Flexa CWT GALAXY User manual

USE AND MAINTENANCE MANUAL
EN
GALAXY
HOT ROLLER LAMINATOR FOR HIGH
QUALITY PRODUCTION
MODEL : CWT GALAXY
YEAR OF CONSTRUCTION : 2019
MANUAL CODE : 756100330_EN
REVISION : 0
DATE : 07/03/2019
Translated from original language
Read carefully before use

Contents 1
1Generalinformation:scopeofthismanual 1
1.1Intendedaudience 1
1.2Professionalsinvolved 2
1.3Manualuseandstorage 3
1.4Howtoconsultthemanual 4
1.4.1Descriptionofthesymbols/pictogramsinthemanual 4
1.4.2Descriptionsofthesymbolsusedinthemaintenancechapter 5
1.5Manufactureridentification 5
1.6Ownershipofinformation 5
1.7Markingdate 6
1.8Directivesandreferencestandards 7
1.9Declarationofconformity 8
1.10Warranty 9
1.11Assistance 9
2Machinepresentation 11
2.1Machineparts 11
2.1.1Self-lockingspindleshaft 11
2.2Operatingprinciple 13
2.3Intendedandimproperuse 14
2.4Technicaldata 15
2.5Overallmachinedimensionsandweight 16
3Safety 17
3.1Generalwarnings 17
3.2Machinesafetydevices 19
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation

3.2.1Arrangementoffixedprotectivecasingandsafetyphotocells 20
3.2.2Arrangementofemergencystopdevicesandthemainelectricalswitch 21
3.2.3Safetylabels 22
3.3Operatorworkstations 23
3.4Personalprotectiveequipment 24
3.5Residualrisks 25
4Transportationandhandling 27
4.1Generalwarnings 27
4.2Liftingandtransportingthemachine-packagedcomponents 28
4.2.1Overallpackagingdimensionsandweight 28
4.2.2Liftingthemachinewithpackaging 28
5Installationinstructions 29
5.1Environmentalconditionsandpreparationforinstallation 29
5.2Checksbeforeinstallation 29
5.3Unpacking 30
5.3.1Removingthemachinefromthepalletwithaforklift 31
5.3.2Removingthemachinefromthepalletusingslides 32
5.3.3Disposingofpackaging 33
5.4Handling 33
5.5Positioning 34
5.6Connections 35
5.6.1Electricalconnections 35
5.7Checksbeforeputtingintoservice 36
6Control,adjustmentandsignallingdevices 37
6.1Positioning/Layoutofthecontroldevices 37
6.2Mainswitch 38
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation

6.3Controlpanel 38
6.4Footpedalcontrol 41
6.5Emergencybuttons 41
6.6Materialtensionadjustmentknobs 42
6.7Adjustmenthand-wheel(liftsandlowerstheupperroller) 42
7Use 43
7.1Puttingintoservice 43
7.2Startingprocessing 43
7.3Cyclepause 43
7.4Emergencystop 44
7.5Restartafteranemergencystop 44
7.6Re-startafterablack-out 44
7.7Shut-down 44
7.8Machineinsafeconditionsforvariousoperations 45
7.8.1Safelyrestartingthemachine 45
7.9Safetyresetprocedure 45
7.10Quickrollerheatingprocedure 46
7.11“Soft”rollerheatingprocedure 46
7.12Footpedalcontrolactivationprocedure 48
7.13Rollerbackwardsmovementactivationprocedure 48
7.14Rollercoolingprocedure 49
7.15Materialcentringprocedure 50
7.16Workingpressureadjustmentprocedure 51
7.17Materialtensionadjustmentprocedure 53
7.18Materialloadingprocedure 54
7.18.1Procedureforapplyingself-adhesivefilmwithoutprotectiveliner(double-sidedadhesive,applicationtape) 54
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation

7.18.2Procedureforapplyingself-adhesivefilmwithprotectiveliner(colouredfilms,plasticcoatings) 55
7.18.3Procedureformountingplasticcoatedimagesonthepanel 56
7.19Spindleshaftreplacementprocedure 57
7.20Cuttingunitadjustmentandbladereplacementprocedure 59
7.21Pathdiagramsofthematerialandthefinishedproduct 60
7.21.1Spindleshaftdefinitions 60
7.21.2Coldprotectivefilmlaminationonsheets 61
7.21.3Coldprotectivefilmlaminationonpanels 62
7.21.4Double-sidedadhesivelaminationonsheets 63
7.21.5Double-sidedadhesivelaminationonpanels 64
7.21.6Coldprotectivefilmanddouble-sidedadhesivelaminationonsheets 65
7.21.7Mountingofimageonpanelalreadymadeadhesive 66
7.21.8Mountingadhesiveimagesonpanels 67
7.21.9Hotfilmlaminationonsheetsandrewindingthefinishedproduct 68
7.21.10Double-sidedadhesivelaminationonsheetsandrewindingthefinishedproduct 69
8Maintenance 71
8.1Generalwarnings 71
8.2Descriptionsofthesymbolsusedinthemaintenancechapter 72
8.3Routinemaintenance 72
8.3.1Routinemaintenancesummarytable 72
8.3.2Casingremovalprocedure 73
8.3.3Photocellreplacement/adjustment 74
8.3.4Generalcleaning 75
8.3.5Lubricatingtheupperrubberrollerliftingscrew 76
8.3.6Chainlubrication 77
8.4Specialmaintenance 78
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation

8.5Oilsandlubricants 78
9Troubleshooting 79
10Dismantlinganddisposal 81
11Attachments 83
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation

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

1Generalinformation:scopeofthismanual
Thismanualisprovidedasanaidandaguideduringthemachineworkphases.Itcontainsinformationregardinguse,
maintenanceandtroubleshooting,providingindicationsforthemostsuitableconductforcorrectuseandcorrectoperationof
themachineasrequiredbytheManufacturer.
Thismanualisanessentialsafetyrequirementandmustaccompanythemachinethroughoutitslifecycle.Itisessentialto
preserveandmakethismanualavailabletoallpersonsinvolvedinuseandmaintenanceofthemachine.


1.1Intendedaudience
Themanualinquestionisaddressedtoqualified,adequatelytrainedpersonnelforoperationofthemachinedescribedinthis
manual.
Themanualinquestionisaddressedtotheoperatorresponsibleforoperationofthemachineandtothetechniciansauthorised
forinstallationandmaintenance.

Thisdocumentand/oritspartscannotbereproducedortransmittedtothirdpartieswithoutpriorauthorisationfrom
FLEXAS.r.l.
Warning
ThecompanyFLEXAS.r.l.isnotresponsibleforanydamagetopersonsorpropertyresultingfromimproperusenot
indicatedinthismanualandincontrasttotheinformationspecifiedinthetechnicalcharacteristicstablerelatedto
eachmodel.
Warning
Operatorsmustnotperforminterventionsreservedformaintenancepersonnelorspecialisedtechnicians.The
manufacturerisnotliablefordamagesresultingfromfailuretocomplywiththiswarning.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 1

1.2Professionalsinvolved
Belowisadescriptionoftheprofessionalswhocanworkonthemachine,dependingonthetypeofactivitiestobecarriedout.
Operator
Mechanicalmaintenancetechnician
Electricalmaintenancetechnician
Manufacturer’sTechnician
Qualified personnel able to operate the machine, carry out loading and unloading of the product to be
machined/processed,carryoutadjustment,cleaning,start-upoperationsorrestoreprocessingfollowingan
emergencystop.Theoperatorisnotauthorisedtoperformmaintenance.
Qualifiedtechnicianabletooperatethemachineinnormalconditions,isinchargeofallmechanicaloperations
regardingtheadjustment,maintenanceandordinaryrepairsdescribedinthismanual.Itisnotauthorisedtoperform
operationsonelectricalsystemsinthepresenceofvoltage.
Qualifiedtechnicianabletooperatethemachineinnormalconditions,isinchargeofalltheelectricaloperations
regardingtheadjustment,maintenanceandordinaryrepairsdescribedinthismanual.Isabletoworkinthepresence
ofvoltageonelectricalcabinetsandjunctionboxes.
Qualifiedtechnicianprovidedbythemanufacturertocarryoutcomplexnatureoperationsinparticularsituationsorin
anycaseaccordingtowhathasbeenagreeduponwiththeuser.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 2

1.3Manualuseandstorage
Thismanualisintendedtoprovidealltheinformationnecessaryforcorrectuseofthemachineanditsmanagementas
autonomouslyandsafelyaspossible.
Usersandmaintenancetechniciansmustcarefullyreadtheinstructionscontainedinthismanualandanyattachmentsbefore
performinganyoperationsonthemachine.
Ifanydoubtsariseregardingcorrectinterpretationoftheinformationinthedocumentation,contactthemanufacturerfor
necessaryclarifications.
Itisthecompetenceandresponsibilityoftheendusertostudyandoptimisethemachiningprocessforwhichthemachinewas
purchased.



Warning
Readthismanualcarefullybeforeoperatingthemachineortakinganyactiononit.Ifyoudonotreaditfirst,youmay
notbeabletorecognisedangeroussituationsthatcancausedeathorseriousinjurytoyourselfandothers.
Caution
Keepthismanualandallattacheddocumentationingoodconditions,legibleandcompleteinallitsparts.Store
documentationnearthemachineinanaccessiblelocationknowntoalloperatorsandmaintenancepersonneland,
moregenerally,toallthosewhoforvariousreasonsmaycomeintocontactwiththemachine.
Warning
Storethemanualinitsoriginalstate.Donotrewrite,modifyordeletemanualpagesortheircontents.The
manufacturerdeclinesallresponsibilityforanydamagetopeople,animalsandpropertycausedbyfailuretocomply
withthewarningsandoperatingproceduresdescribedinthismanual.
Thismanualisanintegralpartofthemachineandmustbekeptforfuturereference.
Caution
Thismanualmustbedeliveredtogetherwiththemachineifitistransferred/soldtoanotheruser.
Caution
Incaseoflossordeteriorationofthemanual,requestacopyfromtheManufacturer,specifyingthedocument
identificationdata:documentname,code,revisionanddateofpreparation.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 3

●
●
1.4Howtoconsultthemanual
Themanualisdividedintochapters,paragraphsandsub-paragraphs,listedintheindex:aneasywaytofindanytopicof
interest.
Thesymbolsusedprovidedirectinformationonthetypeofinformationexpressedbythesymbolitself.Forexample,the
symbol:

1.4.1Descriptionofthesymbols/pictogramsinthemanual
Belowarethevarioussymbolsusedinthemanualtohighlightespeciallyimportantinformationortherecipientsofthe
informationitself.



SignalsthepresenceofaNote.
Danger
TherisksdescribedinthiswayindicateaHIGHLEVELofhazardwhich,ifnotavoided,couldresultinseriousinjuryor
death.
Warning
TherisksdescribedinthiswayindicateaMEDIUMLEVELofhazardwhich,ifnotavoided,couldresultinseriousinjury
ordeath.
Caution
TherisksdescribedinthiswayindicateaLOWLEVELofhazardwhich,ifnotavoided,mayresultinminorormoderate
injury.
ThissymbolindicatesaNOTE:especiallyimportantinformationorin-depthanalysis.
ThissymbolindicatesaREMINDER:thepresenceofaform,adrawingoranattacheddocumentwhichshouldberead
and,ifrequired,filledin.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 4

1.4.2Descriptionsofthesymbolsusedinthemaintenancechapter
Thisparagraphdescribesthesymbolsusedinthemaintenancechapter.
1.5Manufactureridentification
FLEXAS.r.l.
Viadell'Industria,11
31014ColleUmberto(TV)Italy
e-mail:[email protected]
web:www.flexa.it
Tel.:043838565-Fax:043838767

1.6Ownershipofinformation
Iconused Description
Mechanicaltypeintervention
Electricaltypeintervention
Specifiesthefrequencyofinterventions
Thisdocumentand/oritspartscannotbereproducedortransmittedtothirdpartieswithoutpriorauthorisationfrom
FLEXAS.r.l.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 5

1.7Markingdate

Theidentificationplateisappliedonthemachineinthepositionshowninthefigure.

Manufacturer'slogo.A.
CEmarking.B.
Manufacturer'sname.C.
Machinemodel.D.
Serialnumber.E.
Supplyvoltage.F.
Nominalpower.G.
Frequency.H.
Yearofmanufacture.I.
Mass.J.
Caution
Requestanewidentificationplatewhenevertheoneappliedonthemachinebecomesillegible.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 6

●
●
●
●
●
●
1.8Directivesandreferencestandards
Listofdirectivesandreferencestandardsusedforthedesignandconstructionofthemachine.
Directives
2006/42/ECMachinerydirective.
2014/35/EULowvoltagedirective
2014/30/UEEMCDirective(electromagneticcompatibility).

Harmonisedstandards
UNIENISO12100:2010Safetyofmachinery-Generalprinciplesofdesign-Riskassessmentandriskreduction.
UNIISO/TR14121-2:2013Safetyofmachinery-Riskassessment-Part2:Practicalguideandexamplesofmethods.
UNIENISO3744,3745,3746and11200-11204Determinationofsoundpowerlevelsandsoundenergylevelsofnoise
sourcesusingsoundpressure.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 7

1.9Declarationofconformity
Theoriginaldocumentissuppliedseparatelytothismanual.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 8

1.10Warranty

1.11Assistance
ThepurchasermustcontacttheManufacturerdirectly(ortheservicecentreifpresent)foranyneedrelatedtotheuse,
maintenanceorrequestforspareparts,specifyingthemachineidentificationdataindicatedontheidentificationplate.
TheCustomercanmakeuseofthetechnicalsalessupportoflocalagentsorimporterswhoareindirectcontactwiththe
companyFLEXAS.r.l.
Intheeventoffailureorinconveniencethatcannotbeovercome,theCustomermustdirectlycontactthemanufacturerwhose
contactsareasfollows:

Thewarrantyissuppliedseparatelyorwiththecontract.
TELEPHONE: [phone]
EMAIL: [email protected]
ASSISTANCEDEPARTMENT: [email protected]
WEBSITE: www.cwtworktoolsusa.com
MAILINGADDRESS:
CWTWorktoolsUSA
1201TappanCircle
Carrollton,TX.75006
USA
Intheeventofachangeofownershiporcompanymovementofthemachine,itisalwaysnecessarytoinformthe
manufacturerorthereferenceservicecentre,evenafterthewarrantyperiod.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 9

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

2Machinepresentation
PROFESSIONALLAMINATORequippedwithheatedupperrollerforself-adhesivematerials.
Letsyoulaminate,mountimagesandencapsulate.Designedtobereliableandeasytouseforhighqualityresults.

2.1Machineparts

Frontworktop.A.
Rearworktop.B.
Feed-inguide.C.
Sheddingbar.D.
Controlpanel.E.
Adjustmenthand-wheel(liftsandlowerstheupper
roller).
F.
Fixedprotectivecasing.G.
Recoveryclutchadjustment.H.
Brakeadjustment.I.
Footpedalcontrol.J.
Storagecompartment.K.
Printstoragetray(optional).L.
Recoveryclutchadjustment(optional).M.
Materialtrimmingblades(optional).N.

M1
Motorisedrewindingshaft.
M2
Motorisedrewindingshaft(optional).
F1-F2
Unwindingshafts(idler).
F3
Unwindingshaft(idler)-(optional).
R1
Upperrubberandheatedroller(idler).
R2
Lowermotorisedrubberroller.
G1-G2
Guiderollers.
GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 11

2.1.1Self-lockingspindleshaft
Thespindleshafts,whicharethesameandinterchangeablewithoneanother,takeondifferentfunctionsinrelationtothe
positioninwhichtheyareloadedintothemachine(Seepar2.1).
Theshaftssupport3-inchspindles(nominal)andareperfectlysymmetrical(notpolarised),thusallowingforeasyplacementon
themachine.
Theshaftsareequippedwithtwocords(A)foreasyinsertionofthecoreoftheroll(B)ontheshaft(C).
Duringshaft(C)rotation,thecords(A)blockthecoreoftheroll(B).

GALAXY
USE AND MAINTENANCE MANUAL EN
MANUAL CODE: 756100330_EN
REVISION: 0
DATE: 07/03/2019 FLEXA S.r.l. - Partial or whole reproduction prohibited without authorisation 12