transport employed.
To facilitate transport, shipping can be performed with some components disassem-
bled and appropriately protected and packaged.
Some parts, the electric parts in particular, are protected with anti-moisture nylon.
All the necessary information for loading and unloading is found on the packaging.
During unpacking, check the integrity and exact quantity of components.
Packaging material should be appropriately disposed according to the laws in force.
Packaging can be made:
A)on platform with nylon protection
B)On bed with safety fence
C)in case for ship transport
D)in case for air transport

A B C D

IDM-43600101100.tif
IDM C443600103.fm

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TRANSPORT 3

Transport, also according to the destination, can be performed by different vehicles.

The diagram represents the most popular solutions.
During transport, in order to avoid inopportune movement, adequately secure the load
to the transportation vehicle.

IDM-43600101200.tif

HANDLING AND LIFTING 4

The machine can be handled with an adequate capacity fork or hook lifting device.
Position the lifting device in correspondence to the points marked; in the case of using
a hook device, install the eyebolts provided in the holes prepared in its structure.

Important
Before lifting, check the position of the load's centre of gravity.
IDM C443600103.fm

UNPACKAGED PACK PLATFORM PACKAGING BOX PACKAGING

IDM-43600101301.tif

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MACHINE INSTALLATION 5

– All the installation stages must be considered, starting from the general project im-
plementation. Before proceeding to such stages, besides defining the installation ar-
ea, the operator who is authorized to carry out these operations must, in case of
need, perform a "safety plan" to preserve the security of the people directly involved
and strictly apply all the laws, with special reference to those concerning mobile sites.
– The installation area must be in suitable environmental conditions (lighting, ventila-
tion, etc.).
– The floor must be stable and level to guarantee correct machine support.
– The installation area must have all the supply and exhaust connections.
– Locate the installation area defined in the layout.
– If necessary, identify the machine's exact location by drawing the coordinates that
will be used for its correct positioning.

INSTALLATION OF DISMOUNTED PARTS 6

Important
The machine must be installed followed the procedure in the installation manual
by qualified personnel authorized by the manufacturer.
Proceed as indicated.
1 -Mount reel support.
2 -Screw support feet (A) where they attach to the structure.

(A) Support foot

IDM C443600103.fm

IDM-43600101401.tif

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3 -Insert luminous signal (B) in its seat and rotate it clockwise to lock it.

(B) Lighted signal

IDM-43600101501.tif

ALIGNMENT AND LEVELLING 7

In order to assure the correct functioning of the machine, it is necessary to assure the
perfect alignment and levelling of the containers in relation to the inlet and outlet ma-
chine.
Proceed as indicated.
1 -Place the spirit level as shown in the figure.
2 -Loosen the lock nut (A) and use the support feet (B) to level the machine.
3 -Tighten the lock nuts (A) when finished.

(A) Counter nut

(B) Support foot

IDM C443600103.fm

IDM-43600101601.tif

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RECOMMENDATIONS FOR CONNECTIONS 8

Connections should be performed following the manufacturer’s indications in

the enclosed diagrams. Personnel authorised to perform this operation must
possess technical skills, abilities and have acquired certified experience in the
specific field and must perform connections professionally, taking into account
all the regulative and legislative requirements. When connections are complet-
ed, make sure these requisites were observed by performing a general inspec-
tion before making the unit operative.

ELECTRICAL CONNECTIONS 9

Important
Electrical connections must be performed by an expert with precise technical
skills so as to protect personal safety and machine integrity.
Personnel who performs electrical connections must know the reference regu-
lations (even local ones) and apply them based on factory and machine’s overall
electrical system features.
Proceed as indicated.
1 -Make sure that the general eletrical power supply corresponds to the characteris-
tics indicated on the identification plate, on those shown in correspondence with
the connection points, in the diagrams and in the instructions for use.
2 -Close to the machine, install a cut-off switch with magneto thermal release and
differential locking, which must be suitable for the supply line of the plant.
3 -Turn main switch in position 0.
4 -Open the door (A) of the electrical cabinet.

Earthing wire

(C) Terminal

(A) Door

(B) Electrical terminal board

IDM C443600103.fm

Electrical power cord

IDM-43600113900.tif

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5 -After that, introduce the power cords inside the electrical cabinet.

Important
Assure that the protection level of the electrical panel keeps unaltered.
6 -Connect the power cords to the terminal board (B).
7 -Connect the earthing wire to the relevant terminal (C).
8 -Close the door (A) of the electrical panel, and then rotate the main switch to posi-
tion I (ON) to activate the power supply.

Important
The machine can automatically check the correct sequence of the phases.

Earthing wire

(C) Terminal

(A) Door

(B) Electrical terminal board

Electrical power cord

IDM-43600113900.tif

PNEUMATIC CONNECTIONS 10

Make sure that the air supply system corresponds to the specifications indicated on
the identification plate, on those applied near connection points, in the diagrams and
instructions for use.
Connect the feeding pipe (A) and block it with the special clamps.

Important
Use dry air so as not to jeopardise pneumatic system operations and integrity.
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(A) Electrical power cord

IDM-43600101801.tif

FUME EXHAUST HOOK-UP 11

Danger - Warning
When the critical temperature has been exceeded and it is higher than the work-
ing temperature of the machine, hot melt glues emit harmful noxious vapours
for people's health.
For further information about the critical temperatures, see the safety data
sheets of the glues that are used.
The machine is equipped with a fume extraction hood that must be connected to an
exhaust system of adequate capacity (minimum 250 m³/h).
The fume extraction device keeps active for 30 minutes after having turned off the
heating system.
The heating system automatically deactivates when the maximum temperature ex-
ceeds 180 °C. This value was defined according to the safety data sheets of the listed
glues EUROMELT 357 - ETIMELT 128 E - CLARITY HL 4167 EU.

MACHINE TESTING 12

– The machine must be inspected according to a set procedure by qualified and au-
thorised personnel.
– At the end of the testing operation, the system manager keeps the selector key
for the mobile push-button pad, which allows disabling the action of the but-
tons (L).
– When the buttons (L) are disabled, all safety conditions are cancelled, with
subsequent increase in the risks for people. Therefore, the key to disable the
selector must be kept by the system manager, who has to personally disable
the control.
IDM C443600103.fm

– The buttons (L) in the push-button pad must be disabled only when it is nec-
essary to replace the cutting blades.

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ADJUSTMENT RECOMMENDATIONS 1

Before performing any adjustments, authorised personnel must activate all

foreseen safety devices and evaluate the need to warn personnel working in the
near vicinity. In particular, adequately mark the surrounding areas and prevent
access to all devices that could, if activated, cause unexpected personal safety
hazards.

TRANSMISSION CHAIN ADJUSTMENT 2

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).
3 -Loosen screws (B).
4 -Manually adjust tensioner (C) to regulate the tension of chain and, at the same
time, tighten screws (B).
5 -Reassemble the guard (A).
6 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(A) Protection guard

(B) Screw
(C) Tensioner device
IDM C543600103.fm

IDM-00000000000.tif

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REEL BRAKE ADJUSTMENT 3

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Loosen the screws (D).
3 -Insert two feeler gauges (E) of 0.2 mm (see figure).
4 -Act on locking ring (F) until brake lining (G) is resting on feeler gauges.
5 -Remove the thickness gauges and tighten the screws (D).
6 -Check that the reel support turns freely, without being braked.
7 -Turn the main disconnector to position (I) (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(D) Screw
(E) Feeler gauge

(D) Screw

(G) Lining
(F) Ring nut

(E) Feeler gauge

IDM-43600110001.tif
IDM C543600103.fm

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TRANSMISSION BELT ADJUSTMENT 4

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Open the guard (H).
3 -Loosen the screw (L).
4 -Adjust the tensioner (M) manually in order to adjust the tension of the belt (N) and,
at the same time, tighten the screw (L).
5 -Close the guard (H).
6 -Turn the main disconnector to position (I) (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(N) Transmission belt

(H) Protection guard

(L) Screw (M) Tensioner device

IDM-43600110101.tif
IDM C543600103.fm

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ADJUSTMENT OF ADDITIONAL ALIGNER 5

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.
3 -Open the guard (P).
4 -Align the two label ends by means of the knob (Q).
5 -Rotate clockwise in order to lift the label end.
6 -Rotate counter-clockwise in order to lower the label end.
7 -Make some trials in the "simulated cut" mode in order to check the correct align-
ment of the labels (see the "Operating terminal" manual).
8 -Close the guard (P).
9 -Turn the selector (9) to 0.
10-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(Q) Knob

(P) Protection guard

(9) Mode selector

(10) Selector

IDM-43600112301.tif
IDM C543600103.fm

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ADJUSTMENT OF GLUE DISTRIBUTION 6

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.
3 -Open the guard (P).
4 -Rotate the screw (R) (in clockwise or counter-clockwise direction) to adjust the
distribution of the glue over the roller , until achieving a uniform layer.
Clockwise direction: the quantity of glue that is distributed over the roller will
decrease.
Counter-clockwise direction: the quantity of glue that is distributed over the roller
will increase.
5 -Use the mobile push-button pad to activate the labelling unit in "manual mode",
and then check the uniformity of the glue layer over the roller (see "Check glue
uniformity and distribution").
6 -Repeat the operation until the glue layer over the roller is correct.
7 -Close the guard (P).
8 -Turn the selector (9) to 0.
9 -Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(R) Screw

(P) Protection guard

(9) Mode selector

(10) Selector

IDM-43600112901.tif
IDM C543600103.fm

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INFORMATION ON USE
6

RECOMMENDATIONS FOR USE AND FUNCTIONING 1

Accident frequency derived from machine use depends upon many factors that
cannot always be foreseen and controlled. Some accidents can depend upon
unforeseeable environmental factors; others depend especially upon the user's
behaviour. In addition to being authorised and appropriately informed, on first
use personnel must simulate some manoeuvres to identify the main commands
and functions. Only carry out the operations foreseen by the manufacturer and
do not tamper with any device to obtain performances other than those provid-
ed. Before use, check that the safety devices are correctly installed and effi-
cient. Users, in addition to striving to satisfy these requirements, must apply all
the safety regulations and carefully read the descriptions of the controls and
start up.

CONTROL DESCRIPTION 2

1) Operating terminal: sets or modifies the machine operating parameters (see the
"Operating terminal" manual).
2) Emergency stop button with key unlocking device: quickly stops each machine
parts. After normalising the working conditions, unlock the button with the key in order
restart the machine.
3) Luminous push-button (blue light): resets the alarms.
4) Mushroom button (black): stops automatic machine operation.
5) Light push-button (green light): it is used to start the automatic functioning of the
machine.
6) Mushroom button (black): stops the conveyor belt.
Button is only present if the machine has a conveyor belt with independent motor drive.
7) Luminous button (green): starts the conveyor belt.
Button is only present if the machine has a conveyor belt with independent motor drive.

(1) Operating terminal

(7) Key

(5) Key
IDM C643600103.fm

(2) Emergency stop button (4) Key

(9) Mode selector (10) Mode selector
(3) Key (6) Key
IDM-43600101902.tif

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8) Main disconnector (lockable): it is used to connect and isolate the power supply of
the machine.
Pos. (O) (ON): power supply turned on
Pos. (I) (OFF): power supply turned off
9) Selector: for setting the machine's operating modes.
Pos. 0: safety guards connected
Pos. 1: safety guards (machine front side) disconnected
Pos. 2: safety guards (left side) disconnected
Pos. 3: safety guards (machine front opposite side) disconnected
Pos. 4: safety guards (right side) disconnected
10)Key selector: used to set machine operating mode (automatic or manual).
11)Luminous signal: signals the operating conditions of the machine.
Red light: signals, at the same time as device , that the machine is stopped in emer-
gency conditions.
Orange light: indicates the machine is functioning and in an incorrect operational
condition.
Green light: it signals that the machine is running.
White light: signals that the machine has electrical power but is not running.
12)Acoustic signal: signals, at the same time as the red light of device (11), that the
machine is stopped in emergency conditions.
13)Mobile push-button pad: it is used to start the machine in safe conditions, as well
as to make the machine operate in "manual mode" during format change, mainte-
nance phases, etc.
The mobile push-button pad is equipped with the emergency stop button (2), the but-
ton (14) to start the machine in "manual mode", which must be pressed together with
the buttons (16), and a key selector (15) to disable the operation of the buttons (16).
17)Mobile push-button pad: it is used to start, in "manual mode" and in safe condi-
tions, only the labelling unit during format change, maintenance phases, etc.
The mobile push-button pad is equipped with the buttons (18-19) to start the belt
feeding roller in "manual mode", the button (20) to start the label application roller in
"manual mode" and a key selector (15) to disable the operation of the buttons (16).

(11) Lighted signal

(13) Mobile push-button pad

16
(12) Siren.

(17) Mobile push-button pad

16

2 15 14
18
IDM C643600103.fm

19
15
20
IDM-43600111001.tif

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The buttons (16) in the push-button pad must be disabled only when it is necessary to
replace the cutting blades.
When the buttons (16) are disabled, all safety conditions are cancelled, with subse-
quent increase in the risks for people. Therefore, the key to disable the selector (15)
must be kept by the system manager, who has to personally disable the control.
The person in charge of the system must authorise only the properly skilled personnel
to replace the cutting blades. Moreover, he/she must make sure that no improper op-
erations are carried out in order to prevent any risks to people’s safety.
When the cutting blades are replaced, the person in charge of the system must reset
the operation of push-button panel (13-17) by means of key selector (15), must check
the resetting of the safety conditions, remove the key from selector (15) and retain it
in a place unknown to his/her colleagues.
21)Command panel (optional): contains the devices for activating and controlling all
operational functions of the automatic joiner.
22)Luminous indicator (green light): signals that the label film is being fed from reel
(A).
23)Luminous button (red light): resets the automatic joiner encoder.
Button with light on: signals a malfunction of the automatic splicer.

Important
Do not press the button while the labels are being supplied.
24)Button: selects the to fed the label film from one of the reels.
25)Luminous button (green light): confirms that the label is correctly positioned on
the joiner.
Button with light on: signals that the label is not correctly positioned on the splicer.
26)Luminous indicator (green light): signals that the label film is being fed from reel
(B).

(A) Reel

21

(B) Reel
IDM C643600103.fm

22 23 24 25 26

IDM-43600106002.tif

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MACHINE START 3

Proceed as indicated.
1 -Turn the main disconnector to position (ON) to connect power supply.
The operating terminal display turns on and, after the program is started, displays
the main screen.
If alarm messages appear on the display, correct any anomaly before
starting the machine (see the manual of the "Operating terminal).
2 -Press the "Reset" button (3).
3 -Turn the selector (10) to AUT.
4 -Press the button (5).
5 -Turn the selector (10) to MAN.
6 -In sequence activate the different operating units of the machine that are gradually
shown on the display of the operating terminal.
All operating units have been activated when the message "MACHINE IN MANU-
AL" appears on the display.
7 -Select the machine operating mode according to the machine operating require-
ments.
- Operation of the machine in "manual" mode: see Operation in "manual mode".
- Machine operation with "automatic cycle": see "Automatic mode" operations.

(1) Operating terminal

(7) Key

(5) Key

(2) Emergency stop button (4) Key

(9) Mode selector (10) Mode selector
(3) Key (6) Key

IDM-43600101902.tif
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OPERATION IN "MANUAL MODE" 4

Important
The manual commands must be used to individually start the machine's func-
tional units during maintenance and format changes.
Proceed as indicated.
1 -Start the machine (see "Machine start").
2 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
3 -If necessary, rotate the selector (9) to position (1-2-3-4) according to the interven-
tion area.
Pos. 1: safety guards (machine front side) disconnected
Pos. 2: safety guards (left side) disconnected
Pos. 3: safety guards (machine front opposite side) disconnected
Pos. 4: safety guards (right side) disconnected (see "Control description").
4 -Press buttons (B) and keep them pressed; after a few seconds, press also button
(A). The machine starts in "manual mode". When one of the buttons is released,
the machine stops.
5 -Keep the buttons (C) pressed and, after a few seconds, also press the button (D).
The label application roller will start in "manual mode". When one of the buttons is
released, the label application roller will stop.
6 -Keep the buttons (C) pressed and, after a few seconds, also press the button (E)
or the button (E1). The label film feeding roller will start in "manual mode".
When one of the buttons is released, the label film feeding roller will stop.

(9) Mode selector

(10) Selector
(A) Protection guard

C
B

A
E
E1

(D) Key
IDM C643600103.fm

IDM-43600601901.tif

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"AUTOMATIC MODE" OPERATIONS 5

Proceed as indicated.
1 -Start the machine (see "Machine start").
2 -Align and store the notches (see "Change label reel format").
3 -Activate labelling unit (see the manual of the "Operating Terminal").
4 -Turn the selector (10) to AUT.
5 -Select the mode of operation of the container feeding device (see the manual of
the "Operating terminal" ).
6 -Press buttons (7-5).
The conveyor belt starts and the machine begins an automatic cycle.

(7) Key

(3) Key (5) Key

(10) Selector
IDM-43600111201.tif

AUTOMATIC CYCLE STOP 6

Temporary stop of the automatic cycle

1 -Press button (4) and button (6) (if present).

Important
Do not disconnect the electric disconnector to avoid needing to wait for the glue
preheating time.
In case of continuous stop, the upstream and downstream machines arrange to
slow down and/or stop their functions.

Final stop of the automatic cycle

2 -Close the entry blocking device (see the "Operating terminal" manual).
3 -Wait for the machine to be completely empty from the containers.
4 -Press button (4) and button (6) (if present).
5 -Turn main switch (8) to position (O) (OFF) to turn off power supply.
IDM C643600103.fm

The machine is in a safe condition and isolated from its sources of energy.

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(8) Main switch

(4) Key

(6) Key

(10) Selector
IDM-43600111301.tif

EMERGENCY STOP AND RESTART 7

Proceed as indicated.
1 -Press one of the emergency push-buttons (A).
2 -Restore normal operating conditions.
3 -Release the emergency button to permit the machine to resume operations.

Important
The emergency stop button must be unlocked only by the person in charge of
the system, who is properly skilled and has the button unlocking key.
4 -Press the "Reset" button (3).
The machine is in working conditions.
5 -Press button (5) and button (7) (if present).
The conveyor belt starts and the machine begins an automatic cycle.

(7) Key (A) Emergency stop button

(5) Key
IDM C643600103.fm

(3) Key (A) Emergency stop button

(A) Emergency stop button

IDM-43600111401.tif

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FORMAT CHANGE 8

The size change is a set of interventions to perform on the machine by replacing some
parts relating to the shape and to the size of the containers and of the label.

Important
All size change operations must be performed with the machine in safety
conditions.
Intervene on the parts according to the sequence shown.

– Spacer auger (see "Spacer auger change").

– Feeding block device (see "Feeding block device positioning").

– Feeding star (see "Feeding star change").

– Conveyor (see "Conveyor change").

– Exiting star (see "Exiting star change").

– Container support disks (see "Container support disk change").

– Lobe cam ((S) machine version) (see "lobe cam change (S machine version)").

– Label application roller (see "Change label application roller").

– Label cutter shells (see "Change label cutter shells").

– Suction of held label (see "Change value of label held").

– Label reel (see "Change label reel format").

– Automatic joiner pins (see "Change automatic joiner pins").

– Contrast device (see "Change contrast device").

– Label presence check photocell (see "Positioning of the label presence check pho-
tocell").

– Conveyor belt guides (see "Conveyor belt guide positioning").

– Labelling unit (see "Positioning of the labelling unit").

– Entry of new format values in the operation terminal (see the "Operating terminal"
manual).

SPACER AUGER CHANGE 9

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to (3).
3 -Open the guard (F).
4 -Loosen the handles (G).
5 -slip of spiral conveyors (H) and replace them with those of the new format.
6 -Fasten the handle (G).
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(F) Protection guard

(9) Mode selector

(H) Spacer auger (10) Selector

(G) Handle

IDM-43600102202.tif

POSITIONING OF THE SPIRAL CONVEYOR SPACER 10

Important
Keep the safety conditions applied during the stage "Spacer auger change".

Proceed as indicated.
1 -Identify the number corresponding to the new size and rotate the drum (A) until
the screw head (B) comes close to the stopping area (C).
2 -Loosen the handles (D).
3 -Push the spiral conveyor unit in order to stop the stopper (C) on the screw (B).
4 -tighten handles (D).

Spacer auger
(D) Handle

(D) Handle

(A) Stopper drum (B) Screw

IDM C643600103.fm

(C) Reference stop

IDM-00000000000.tif

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FEEDING BLOCK DEVICE POSITIONING 11

Important
Keep the safety conditions applied during the stage "Spacer auger change".

Proceed as indicated.
1 -Loosen the handles (L).
2 -Place some containers of the new size.
3 -Adjust the position of the feeding block device (M) in relation to the sizes of the
container (see figure).
4 -tighten handles (L).

(L) Handle

Container

(M) Container feeding block device

IDM-43600102302.tif

FEEDING STAR CHANGE 12

Important
Keep the safety conditions applied during the stage "Spacer auger change".

Proceed as indicated.
1 -Rotate the brackets (N) to unlock the star (P).
2 -replace the feeding star (P) with the proper one for the new size.
IDM C643600103.fm

3 -Rotate the brackets (N) to block the star.

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(N) Hold bracket (P) Container feeding star

(N) Hold bracket

IDM-43600102402.tif

CONVEYOR CHANGE 13

Important
Keep the safety conditions applied during the stage "Spacer auger change".

Proceed as indicated.
1 -Use handle (Q) to unlock conveyor (R).
2 -Replace the central conveyor (R) with the proper one for the new format.
3 -Use handle (Q) to unlock conveyor.

(R) Container conveyor

IDM C643600103.fm

(Q) Handle

IDM-43600102502.tif

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EXITING STAR CHANGE 14

Important
Keep the safety conditions applied during the stage "Spacer auger change".

Proceed as indicated.
1 -Rotate the brackets (S) to unlock the star (T).
2 -Replace the exiting star (T) with the proper one for the new size.
3 -Rotate the brackets (S) to block the star.
4 -Close the guard (F).

(T) Container exit star

(S) Hold bracket

(F) Protection guard

(S) Hold bracket

IDM-43600112001.tif

CONTAINER SUPPORT DISK CHANGE 15

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to (4).
3 -Open the guard (U).
IDM C643600103.fm

4 -Replace the container support disks (V) with the proper one for the new size.

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(9) Mode selector

(U) Protection guard

(10) Selector

(V) Container support

bottom

IDM-00000000000.tif

LOBE CAM CHANGE (S MACHINE VERSION) 16

Important
Keep the safety conditions applied during the stage "Container support disk
change".
Proceed as indicated.
1 -Loosen the handles (A).
2 -Replace "lobe" cam (B) with the specific one for the new size.
3 -tighten handles (A).
4 -Turn registration screw (C) until the correct reference value appears on revolution
counter (D).

Important
The reference value must correspond to that shown in the "format change" table.

(A) Handle
IDM C643600103.fm

(C) Screw (A) Handle (B) "Lobe" cam

(D) Revolution counter
IDM-43600102602.tif

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CHANGE LABEL APPLICATION ROLLER 17

Proceed as indicated.
1 -Move the label application roller to the position of change by means of the oper-
ating terminal controls (see the "Operating terminal" manual).
2 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
3 -Turn the selector (9) to 1.
4 -Open the guard (H).

(H) Protection guard

(9) Mode selector

(10) Selector
IDM-43600111901.tif

5 -Unscrew screw (P) and screw it in the hole until roller (Q) is unlocked.
6 -Remove roller (Q).
7 -Mount specific roller for the new format and align reference notches (R).
8 -Screw screw (P) to lock roller.
9 -Enable the label application roller by means of the operating terminal controls
(see the "Operating terminal" manual).

(Q) Label application roller (P) Screw

(H) Protection guard

IDM C643600103.fm

(Q) Label application roller

IDM-43600102802.tif

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CHANGE LABEL CUTTER SHELLS 18

Important
Keep the safety conditions applied during the stage "Change label application
roller".
Proceed as indicated.
1 -Move the cutting roller to the position of change by means of the operating termi-
nal controls (see the "Operating terminal" manual).
2 -Unscrew screws (T) and dismount shell (S).
3 -Mount the specific shell for the new format and retighten screws (T).
4 -Rotate the roller of 180° by means of the operating terminal controls (see the "Op-
erating terminal" manual).
5 -Unscrew screws (T) and dismount shell (U).
6 -Mount the specific shell for the new format and retighten screws (T).
7 -Enable the cutting roller by means of the operating terminal controls (see the "Op-
erating terminal" manual).

Danger - Warning
During this operation it is not possible to use the unit's mobile button pad (Jog),
with 30" activation.

(T) Screw

(S) Cutting roller shell

(T) Screw

IDM-43600102902.tif
IDM C643600103.fm

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CHANGE VALUE OF LABEL HELD 19

Important
Keep the safety conditions applied during the stage "Change label application
roller".
Proceed as indicated.
1 -Rotate knob (V) until display (Z) shows the correct value.
The value must correspond to the format and type of label (see "Format change"
table).

(V) Knob
(Z) Digital display

IDM-43600111601.tif

CHANGE LABEL REEL FORMAT 20

Important
Keep the safety conditions applied during the stage "Change label application
roller".
Proceed as indicated.
1 -Open the film feeding roller by means of the operating terminal controls.
2 -Select the reel to be used by means of the operating terminal controls.
3 -Unscrew stop ring (B).

(C) Reel
IDM C643600103.fm

(B) Hold ring

IDM-43600103002.tif

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4 -Dismount reel (C) and replace it with the specific one for the new format.
5 -Screw ring (B) to lock the reel.
6 -Manually unwind the film of the reel following the path shown in the figure until it
corresponds to cutting roller (D).
7 -Close the film feeding roller (E) and activate the "aligner device" by means of the
operating terminal controls (see the "Operating terminal" manual).
8 -Keep the buttons (A1) pressed and, after a few seconds, also press the button (A).
The label film feeding roller will start in "manual mode" and the reel will unwind.
Release the controls only when the label film is aligned with the aligner device (F).

(D) Cutting roller

(F) Label belt aligner device

(A1) Key

(A) Key

(E) Label belt feeding roller

IDM-43600111701.tif

9 -Rotate handle (G) to adjust the height of the film reel notch detection photocell.

(G) Grip
IDM C643600103.fm

IDM-43600103100.tif

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10-Turn indicator (H) to "TEACH" to adjust the sensitivity of the photocell.
11-Unwind the reel by means of the mobile push-button pad to position the notch in
front of the photocell.
12-Press button (L) until yellow light (M) changes brightness.

Important
The variation of the luminous intensity of the pilot light shows that a self-learn-
ing phase is complete.

(M) Indicator light

(L) Key

(H) Indicator

IDM-43600109900.tif

13-Unwind the reel by means of the mobile push-button pad to position the film notch
5 mm before the reading point of the photocell.
14-Press button (L) and turn indicator (H) to "RUN" to store the positions

Mobile push-button pad

IDM C643600103.fm

IDM-00000000000.tif

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CHANGE AUTOMATIC JOINER PINS 21

Proceed as indicated.
Slip out pins (N) and replace them with the specific ones for the new format (see "For-
mat change" table).

(N) Pin

IDM-43600106100.tif

CHANGE CONTRAST DEVICE 22

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 4.
3 -Open the guard (A).
4 -Loosen the screws (B).
5 -Replace contrast device (C) with the specific one for the new format.
6 -Tighten screws (B).
7 -Close the guard (A).

(C) Contrast device

(A) Protection guard

(9) Mode selector

IDM C643600103.fm

(B) Screw
(10) Selector
IDM-43600112401.tif

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POSITIONING OF THE LABEL PRESENCE CHECK PHOTOCELL 23

Important
Keep the safety conditions applied during the stage "Change contrast device".
Proceed as indicated.
1 -Loosen the handles (D-E).
2 -Position the photocell (F) according to the size of the container.

Important
The reference value must correspond to that shown in the "format change" table.
3 -tighten handles (D-E).

(D) Handle

(F) Photocell
(E) Handle

IDM-43600112500.tif

CONVEYOR BELT GUIDE POSITIONING 24

Proceed as indicated.
1 -Loosen knobs (P).
2 -Adjust the distance between the guides (Q) in relation to the sizes of the container
of the new size.

Important
The guides must have play 4÷5 mm greater than the dimensions of the container.
3 -Fasten knobs (P).
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(Q) Conveyor belt guides

(P) Knob

IDM-43600103302.tif

POSITIONING OF THE LABELLING UNIT 25

Proceed as indicated.
1 -Act on shaft (T) and regulate the depth of labeling unit until the correct reference
value appears on revolution counter (U).

Important
The reference value must correspond to that shown in the "format change" table.
2 -Adjust the height of the labelling unit and of the central turntable by means of the
operating terminal controls (see the "Operating terminal" manual).

(U) Revolution counter

IDM C643600103.fm

(T) Shaft

IDM-43600103202.tif

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REEL INSERTION (WITHOUT AUTOMATIC JOINER) 26

The intervention involves a series of preliminary phases that must be performed be-
fore starting the machine and/or every time that the label format changes.

Important
The steps to perform are the same for one reel or two.
Proceed as indicated.
1 -Open the film feeding roller by means of the operating terminal controls (see the
"Operating terminal" manual).
2 -Unscrew stop ring (B).
3 -Insert reel (C).
4 -Screw ring (B) to lock the reel.

(C) Reel

(B) Hold ring

IDM-43600103002.tif

5 -Manually unwind the film of the reel following the path shown in the figure until it
corresponds to cutting roller (D).
6 -Close the film feeding roller (E) by means of the operating terminal controls.
7 -Align and store the notches (see "Change label reel format").

(E) Label belt feeding roller

(D) Cutting roller

IDM C643600103.fm

IDM-43600103000.tif

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REEL INSERTION (WITH AUTOMATIC JOINER) 27

The intervention involves a series of preliminary phases that must be performed be-
fore starting the machine and/or every time that the label format changes.
Proceed as indicated.

Caution - Precaution
For this operation, wear protective gloves.
1 -Open the film feeding roller by means of the operating terminal controls (see the
"Operating terminal" manual).
2 -Unscrew stop ring (B).
3 -Insert reel (C).
4 -Screw ring (B) to lock the reel.

(C) Reel

(B) Hold ring

IDM-43600103002.tif

5 -Press button (17) to select the reel to use.

6 -Unhook and rotate support rollers (G).
7 -Manually unwind the film of the reel following the path shown in the figure until it
corresponds to cutting roller (D).
8 -Rotate roller support (G) and lock it with closing device (H).
9 -Press the button (18).

(H) Closing device

(G) Roller support
IDM C643600103.fm

(D) Cutting roller (16) Key (18) Key

(E) Label belt feeding roller (17) Key
IDM-43600113800.tif

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10-Close the film feeding roller (E) by means of the operating terminal controls.
11-Align and store the notches (see "Change label reel format").

REEL CHANGE 28

When the spool in use is about to run out, the spool end photocell activates, the ma-
chine closes the entry block and continues to turn at the lowest speed.

Manual joining of the reel film

Proceed as indicated.
1 -Block the belt by means of handle (A).
2 -Cut the belt at a distance of 5 cm from reference mark.
3 -Replace the reel.
4 -Cut belt end of the new reel at a distance of 5 cm from reference mark.
5 -Overlap the ends of the film so that the notches match perfectly.
6 -Splice belts with adhesive next to the two ends.
7 -Use handle (A) to unlock the film.
8 -Press the "Reset" button (3).
9 -Press button (5) and button (7) (if present).
The conveyor belt starts and the machine begins an automatic cycle.

(7) Key
(5) Key (3) Key
IDM C643600103.fm

(A) Handle
IDM-43600103402.tif

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Joining the film reel (with automatic joiner)
While the machine is working, it is possible to prepare the reserve reel for automatic
joining.
Proceed as indicated.

Caution - Precaution
For this operation, wear protective gloves.
10-Insert reel (C).
11-Screw ring (D) to lock the reel.
12-Cut the end of film corresponding to reference notch (E).
13-Apply the biadhesive 5 mm from the notch at the beginning of the film.

Important
Remove the strip protecting the biadhesive.

Two-sided adhesive tape

(E) Reference mark

(D) Hold ring

(C) Reel
IDM-43600804401.tif

14-Unhook and rotate support rollers (F).

(F) Roller support

(G) Pad

(H) Closing device

IDM C643600103.fm

(18) Key
(C) Reel

IDM-43600804501.tif

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15-Manually unwind the film of the reel following the path shown in the figure until it
corresponds to the lower border of pad (G).
The film is held in position by the suction provided by pad.
16-Rotate roller support (F) and lock it with closing device (H).
17-Press the button (18).
Under these conditions, when the reel is finished, the joiner automatically joins the
film with the reserve reel.

(F) Roller support

(G) Pad

(H) Closing device

(18) Key
(C) Reel

IDM-43600804501.tif

GLUE SUPPLY 29

Important
When the acoustic device signals that the glue is running out, you have about
15 minutes to refill it before the machine stops feeding product.
From glue tub cover (A), insert the number of glue packages needed to make the
melted glue in the tub rise to the level of fins (B).

(A) Cover

Heat dissipation fins

IDM C643600103.fm

IDM-43600103500.tif

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RECOMMENDATIONS FOR USE 30

During use, the operator must prevent malfunctions or sudden stops of the machine.

Caution - Precaution
In the presence of anomalies, after the stopping the machine, the operator must
notify the system manager, who will authorize the interventions necessary for
normalizing operating conditions.

MACHINE RESET BUTTON 31

The machine stops whenever a serious anomaly occurs.

1 -Solve the anomaly that occurred.
2 -Press the "Reset" button (3).

Important
The machine will restart from the point where it stopped.
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MAINTENANCE INSTRUCTIONS 1

Before performing any maintenance operation, activate all of the security devic-
es provided and evaluate the necessity to adequately inform personnel operat-
ing in the near vicinity. In particular, confine the neighbouring areas to impede
access to the devices that could, if activated, produce unexpected danger con-
ditions provoking hazards to personal safety and health.
Only a single person must carry out the maintenance interventions with the ma-
chine in "manual mode" and by using the mobile push-button pad.

MAINTENANCE PERIOD TABLE 2

Important
Keep the machine in maximum working conditions by performing the pro-
grammed maintenance operations advised by the manufacturer. Good mainte-
nance achieves the best machine performance, longer machine life and
constant observance of the safety regulations.

5 15 17
10
11

12
6

4 14

20 8

9 19
3 4
13 18
1
IDM C743600103.fm

16

IDM-43600106303.tif

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Table 7.1: Maintenance intervals

Component Type of intervention Action Reference

Frequently and when needed

Clean the surface of the
See "Clean label
rollers with a cloth soaked
application roller"
1 Label application roller Cleaning in anti-silicone liquid

See "Clean label

Clean the slides
application roller slides"

Clean the surface of the

Cleaning rollers with a cloth soaked See "Clean cutting roller"
in anti-silicone liquid
2 Cutting roller
Check for wear and the
See "Check cutting blade
Checks and controls cutting efficiency of the
efficiency"
blades

Clean the glue distribution

See "Clean glue roller"
roller
Cleaning
Clean the blow open See "Cleaning the opening
3 Glue roller device blower device"

Check the uniformity and

See "Check glue uniformity
Checks and controls correct distribution of the
and distribution"
glue

Check for the correct roller See "Check idle roller

4 Idle rollers Checks and controls
rotation rotation"

Clean the surface of the

19 Contrast device Cleaning device with a cloth soaked
in antisilicone additive

Every 50 hours
Check the uniformity of See "Check glue uniformity
Checks and controls
glue application and distribution"
3 Glue roller
Lubricate with grease See "Lubricating the glue
Lubrication
(see "Lubricant table" ) roller"

Container conveying
device greasers (belts, Lubricate with grease See "Check idle roller
5 Lubrication
spiral conveyors, stars, (see "Lubricant table" ) rotation"
turntable, etc.)

Every 100 hours

Check the wear on the See "Replacing label
1 Label application roller Checks and controls
slides application roller slides"
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Table 7.1: Maintenance intervals
Component Type of intervention Action Reference

See "Cleaning the air

8 Vacuum system unit Cleaning Clean the filters
filters"

Container support Lubricate with grease See "Lubrication point

10 Lubrication
disks (see "Lubricant table" ) diagram"

Plate transmission Lubricate with grease See "Lubrication point

18 Lubrication
(N machine version) (see "Lubricant table" ) diagram"

Every 200 hours

See "Cleaning the cutting
2 Cutting roller Cleaning Clean the cutting shells
shells"

Clean the vacuum See "Clean the vacuum

1 Label application roller Cleaning
distributor distributor"

Automatic lubrication
7 Cleaning Clean the oil filter See "Clean oil filter"
tank

See "Cleaning the glue

9 Glue tank Cleaning Clean the glue filter
filter"

Check for the correct roller See "Check idle roller

4 Idle rollers Checks and controls
rotation rotation"

Check for wear and the

See "Check cutting blade
2 Cutting roller Checks and controls cutting efficiency of the
efficiency"
blades

Lubricate with grease See "Lubricate head drive

11 Head drive device Lubrication
(see "Lubricant table") device"

Container holding Check for the correct head

12 Checks and controls See "Check head rotation"
heads rotation

Plate drive rollers See "Check for plate drive

6 Checks and controls Check for roller wear
(machine version S) wear (S machine version)"

See "Check of the plate

Check for transmission
rotation belt (machine
Plate transmission belt wear
18 Checks and controls version N)"
(N machine version)
Check the belt tension and See "Transmission belt
adjust it, when necessary adjustment"

Clean the filter with a jet of

20 Electric panel Cleaning
air

Every 300 hours

13 Reel support Cleaning Clean the brakes See "Clean brake reel"

Check the wear condition

See "Check head drive
11 Head drive device Checks and controls of the bearings and replace
device bearings"
them if need be
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Table 7.1: Maintenance intervals
Component Type of intervention Action Reference

Check tightening of the See "Transmission chain

15 Spacer auger Checks and controls
transmission chain adjustment"

Every 500 hours

9 Glue tank Cleaning Clean the tank See "Glue tank cleaning"

See "Transmission gear

16 Transmission Lubrication Lubricate gears
lubrication"

Labelling unit lifting Lubricate with grease See "Lubrication of the

5 Lubrication
device (see "Lubricant table") labelling unit chain"

Jack cam lubrication Replace the cartridge with See "Change lubrication
17 Replace
cartridge an original spare part cartridge"

See "Transmission gear

14 Transmission Lubrication Lubricate gears
lubrication"

Every 1000 hours

Automatic lubrication Change oil with the one See "Automatic lubrication
7 Oil replacement
tank shown oil change"

Check the oil level, and, if

necessary, top up or See "Auger drive oil
15 Spacer auger Checks and controls
replace it according to the change"
established intervals

Change oil with the one See "Oil change of main

16 Transmission Oil replacement
shown drive reduction gear"

(*) The maintenance frequency indicated in the table refers to actual work station operating hours.

Important
To keep the machine in perfectly efficient conditions, it is advisable to make the
P.E. Labellers technicians perform a general check once a year or after 2000
working hours.
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LUBRICATION POINT DIAGRAM 3

Lubricate the illustrated parts at the time and with the methods indicated.

IDM-43600103603.tif

Legenda: Inject grease Paint with grease

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LUBRICANT TABLE 4

The table shows the lubricants recommended by the builder.

Use oil and lubricants with characteristics equal to those indicated.

Table 7.2: Features of the lubricants

Lubricants Use

Lubricating labeling unit

Grease MOBILUX EP2 Lubricate central turntable supports
Lubricating the plates
Grease FUCHS GT 300 NF
Lubricating the glue roller
Grease KLUBER PARALIQ GTE 703
Lubricating labeling unit
MOBIL VELOCITE OIL N°10 Plate operating roller lubrication (version S)
Lubricating main gear motor

MACHINE CLEANING 5

All maintenance procedures that require precise technical competence or spe-

cific skills must be exclusively performed by qualified personnel with acquired
certified experience in the specific field.
The person who carries out this operation must arrange proper safety condi-
tions to assure his own security and that of the operators concerned.

Caution - Precaution
Protective gloves must be worn to prevent cutting risks to upper limbs.
It is necessary to perform some general maintenance to ensure the perfect operation
of the machine (see "Maintenance period table").
– Cleaning the labeling unit (see page 72).
– Clean label application roller (see page 73).
– Clean cutting roller (see page 74).
– Clean glue roller (see page 75).
– Clean label application roller slides (see page 76).
– Cleaning the cutting shells (see page 77).
– Cleaning the air filters (see page 78).
– Clean the vacuum distributor (see page 78).
– Clean oil filter (see page 79).
– Cleaning the glue filter (see page 80).
– Clean brake reel (see page 81).
– Glue tank cleaning (see page 82).
– Cleaning the opening blower device (see page 83).
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CLEANING THE LABELING UNIT 6

The operation must be performed after an anomaly (such as an accumulation of labels

on the label application roller). It can be executed with the machine without containers
or with containers. In this latter case, some containers (2-3) will not be labeled.

Important
The manufacturer recommends performing this procedure with the machine
empty.
Proceed as indicated.
1 -Press button (4) and button (6) (if present). Conveyor belt and machine stop.
2 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
3 -Turn selector (9) to position 1-2-3-4 depending on the area of intervention
(see "Control description").
4 -Act on the operating terminal to deactivate the labeling unit and vacuum pump
(see the "Operating terminal" manual).
5 -Clean the surface of the rollers with a cloth soaked with anti-silicone, using the
mobile pushbutton pad of the labeling unit.
6 -Position the film reel correctly (see "Change label reel format").
7 -Act on the operating terminal to activate the labeling unit and vacuum pump
(see the "Operating terminal" manual).
8 -Turn the selector (9) to 0.
9 -Turn the selector (10) to AUT.
10-Press button (5) and button (7) (if present). The conveyor belt starts and the
machine begins an automatic cycle.

(5) Key
(7) Key

(9) Mode selector

IDM C743600103.fm

(10) Selector

IDM-43600110201.tif

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CLEAN LABEL APPLICATION ROLLER 7

Proceed as indicated.
1 -Act on the operating terminal to deactivate the vacuum pump (see the "Operating
terminal" manual).
2 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
3 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
4 -Open the guard (A).
5 -Keep the buttons (B1) pressed and, after a few seconds, also press the button (B).
The label application roller will start in "manual mode".
When one of the buttons is released, the label application roller will stop.
6 -Clean the surface of the rollers with a cloth soaked in anti-silicone liquid.
7 -Repeat the control activation in order to complete the cleaning operations.

Important
We recommend the using STANDOX 90611462, PPG DX330 SPIRIT WIPE, NA-
TIONAL DETERMELT 3 solvent , to remove glue residue.
8 -Close the guard (A).
9 -Turn the selector (9) to 0.
10-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(9) Mode selector (A) Protection guard Label application roller

(B) Key

(10) Selector

(B1) Key

IDM-43600110301.tif
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CLEAN CUTTING ROLLER 8

Proceed as indicated.
1 -Act on the operating terminal to deactivate the vacuum pump (see the "Operating
terminal" manual).
2 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
3 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
4 -Open the guard (A).
5 -Press buttons (B1) and keep them pressed and, after some seconds, press button
(B) too. The cutting roller is activated in "manual mode". When one of the buttons
is released, the cutting roller will stop.
6 -Clean the surface of the rollers with a cloth soaked in anti-silicone liquid.
7 -Repeat the control activation in order to complete the cleaning operations.

Important
We recommend the using STANDOX 90611462, PPG DX330 SPIRIT WIPE, NA-
TIONAL DETERMELT 3 solvent , to remove glue residue.
8 -Close the guard (A).
9 -Turn the selector 9 to 0.
10-Turn the selector 10 to AUT.
The machine is pre-arranged for operating in "automatic mode".

(9) Mode selector (A) Protection guard

(B) Key

(10) Selector

IDM-43600110401.tif
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CLEAN GLUE ROLLER 9

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Unscrew the knob (B) to disassemble the cover (C).
5 -Unscrew the handle (D) to distance the doser from the glue roller.
6 -Clean any residue from the roller.

Important
Take care not to damage the surface of the roller.
7 -Put the doser to the initial position and assemble the cover (C).
8 -Close the guard (A).
9 -Turn the selector (9) to 0.
10-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(A) Protection guard

(B) Knob

(C) Cover

(D) Grip

(9) Mode selector

(10) Selector
IDM-43600110501.tif
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CLEAN LABEL APPLICATION ROLLER SLIDES 10

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Dismount roller (B) and rest it on the work surface (see "cambio rullo applicazione
etichette").
5 -Unscrew screws (C) and dismount slide blocks (D).
6 -Clean slide blocks (D) and their seats with an anti-silicone liquid soaked cloth.

Important
Do not immerse the sliding blocks into the antisilicone additive in order to pre-
vent any damage to the construction material.
7 -Mount slide blocks (D) and roller (B)
8 -Close the guard (A).
9 -Turn the selector (9) to 0.
10-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(B) Label application roller

(9) Mode selector (A) Protection guard

(C) Screw

(10) Selector

(D) Label application roller sliding block

IDM-43600106502.tif
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CLEANING THE CUTTING SHELLS 11

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Dismount shells (B) (see "Change label cutter shells").
5 -Clean the shells with a cloth soaked in anti-silicone liquid. Blow with a jet of air, if
necessary.
6 -Mount shells (B).
7 -Close the guard (A).
8 -Turn the selector 9 to 0.
9 -Turn the selector 10 to AUT.
The machine is pre-arranged for operating in "automatic mode".

(9) Mode selector

(A) Protection guard

(10) Selector

(B) Cutting roller shell

IDM-43600106602.tif
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CLEANING THE AIR FILTERS 12

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).
3 -Dismount the filters (B) and clean tem with a cloth soaked in anti-silicone liquid.
Blow with a jet of air, if necessary.
4 -Remount the filters (B)
5 -Reassemble the guard (A).
6 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(A) Protection guard

(B) Air filter

IDM-43600106701.tif

CLEAN THE VACUUM DISTRIBUTOR 13

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Remove the roller (D) (see "Change label application roller").
5 -Clean the distributor (C) with a cloth soaked with anti-silicone liquid.
6 -Mount roller (B).
IDM C743600103.fm

7 -Close the guard (A).

8 -Turn the selector (9) to 0.

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9 -Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(B) Label application roller

(A) Protection guard

(9) Mode selector (C) Spreader

(10) Selector

IDM-43600106802.tif

CLEAN OIL FILTER 14

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).
3 -Disassemble the oil filter (B) and clean it with compressed air.
4 -Install the oil filter (B).
5 -Reassemble the guard (A).
6 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(A) Protection guard

IDM C743600103.fm

(B) Oil filter

IDM-43600106901.tif

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CLEANING THE GLUE FILTER 15

Proceed as indicated.
1 -Clean the glue tub (see "Glue tank cleaning").
2 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
3 -Open the guard (A).
4 -Open the cover of the glue tub.
5 -Remove the screw (B).
6 -Unscrew screw (C) from screw hole (B).

(A) Protection guard

(B) Screw

IDM-43600107002.tif

7 -With the aid of pliers, remove filter (D) through opening.

8 -Clean filter (D) with a cloth soaked in anti-silicone liquid. Blow with a jet of air, if
necessary.
9 -Remount filter (D) and fix it with the screw.
10-Remount and tighten screw (B).
11-Fill the glue tank.
12-Close cover of the glue tub.
13-Close the guard (A).
14-Turn the main disconnector to position (ON) to connect power supply.
IDM C743600103.fm

The machine is pre-arranged for operating in "automatic mode".

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(C) Screw

(D) Glue filter

IDM-43600107200.tif

CLEAN BRAKE REEL 16

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove the stop ring (A) and remove the brake lining (B).
3 -Clean the surface of the brake lining with abrasive paper.
4 -Remount brake lining (B) and stop ring (A)
5 -Adjust brake (see "Reel brake adjustment").
6 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(A) Stop ring

(B) Lining
IDM C743600103.fm

IDM-43600107102.tif

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GLUE TANK CLEANING 17

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Prepare a container of appropriate capacity.
5 -Unscrew the plug (B) and let all the glue flow into the container.
6 -Screw the plug (B) back and fill in the glue tank with white mineral oil, or rather
with a wax-based detergent DETERMELT 1.
7 -Act on the operating terminal to activate glue pump and clean residue from the
system.

Important
Keep the pump running for about 2 hours.
8 -Stop the glue pump.
9 -Unscrew plug (B), let all the product in the container flow out.
10-Re-screw the plug and insert some packs of glue into the tank.
11-Act on the operating terminal to activate glue pump.

Important
Keep the pump running for about 2 hours.
12-Stop the glue pump.
13-Unscrew the plug (B), let all the product flow into the container.
14-Clean filter (see "Cleaning the glue filter").

(A) Protection guard

(B) Discharge cap
IDM C743600103.fm

(9) Mode selector

(10) Selector
IDM-43600110601.tif

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15-Tighten plug and fill tub with glue.
16-Close the guard (A).
17-Turn the selector (9) to 0.
18-Turn the selector (10) to AUT.
19-The machine is pre-arranged for operating in "automatic mode".

CLEANING THE OPENING BLOWER DEVICE 18

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Remove the roller (D) (see "Change label application roller").
5 -Unscrew screws (C) to remove device (D).
6 -Clean device (D) with a cloth soaked in anti-silicone liquid.
7 -Mount device (D) and attach it with screws (C).
8 -Assemble the roller (B).
9 -Close the guard (A).
10-Turn the selector (9) to 0.
11-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(B) Label application roller

(A) Protection guard

(C) Screw
(D) Opening blower device
IDM C743600103.fm

(9) Mode selector

(10) Selector
IDM-43600107602.tif

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BELT FEEDING ROLLER CLEANING 19

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Open the film feeding roller (B) by means of the operating terminal controls
(see the "Operating terminal" manual).
5 -Clean the surfaces of rollers (B-B1) with a sponge soaked in warm water and mild
soap, rinse and dry thoroughly.
6 -Close the film feeding roller (B) by means of the operating terminal controls.
7 -Close the guard (A).
8 -Turn the selector (9) to 0.
9 -Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(C) Label belt feeding roller

(9) Mode selector (A) Protection guard

(10) Selector
(C1) Roller

IDM-43600113600.tif
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LUBRICATING THE GLUE ROLLER 20

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Remove the roller (D) (see "Change label application roller").
5 -Inject the grease into the lubricating nipples (C) (see " Lubrication point diagram").

Important
Use oil of the type indicated in the lubricants chart.
6 -Assemble the roller (B).
7 -Close the guard (A).
8 -Turn the selector (9) to 0.
9 -Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(B) Label application roller

(C) Grease nipple
(9) Mode selector

(10) Selector

(A) Protection guard

(C) Grease nipple

IDM-43600107802.tif
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LUBRICATING THE PLATES 21

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 3.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Lubricate the plates
5 -Press buttons (B1) and keep them pressed; after a few seconds press also button
(B). The machine starts in "manual mode".
When one of the push-buttons is released, the machine stops.
6 -Lubricate the new plates and, if necessary, repeat the activation of the controls to
complete the lubrication of the others.
7 -Close the guard (A).
8 -Turn the selector (9) to 0.
9 -Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(9) Mode selector

(B1) Key

(10) Selector (A) Protection guard

(B) Key

IDM-43600108102.tif
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LUBRICATE HEAD DRIVE DEVICE 22

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Open the guard (D).
3 -Remove the screws (E) and guard (F).
4 -Lubricate the rod and bearing of head drive device (G).
5 -Manually rotate central turntable to lubricate all devices.

Important
Use oil of the type indicated in the lubricants chart.
6 -Assemble the guard (F) and secure it with the screws.
7 -Close the guard (D).
8 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(E) Screw

(F) Protection guard

(D) Protection guard

(G) Head operating device

IDM-43600108301.tif
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LUBRICATION OF THE LABELLING UNIT CHAIN 23

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).
3 -Lubricate the chain(B) (see "Lubricant table").
4 -Reassemble the guard (A).
5 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(B) Transmission chain

(A) Protection guard

IDM-43600108401.tif

LUBRICATION OF THE MAIN TRANSMISSION CHAIN 24

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).
3 -Lubricate the chain(B) (see "Lubricant table").
4 -Reassemble the guard (A).
5 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".
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(B) Drive gear

(A) Protection guard

IDM-43600108501tif

TRANSMISSION GEAR LUBRICATION 25

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).
3 -Lubricate gears (B) (see "Lubrication point diagram").
4 -Reassemble the guard (A).
5 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(B) Drive gear

IDM C743600103.fm

(A) Protection guard

IDM-43600113001.tif

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CHANGE LUBRICATION CARTRIDGE 26

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Open the guard (D).
3 -Unscrew the cartridge (H) and replace it.
4 -Close the guard (D).
5 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(H) Lubrication cartridge

(D) Protection guard

IDM-43600108602.tif
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OIL CHANGE OF MAIN DRIVE REDUCTION GEAR 27

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.
2 -Remove shelter (A).
3 -Prepare a container of appropriate capacity.
4 -Unscrew the dose cap (B).
5 -Unscrew the exhaust plug (C) and let all the oil flow into the container.

Important
Do not litter the environment with polluting material; perform disposal accord-
ing to the pertinent laws in force.
6 -Re-screw the exhaust plug (C).
7 -Introduce the new oil by the feeding plug up to the correct level displayed on the
indicator.

Important
Use the recommended oil (see "Lubricant table").
8 -Screw again the load plug.
9 -Reassemble the guard.
10-Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(A) Protection guard

(B) Dose cap

Level gauge

(C) Discharge cap

IDM-43600113700.tif
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AUTOMATIC LUBRICATION OIL CHANGE 28

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).
3 -Prepare a container of appropriate capacity.
4 -Unscrew the dose cap (C).
5 -Unscrew the exhaust plug (B) and let all the oil flow into the container.

Important
Do not litter the environment with polluting material; perform disposal accord-
ing to the pertinent laws in force.
6 -Re-screw the exhaust plug (B).
7 -Introduce the new oil by the feeding plug up to the correct level displayed on the
indicator.

Important
Use the recommended oil (see "Lubricant table").
The oil level should be included between the minimum and maximum marks.
8 -Screw again the load plug (C).
9 -Reassemble the guard (A).
10-Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(C) Dose cap

Level gauge

(A) Protection guard

(B) Discharge cap

IDM C743600103.fm

IDM-43600108700.tif

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PLATE ROLLER LUBRICATION OIL CHANGE 29

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).
3 -Prepare a container of appropriate capacity.
4 -Open the tap (B) and let the oil flow into the container.

Important
Do not litter the environment with polluting material; perform disposal accord-
ing to the pertinent laws in force.
5 -Close the faucet (B).
6 -Unscrew the dose cap (C).
7 -Pour the new oil through the filling plug.

Important
Use the recommended oil (see "Lubricant table").
8 -Screw again the load plug (C).
9 -Reassemble the guard (A).
10-Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(A) Protection guard

(C) Dose cap

(B) Tap
IDM C743600103.fm

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AUGER DRIVE OIL CHANGE 30

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Open the guard (A).
3 -Prepare a container of appropriate capacity.
4 -Unscrew the dose cap (B).
5 -Unscrew the exhaust plug (C) and let all the oil flow into the container.

Important
Do not litter the environment with polluting material; perform disposal accord-
ing to the pertinent laws in force.
6 -Re-screw the exhaust plug (C).
7 -Introduce the new oil by the feeding plug up to the correct level displayed on the
indicator.

Important
Use the recommended oil (see "Lubricant table").
8 -Screw again the load plug (B).
9 -Close the guard (A).
10-Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

Level gauge

(B) Dose cap

(C) Discharge cap

(A) Protection guard

IDM-43600110701.tif
IDM C743600103.fm

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CHECK GLUE UNIFORMITY AND DISTRIBUTION 31

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Unscrew the knob (B) to disassemble the cover (C).
5 -Press buttons (D1) and keep them pressed; after a few seconds press also button
(D). The machine starts in "manual mode".
When one of the push-buttons is released, the machine stops.

(9) Mode selector (B) Knob

(C) Cover

(D1) Key

(10) Selector

(D) Key

IDM-43600108802.tif

6 -Check that the glue is correctly distributed on the label (see figure).

Area with glue Area with glue

Label
Area with glue Area with glue
IDM C743600103.fm

Label
IDM-43600604700.tif

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7 -Rotate the screw (G) (in clockwise or counter-clockwise direction) to adjust the
distribution of the glue over the roller (F), until achieving a uniform layer (see "Ad-
justment of glue distribution").
8 -If, after having adjusted the glue distribution, it continues to be non-uniform and
unhomogeneous, check the efficiency of the glue doser (H) and, if necessary, re-
place it (see "How to replace the glue doser").
9 -Install the cover (C).
10-Close the guard (A).
11-Turn the selector (9) to 0.
12-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(G) Screw

(H) Glue dosing device (F) Glue application roller

IDM-43600113100.tif

CHECK IDLE ROLLER ROTATION 32

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Check for the correct roller rotation
3 -If necessary, remove cover (B) and lubricate with oil.
4 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".
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(B) Cap

Roller

IDM-43600109301.tif

CHECK HEAD ROTATION 33

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 4.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (L).
4 -Manually rotate the heads (M) to verify the correct operation of the bearings.
5 -Press buttons (B1) and keep them pressed; after a few seconds press also button
(B). The machine starts in "manual mode". When one of the push-buttons is re-
leased, the machine stops.
6 -Repeat the operation to check the correct functioning of the other heads.
7 -Close the guard (L).
8 -Turn the selector (9) to 0.
9 -Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(9) Mode selector

(M) Container stopping head
(B1) Key
IDM C743600103.fm

(L) Protection guard

(10) Selector
(B) Key
IDM-43600109002.tif

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CHECK FOR PLATE DRIVE WEAR (S MACHINE VERSION) 34

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 4.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (L).
4 -Loosen the handles (N).
5 -Dismount lobe cam (P).

(N) Handle

(9) Mode selector

(10) Selector

(L) Protection guard

(N) Handle
(P) "Lobe" cam
IDM-43600110801.tif

6 -Check the diameter of rollers (Q) and replace them, if necessary.

7 -Press buttons (B1) and keep them pressed; after a few seconds press also button
(B). The machine starts in "manual mode". When one of the push-buttons is re-
leased, the machine stops.

(B1) Key

(L) Protection guard

(B) Key
IDM C743600103.fm

(Q) Plate drive roller

IDM-43600109102.tif

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8 -Repeat the operation to check the correct dimension of the other rollers.
9 -Mount lobe cam (P) and tighten handles (N).
10-Close the guard (L).
11-Turn the selector (9) to 0.
12-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

CHECK OF THE PLATE ROTATION BELT (MACHINE VERSION N) 35

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 4.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (L).
4 -Press buttons (B1) and keep them pressed; after a few seconds press also button
(B). The machine starts in "manual mode".
When one of the push-buttons is released, the machine stops.
5 -Check the integrity of belt (R) and replace it, if necessary (see "Transmission belt
replacement (N machine version)").
6 -Check the belt tension and adjust it, where necessary (see "Transmission belt ad-
justment").
7 -Close the guard (L).
8 -Turn the selector (9) to 0.
9 -Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(9) Mode selector (R) Transmission belt

(B1) Key
IDM C743600103.fm

(10) Selector (L) Protection guard

(B) Key

IDM-43600109202.tif

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CHECK HEAD DRIVE DEVICE BEARINGS 36

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Open the guard (D).
3 -Remove the screws (E) and guard (F).
4 -Manually rotate central turntable to check the integrity of bearings (S) and replace
them, if necessary.

Important
Replace the worn parts with original spare parts. If several bearings need to be
replaced, it's a good idea to replace them all.
5 -Assemble the guard (F) and secure it with the screws.
6 -Close the guard (D).
7 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(E) Screw

(F) Protection guard

(D) Protection guard

(S) Bearing

IDM-43600109501.tif

CHECK CUTTING BLADE EFFICIENCY 37

To check for blade wear, check that the ends of the labels are cut correctly.
Proceed as indicated.
1 -Start the "simulated cut" function by means of the operating terminal controls
IDM C743600103.fm

(see the "Operating terminal" manual).

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2 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
3 -Turn the selector (9) to (1).
4 -Open the guard (A).
5 -Keep the buttons (B1) pressed and, after a few seconds, also press the button (B).
The label application roller and the cutting roller will start in "manual mode".
When one of the buttons is released, the label application roller and the cutting
roller will stop.

(A) Protection guard

(9) Mode selector (B1) Key

(10) Selector
(B) Key
IDM-43600112101.tif

6 -Make sure that the label ends are correctly cut.

7 -Replace cutting blade , if necessary (consult the enclosed manual).
8 -Close the guard (A).
9 -Turn the selector (9) to 0.
10-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".
IDM C743600103.fm

IDM-43600606500.tif

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CHECK TRANSMISSION CHAIN TENSION 38

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).
3 -Check and, if necessary, adjust the chain tensioning (see "transmission chain ad-
justment").
4 -Reassemble the guard (A).
5 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

Transmission chain
(A) Protection guard

IDM-43600110901.tif
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TROUBLESHOOTING 1

The machine is designed to automatically signal the principal anomalies that could oc-
cur during its operation by sending alarm messages that can be consulted on the op-
erations terminal. Since this is an automatic machine, its operating cycle consists of a
sequence of movements that receive approval from the previous maneuver and give
approval to the next maneuver. For this reason, when the work cycle is interrupted, it
is possible to identify the last movement performed that did not give its approval to the
next maneuver.
The table shows a list of several generic problems that may be encountered during
use of the machine.

Table 8.1: Operation irregularities of the machine

Problem Causes Solutions

"No oil" alarm at the labeling

Clogged filter Remove and clean filter
station with pump running
The idle roller oscillates in an
Presence of oxide in the reel Clean the reel brakes (see "Clean
anomalous manner while the
brakes brake reel").
machine is at constant speed
Check the winding quality and replace
Defective reel
the reel, if necessary
Aligner device out of scale Verify the correct alignment of the reel
Reel support not correctly
support
adjusted
Contact the Servicing Department
Adjust the value of the label-holding
suction (see "Change value of label
held")
Clean the holes of the sliding blocks,
The label film is winding on the The label-holding suction value the label application roller and the
feed roller is too low cutting roller (see "Clean label
application roller slides", "Clean label
application roller", "Clean cutting roller")
Clean the filters of pneumatic manifold
(see "Cleaning the air filters")
Adjust the value of the label-holding
The label-holding suction value
suction (see "Change value of label
is too high
held")
The label is not correctly cut
Adjust the blades, or replace, if
Cutting blade not correctly
necessary (consult the enclosed
adjusted and/or worn
manual)
Adjust the value of the label-holding
suction (see "Change value of label
held")
Clean the holes of the sliding blocks,
The label is not correctly
The label-holding suction value the label application roller and the
positioned on the label
is not correct cutting roller (see "Clean label
application roller
application roller slides", "Clean label
application roller", "Clean cutting roller")
Clean the filters of pneumatic manifold
(see "Cleaning the air filters")
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Table 8.1: Operation irregularities of the machine
Problem Causes Solutions

The label application roller was

Position the roller correctly
not correctly positioned in the
(see "Change label application roller")
format change step
The label is not correctly
Disassemble and clean the device (see
positioned on the label The blow open device is dirty
"Cleaning the opening blower device")
application roller
Adjust the blades, or replace, if
Cutting blade not correctly
necessary (consult the enclosed
adjusted and/or worn
manual)
Adjust the value of the label-holding
suction (see "Change value of label
held")
Clean the holes of the sliding blocks
The label-holding suction value
and the label application roller (see
is not correct
The cut label remains blocked on "Clean label application roller slides",
the glue roller "Clean label application roller")

Clean the filters of pneumatic manifold

(see "Cleaning the air filters")

The label application roller was

Position the roller correctly
not correctly positioned in the
(see "Change label application roller")
format change step

The microreducer of the main The glue scraper is blocked and

Disassemble and clean the scrapper
transmission is excessively pressing on the glue roller
overheating, it blocks and the The vacuum distributor located
machine stops in emergency Clean the vacuum distributor
under the label application roller
conditions (see "Clean the vacuum distributor")
is dirty

The doser is clogged Disassemble and clean the doser

Check and correctly screw on the

There is insufficient glue on the Doser not correctly installed
doser, if necessary
roller
Dismount and clean the filter
Glue tub filter dirty
(see "Cleaning the glue filter")

The doser is clogged Disassemble and clean the doser

Replace the glue and clean the tank

There is insufficient glue on the Low quality glue
(see "Glue tank cleaning")
label
Dismount and clean the filter
Glue tub filter dirty
(see "Cleaning the glue filter")

Disassemble and clean the slides (see

"Clean label application roller slides")
The label is not being applied to The label application roller slides
the container are dirty with glue Clean the label application roller and
the cutting roller (see "Clean label
application roller", "Clean cutting roller")
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Table 8.1: Operation irregularities of the machine
Problem Causes Solutions

Adjust the value of the label-holding

suction (see "Change value of label
held")
Clean the holes of the sliding blocks,
The label-holding suction value the label application roller and the
is not correct cutting roller (see "Clean label
application roller slides", "Clean label
The label is not being applied to application roller", "Clean cutting roller")
the container
Clean the filters of pneumatic manifold
(see "Cleaning the air filters")
The label application roller was
Position the roller correctly
not correctly positioned in the
(see "Change label application roller")
format change step
Check the quality and integrity of the
Faulty containers
containers
The container slides on the plate Check the quality and integrity of the
during labeling containers
Check the efficiency of the drying
The label is not correctly pressed The container is wet
system
on the container
The smoothing devices (rollers,
Adjust the position of the smoothing
brushes) are not correctly
devices
positioned
IDM C843600103.fm

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REPLACEMENT INSTRUCTIONS 1

– Before performing any replacement operation, activate all of the security devices
provided and evaluate the necessity to adequately inform personnel operating in the
near vicinity. In particular, confine the neighbouring areas to impede access to the
devices that could, if activated, produce unexpected danger conditions provoking
hazards to personal safety and health. In the event deteriorated parts need replace-
ment, only use original spare parts. The manufacturer is not liable for damages to
persons or parts caused by the use of non-original parts and extraordinary opera-
tions that can modify safety requirements without express authorisation. To request
parts follow the indications found in the spare parts catalogue.
– This operation must be performed by skilled technicians according to the work safety
laws in force. Do not litter the environment with non-biodegradable products, lubri-
cants and non-ferrous parts (rubber, PVC, resin, etc.). Perform disposal according to
the pertinent laws in force.
– When operations requesting the use of the mobile push-button panel with disabled
safety functions must be performed, these functions must be disabled by the person
in charge of the system.
– The person in charge of the system must authorise only the properly skilled person-
nel to replace the cutting blades. Moreover, he/she must make sure that no improper
operations are carried out in order to prevent any risks to people’s safety.
– After completing these operations, the person in charge of the system must reset the
operation of push-button panel by means of key selector , must check the resetting
of the safety conditions, remove the key from selector and retain it in a place un-
known to his/her colleagues.

RECOMMENDED SPARE PARTS 2

Replace worn parts with original spare parts. Use tools and equipment in good work-
ing conditions and the lubricants recommended by the manufacturer to ensure correct
work station operations and the foreseen safety level.
The use of P.E. Labellers S.p.A original spare parts ensures the warranty right and en-
ables the maximum efficiency and machine life.
The list includes the spare parts subject to wear, which are not covered by warranty.
– Sliding blocks of the label application roller.
– Transmission belt (for machine version N)
– "Lobe" cam sectors (for machine version S)
– Oil filter
– Air filters
– Glue dosing device
– Contrast device
– Cutting blades

REPLACING AIR FILTERS 3

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.
IDM C943600103.fm

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (A).

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3 -Act on spring closures (B) to open the filter containers.
4 -Replace filters (C) and reclose containers.
5 -Reassemble the guard (A).
6 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(B) Spring closure

(C) Air filter

(A) Protection guard

IDM-43600103801.tif

REPLACING "FR UNIT" AIR FILTER 4

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Shut off the air flow.
3 -Remove shelter (E).
4 -Remove cup (D).
5 -Remove the filter, replace it and screw on the cup (D).
6 -Reassemble the guard (E).
7 -Turn the main disconnector to position (ON) to connect power supply.
Upon the glue preheating stage, the machine does not start automatically, but the
operator has the task to perform the specific procedure.

(D) Filter cup

IDM C943600103.fm

(E) Protection guard

IDM-43600103901.tif

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REPLACING OIL FILTER 5

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (H).
3 -Unscrew screws (F), remove filter (G) and replace it.
4 -Replace filter (G), tighten screws (F).
5 -Turn the main disconnector to position (ON) to connect power supply.
6 -Reassemble the guard (H).
Upon the glue preheating stage, the machine does not start automatically, but the
operator has the task to perform the specific procedure.

(F) Screw

(H) Protection guard

(G) Oil filter

IDM-43600104002.tif
IDM C943600103.fm

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REPLACING LABEL APPLICATION ROLLER SLIDES 6

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (L).
4 -Dismount roller (M) and rest it on the work surface (see "Change label application
roller").
5 -Unscrew screws (N) and dismount slide blocks (P).
6 -Clean seats with a cloth soaked in anti-silicone liquid.
7 -Mount new slides (P) and lock them with screws (N).
8 -Assemble the roller (M).
9 -Close the guard (L).
10-Turn the selector (9) to 0.
11-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

(9) Mode selector (M) Label application roller

(L) Protection guard

(10) Selector (N) Screw

(P) Label application roller sliding block

IDM-43600104103.tif
IDM C943600103.fm

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REPLACING ELECTRICAL HEATING ELEMENTS 7

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Open the guard (Q).

Danger - Warning
To avoid risk of burns, make sure that the glue is cold before working on the tub.
3 -Remove the screws (R) and flange (S).
4 -Unscrew screws to remove protections (T-U).
5 -Disconnect wires of heating elements (V).
6 -Replace probe heating element (V).
7 -Reconnect wires of heating elements
8 -Refit the guards (T-U).
9 -Close the guard (Q).
10-Turn the main disconnector to position (ON) to connect power supply. Upon the
glue preheating stage, the machine does not start automatically, but the operator
has the task to perform the specific procedure (see "Machine start").

(R) Screw
(S) Flange

(U) Protection guard

(V) Electric resistance

(V) Electric resistance

(T) Protection guard

(Q) Protection guard

IDM-43600104202.tif

CENTRAL TURNTABLE ENCODER REPLACEMENT 8

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.
IDM C943600103.fm

Important
The electric heating circuit of the glue is not powered.

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2 -Remove shelter (A).
3 -Loosen the screw (B) on the joint.
4 -Disconnect the connector (C).
5 -Unscrew the screws, remove the encoder (D) and replace it.
6 -Connect connector (C).
7 -Manually rotate central turntable until reference notch (E) coincides with index (F).
8 -Open the door of the electrical panel and turn the main switch to the I (ON)
position to turn on the electricity.

(E) Reference mark

(B) Screw

(F) Reference notch

(A) Protection guard (C) Connector
(D) Encoder
IDM-43600104701.tif

9 -Rotate the shaft of the encoder (D), and then check that the LEDs E0.0 and E0.1
turn on inside the electrical panel.
10-Rotate the main switch in position (O) (OFF) to turn off electric supply and close
the door of the electric cabinet.
11-Tighten the screw (B).
12-Reassemble the guard (A).
13-Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(D) Encoder
IDM C943600103.fm

IDM-43600104802.tif

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REPLACEMENT OF THE AXIS ENCODER 9

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Remove shelter (G).
3 -Loosen the screw (H) on the joint.
4 -Disconnect the connector (L).
5 -Unscrew the screws, remove the encoder (M) and replace it.

Important
Take care to maintain the axiality of the encoder shaft with the joint to ensure
its correct operation.
6 -Tighten the screw (H).
7 -Connect connector (L).
8 -Reassemble the guard (G).
9 -Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

(M) Encoder (H) Screw

(G) Protection guard

(L) Connector

IDM-43600105701.tif
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TRANSMISSION BELT REPLACEMENT (N MACHINE VERSION) 10

Proceed as indicated.
1 -Deactivate the main electric switch to put the machine in safety conditions.

Important
The electric heating circuit of the glue is not powered.
2 -Open the guard (N).
3 -Dismount entry star (P) (see "Feeding star change").
4 -Dismount exit star (Q) (see "Exiting star change").
5 -Dismount conveyor (R) (see "Conveyor change").
6 -Loosen the screws (S).
7 -Disconnect electrical wires in the upper part of central turntable (T).

(R) Container conveyor

(T) Central turntable
(S) Screw (P) Container feeding star

(Q) Container exit star

(N) Protection guard
IDM-43600109702.tif

8 -Unscrew the screws (U) and remove the support (V).

9 -Remove the screws (X) and guard (Y).

Caution - Precaution
This operation must be performed by at least two people.

(U) Screw

(X) Screw
IDM C943600103.fm

(V) Support

(Y) Protection guard

IDM-43600105001.tif

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10-Loosen belt (Z).
11-Remove the belt (Z) and replace.
12-Adjust belt tension (see "Transmission belt adjustment").

(Z) Transmission belt

IDM-43600105102.tif

13-Assemble the guard (Y) and secure it with the screws (X).
14-Assemble the support (V) and secure it with the screws (U).
15-Connect electrical wires.
16-Screw screws (S).
17-Mount entry star (P).
18-Mount exit start (Q).
19-Mount conveyor (R).
20-Close the guard (N).
21-Turn the main disconnector to position (ON) to connect power supply.
The machine is pre-arranged for operating in "automatic mode".

HOW TO REPLACE THE GLUE DOSER 11

Proceed as indicated.
1 -Rotate selector (10) to position MAN to activate the machine operation in "manual
mode".
2 -Turn the selector (9) to 1.

Important
The electric heating circuit of the glue is powered.
3 -Open the guard (A).
4 -Unscrew the knob (B) to disassemble the cover (C).
IDM C943600103.fm

5 -Loosen screws (D) and disassemble bracket (E).

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(C) Cover
(B) Knob

(9) Mode selector

(A) Protection guard

(10) Selector

(D) Screw

(E) Bracket

IDM-43600113201.tif

6 -Remove the screws (F) to dismount the support (G).

(F) Screw
(G) Support

(H) Glue dosing device

IDM C943600103.fm

IDM-43600113300.tif

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7 -Remove and replace the doser (H).
8 -Assemble the support (G) and secure it with the screws.
9 -By using the screw (L), make the references (M1) and (M2) coincide.

(L) Screw
(M2) Reference mark
(M1) Reference mark

(H) Glue dosing device

(D) Screw

(E) Bracket

(G) Support

IDM-43600113401.tif

10-Assemble the doser (H) (complete with the bracket (E)) to the support (G) without
completely tightening the screws (D).
11-Prize the doser (H) to uniformly lean it against the glue roller (N).
12-Tighten screws (D).
13-Adjust the distribution of the glue over the roller (see "Adjustment of glue distribu-
tion").

(H) Glue dosing device

(N) Glue application roller

(H) Glue dosing device

(N) Glue application roller

IDM C943600103.fm

(D) Screw

IDM-43600113501.tif

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14-Install the cover (C).
15-Close the guard (A).
16-Turn the selector (9) to 0.
17-Turn the selector (10) to AUT.
The machine is pre-arranged for operating in "automatic mode".

MACHINE DISPOSAL 12

– To prevent the machine from becoming a personal and environmental hazard,

disconnect and disable all power sources (electrical, pneumatic, hydraulic, etc.) and
empty any remaining liquids (lubricants, oils, etc.).
– Deposit the machine in a suitable area, not easily accessible and appropriately
confined to prevent unauthorised access.

MACHINE DEMOLITION 13

– Personnel authorised to demolish the machine must, if necessary, implement a

"safety plan" to protect those directly involved and strictly apply all current workman’s
safety regulations.
– Remove all main machine parts. For further information on these operations, contact
the manufacturer’s authorised service centre.
– During demolition, select all components according to the chemical properties and
differentiate disposal according to current pertinent laws.
– Do not litter the environment with non-biodegradable products, lubricants and non-
ferrous parts (rubber, PVC, resin, etc.). Perform disposal according to the pertinent
laws in force.
IDM C943600103.fm

English language 117 Operation and maintenance manual