ITALPRESSE ESTREMA/S User manual

1
Press to apply PVC on 3D panels
“ESTREMA/S”
Upstroke movement of the platen
U S E R ’ S M A N U A L
Translation of the original instructions

Dati di identificazione della macchina
Machine identification numbers
Données signalétiques de la machine
Kenndaten der Maschine
Datos de identificaccion de la maquina
PRESSA A MEMBRANA - MEMBRANE PRESS
2014
400 60
183630114
2
ESTREMA/S
Mod.
pos. 22995

2
Top Management declaration on the pursuit of the objectives set out in the company safety policy:
The top management of ITALPRESSE S.p.A. numbers among its objectives the achievement of intrinsic safety for the machines pro-
duced in the factory at Bagnatica (Bergamo). EC directive 2006/42/EC and subsequent modifications lay down the procedures to be
followed to guarantee the essential safety requirements and the protection of the operators and those exposed to the operation of
the machinery.The application of the criteria laid down in the directive, the checking of their effectiveness and updating are guaran-
teed by general management, and on its behalf by the Safety Manager, by means of the services of qualified technicians operating
together with the production sections.The technical service staff are authorised to identify any problems together with management,
find a solution by means of corrective action and ensure that this is applied. With the approval of this declaration by the manage-
ment of ITALPRESSE S.p.A., and on its behalf the Safety Manager, we accept the commitment to put the methods into practice and
guarantee their application.
Company Management
Déclaration de la Direction concernant la réalisation des objectifs de la politique de sécurité de l'entreprise.
La Direction d'ITALPRESSE S.p.A. place parmi les objectifs majeurs de l'entreprise la réalisation de la sécurité intrinsèque des machi-
nes produites dans son usine de Bagnatica (Bergame).
La directive 2006/42/CE et successives modifications indique quelles sont les procédures à appliquer pour garantir les conditions
fondamentales relatives à la sécurité et à la tutelle de la santé des opérateurs et des personnes exposées.Afin de garantir l'applica-
tion des critères illustrés dans cette directive, le contrôle de leur efficacité et leur mise à jour, la Direction Générale, et pour elle le
Responsable de la Sécurité, fait à ce propos recours aux Services Techniques qui opèrent en étroite collaboration avec les Unités
de Production. Ces Services ont pour rôle d'identifier les problèmes corrélés à la directive, d'y apporter des solutions moyennant
l'introduction de mesures correctives et de vérifier l'application de celles-ci. Par l'approbation de la présente déclaration, la Direction
d'ITALPRESSE S.p.A., et pour elle le Responsable de la Sécurité, s'engage à rendre opérationnelles les méthodologies suggérées et à
en garantir leur application.
La Direction
Dichiarazione dell'Alta Direzione sul perseguimento degli obiettivi della Politica della Sicurezza aziendale:
La Direzione di ITALPRESSE S.p.A. considera tra i propri obiettivi aziendali il raggiungimento della Sicurezza intrinseca delle Macchine
prodotte nel proprio Stabilimento di Bagnatica (BG). La Direttiva 2006/42/CE e successive modifiche indicano le procedure che devo-
no essere messe in atto per garantire i requisiti essenziali ai fini della Sicurezza e della tutela della salute degli operatori e delle per-
sone esposte.
L'applicazione dei criteri illustrati nella Direttiva, la verifica della loro efficacia ed il loro aggiornamento sono garantiti dalla Direzione
Generale, e per lei dal Responsabile della Sicurezza, che a tal fine si avvale dei Servizi Tecnici che operano in collaborazione coi repar-
ti di Produzione. Ai Servizi suddetti è attribuita l'autorità di identificare i problemi correlati con la Direttiva, di individuare la loro
soluzione attraverso l'introduzione di azioni correttive e di verificarne l'applicazione.
Con l'approvazione della presente Dichiarazione la Direzione di ITALPRESSE S.p.A., e per lei il Responsabile della Sicurezza, si assu-
me l'impegno di rendere operative le metodologie e di garantirne l'applicazione.
La Direzione
Erklärung der obersten Firmenleitung zur Verfolgung der sicherheitspolitischen Ziele des Unternehmens:
Die Direktion der ITALPRESSE S.p.A. sieht es als eins der Ziele des Unternehmens an, für die im eigenenWerk Bagnatica (BG) gebau-
ten Maschinen eine vollkommene Sicherheit zu erreichen. Die EG-Richtlinie 2006/42/EG und nachfolgende Änderungen nennt die
Verfahrensweisen, die als Grundvoraussetzungen zur Unfallverhütung und zum Schutz der Gesundheit der mit der Bedienung der
Maschine betrauten oder ihrenWirkungen ausgesetzten Pesonen umgesetzt werden müssen. Die Anwendung der durch die Richtlinie
vorgegebenen Kriterien, die Überprüfung ihrer Effizienz sowie ihre ständige Verbesserung werden von der Direktion, und fuer sie
von der verantwortlichen Person für die Sicherheit, garantiert, denn zu diesem Zweck sind Techniker in Zusammenarbeit mit den
Produktionsabteilungen im Einsatz. Diesem technischen Dienst ist die Aufgabe übertragen, alle im Zusammenhang mit den Vorgaben
der Richtlinie stehenden Probleme festzustellen, Lösungsvorschläge für korrektive Veränderungen zu erarbeiten und deren
Durchführung zu berprüfen. Mit der Annahme der vorliegenden Erklärung übernimmt die Direktion der ITALPRESSE S.p.A., und für
sie die verantwortliche Person für die Sicherheit, die Verpflichtung, diese Methoden in die Praxis umzusetzen und ihre Durchführung
zu garantieren.
Die Direktion
Declaración de la Dirección General con respecto a los objetivos de la Política de Seguridad empresarial:
La Dirección de ITALPRESSE S.p.A. considera entre los propios objetivos empresariales el logro de la Seguridad intrínseca de las
Máquinas producidas en el propio Establecimiento de Bagnatica (Bergamo-Italia). La Norma 2006/42/CE y sucesivas modificaciones
indican los procedimientos que se debe respetar para garantizar los requisitos esenciales para la Seguridad y tutela de la salud de
los operadores y personas expuestas. La aplicación de los criterios ilustrados en la Norma, la verificación de su eficacia y su puesta
al día están garantizados por la Dirección General, y por ella por el Responsable de la Seguridad, que para dicho fin cuenta con el
asesoramiento de los Servicios Técnicos que trabajan en colaboración con los Repartos de Producción.A los susodichos Servicios
se le atribuye la autoridad para identificar los problemas relacionados con la Norma, identificar sus soluciones por medio de la intro-
ducción de acciones para la corrección y comprobar la aplicación. Con la aprobación de la presente Declaración la Dirección de
ITALPRESSE S.p.A., y por ella el Responsable de la Seguridad, se asume el compromiso de activar las metodologías y garantizar su
aplicación.
La Dirección

ITALPRESSE S.p.A.
via delle Groane, 15 - 24060 Bagnatica (Bg) ITALIA
Oggetto della dichiarazione/Object of declaration/Sujet de la déclaration/Objekt der Erklaerung/Objeto de la declaracion
PRESSA A MEMBRANA - MEMBRANE PRESS
Macchina modello/Model/Modèle/ Matricola/Serial Number/Matricule/ Anno di fabbricazione/Manufacturing year/
Maschinenbezeichnung/Modelo Seriennummer/Matricula Année de fabrication/Baujahr/Año de fabrication
ESTREMA/S 183630114 2014
4
L’Amministratore Delegato - President - Der Geschaftsfuehrer -
Administrateur délégué - El administrator delegado
Carlo Sala
Mod. A-2014.00
DICHIARAZIONE CE di CONFORMITÀ
Si dichiara che la macchina oggetto della dichiarazione è conforme a quanto prescritto dalla direttiva europea 2006/42/CE (Direttiva Macchine)
e dalla direttiva 2004/108/CE (Direttiva Compatibilità Elettromagnetica),
e se ne costituisce il fascicolo tecnico
EC DECLARATION OF CONFORMITY
We declare that the machine object of this declaration complies with the prescriptions of European Directive 2006/42/CE (Machines Directive)
and 2004/108/CE (Electromagnetic Compatibility Directive)
and the relevant technical file is constituted.
DECLARATION CE DE CONFORMITE’
On déclare que la machine objet de la déclaration est conforme à ce qui est préscrit par la directive européenne 2006/42/CE (Directive Machine)
et par la directive 2004/108/CE (Directive Compatibilité Électromagnétique),
et on en constitue dossier technique.
CE Konformitätserklärung
Der Unterzeichner erklärt, dass die o.a. Maschinen den Bestimmungen der Richtlinien 2006/42/CE (Maschinenrichtlinie)
und 2004/108/CE (Elektromagnetische Verträglichkeit) entspricht und bezügliche technische Dokumentation erzeugt wird.
DECLARACION CE DE CONFORMIDAD
Se declara que la máquina objeto de la declaración es de conformidad según lo prescripto por la directiva europea
2006/42/CE (Directiva Máquinas); y por la directiva 2004/108/CE (Directiva Compatibilidad Electromagnetica),
y se constituye el expediente técnico
Bagnatica, 28/01/2014

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Precautions and safety instructions:
• Before starting up, using, maintaining or carrying out any other operation on the machine, read
the user’s manual carefully.This manual should always be kept close at hand.
• In no circumstances use the machine other than in the ways described in this manual.The manu-
facturer accepts no responsibility for damage to persons or property deriving from failure to obser-
ve the safety regulations.
• The operator should be in possession of all the necessary prerequisites for the use of a complex
machine.
• Use all the necessary precautions (overalls, protective gloves, etc) to avoid burns from the hot
working surfaces of the machine (the temperature is 110°C approx).
• Always use the robust work gloves laid down in the accident prevention laws of all countries.
• Do not allow unauthorised personnel to repair or carry out maintenance or other operations of
any kind on the machine.
• The transport, installation and assembly operations should be carried out only by personnel with
the necessary technical competence and experience in all the sectors involved.
• All operations on the electrical system should be carried out only by specialist sector technicians.
• The working area surrounding the machine should always be kept clean and unobstructed, for the
sake of immediate, easy access to the electrical commands.
• The symbols below, used in the manual, warn the operator of the presence of risk factors in
carrying out specific operations on the machine.
BEFORE OPERATING THE PRESS AND DURING ITS NORMAL WORK,THE OPERA-
TOR MUST ALWAYS CHECKTHAT NO PEOPLE (OR ANIMALS) ARE NEAR THE
MACHINE!
IMPORTANT: this machine is designed to be used by a single operator.
NEVER INSERT PARTS OF THE BODY BETWEEN MOVING PLATENS
AND/OR OUTSIDE THEIR HOUSING!
WARNING: BEFORE PERFORMING ANY CONNECTION, TEST, MAINTENANCE, LUBRICATION OR CLEA-
NING OPERATIONS, THE MACHINE MUST BE LOCKED OUT WITH THE POWER OFF.
-THE PERSON IN CHARGE FOR THESE OPERATIONS MUST REMOVE THE KEY FROM THE “ TENSION
SELECTOR OFF-ON” LOCK AND KEEP IT IN A POCKET ON HIM.
-BEFORE RESTARTING THE MACHINE, MAKE SURE THAT ALL THE SAFETY DEVICES REMOVED DURING
THE MAINTENANCE OPERATIONS HAVE BEEN PROPERLY RESTORED AND/OR RE-INSTALLED.

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SAFETY LABELS: the following safety labels are positioned on the machine and must
not be removed for any reason.

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CONTENTS
0. General information
0.1 Products that can be obtained
0.2 Control board
1. Packaging/transport
2. Raising methods
3. Installation
3.1 Installation requirements
3.1.1 Atmospheric requirements
3.1.2 Minimum space for use and maintenance
3.1.3 Type of support surface for the machine
3.1.4 Electric power supply
3.2 Installation and connections
3.2.1 Levelling of the press
3.2.2 Safety device
3.2.3 Electrical connection
3.2.4 Compressed air connection
4. Start–up
4.1 Oil level check
4.2 Motor rotation direction control
4.3 Platen heating
4.4 General load regulations for the pressing panels
5. Start-up/operation/stop
6. Malfunctions/breakdowns/faults
6.1 Poor vacuum level
6.2 Losses due to cylinder drawing
6.3 Ageing of the hydraulic oil
6.4 Magnetothermal blockage
7. Production change
8. Cleaning
8.1 Vacuum pump filter
8.2 Load tray
8.3 Central oleodynamic unit:
8.4 Cleaning the heater unit

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9. Maintenance/inspection/checks
9.1 Oil replacement
9.2 Vacuum pump purifier
9.3 Filter maintenance
9.4 Gaskets
9.5 Greasing the mechanical parts
10.Temporary shutdown
11Permanent shutdown (dismantling)
12.Technical specifications of the machine
12.1 Phonometric measurements
13.Technical assistance
14.Supplies and materials used
14.1 Recommended oils
14.2 Transmission grease
14.3 Production materials
15 Diagrams
15.1 Oil–dynamic diagram
15.2 Pneumatic diagrams
15.3 Vacuum seal system
15.4 Cylinder drawings and parts
15.5 Motor pump group
15.6 Electrical diagrams

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0. General information
This user’s manual was drawn up by the manufacturer and is an integral part of the machine
accessories.
The information contained herein should be read by qualified personnel only.
WARNING:THE MACHINE HAS BEEN DESIGNED TO BE USED
BY ONE OPERATOR ONLY
.
0.1 Products that can be obtained
The machine is designed for flat laminating and 3D thermoforming of PVC foils.

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0.2 Control board
TOUCH
S1 P1+L2 P5+L5
P2
P12
S1
P5+L5
P1+L2
P3
TOUCH
P12
ARR OW PR ES S
CONTROL UNIT
PUSHBUTTONWITH
LOGO DESCRIPTION
GRE EN LIGHT P US HB UTTON
GENER AL AUXILIAR IE S
RUN
KEY SELECTOR
TENSION OFF-ON
RED LIGHTPUSHBUTTON
EMERGENCY RESET
RED MUSHROOM
PUSHBUTTONMACHINE
EMERGENZE
OPE NING
P30
P3
P11
S32
S31
BLACK PUSHBUTTON
P11
P30
P25
2
2
P3
P10
1
1
BLACK PUSHBUTTON
SHUTTLE TRAY
SHUTTLE TRAY
EMERGENCY
PUSHBUTTON
PUSHBUTTON
CONTROL BOARD
EXCLUSION SELECTO
XCLUSIONSELECTOR
OPTIONAL
EMERGENCY
STOP
REAR WING
STOP
AUTOMATIC INLE T
MAC HINE BORDER
AUTOMATIC INLE T
S AFETY LIMIT SWITCH
S AFETY LIMIT SWITCH
FRONT WING

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1. Packaging/transport
There are normally three methods of shipping the machine to the user:
• in packing cases
• in containers
• by truck
Transport in cases:
Packaging characteristics:
• The machine is contained in a single case.
• It is covered in cellophane and attached to the bottom of the case by rods to prevent it
from moving during shipping.
• The inner walls of the case are covered with tar-coated paper as protection from dampness.
• A layer of cellophane is stapled to the outside of the case to protect it from the rain.
• Reinforcing steel bands are wound around the case.
• The cases bear written instructions on the movement methods.
Raising:
Before raising the machine from the packaging, take note of its weight as
set out in table of chapter 2!
The case has two holes on the upper part.To open these holes, pull away the celophane covering.
! THE TOP OF THE CASE IS NOT REMOVABLE
When the holes are opened, access is gained to the hooking points of the machine as shown in
the diagram.

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Once the case has been moved, REPLACE the wooden panels and cover the holes.
! DO NOT USE STRAPS OR MULES TO MOVE THE CASE.
Opening the case:
• Remove the metal straps taking care to avoid injury due to the tension.
• Remove the outer cellophane covering.
• Open the side walls using a suitable lever (crowbar)
• Remove the lid and side walls.
• Remove the cellophane around the machine.
• Before moving the machine, remove the rods that attach it to the bottom of the case:
To move the parts of the machine, use the method described in chapter 2.
Container or road transport:
The base of the machine should be fixed to the support surface by the wooden wedges. It should
also be held down using cords or straps to keep it under tension.
BEFORE RAISING THE MACHINE FROM THE SUPPORT SURFACE, REMOVE THE
WEDGES.
The machine should be raised as shown in chapter 2 below.

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2. Raising methods
The raising and movement of the machine should be carried out by personnel trained and spe-
cialised in this type of operation.
The operations can be carried out only by overhead crane or crane, proceeding as described
below and with reference to figure 2.1:
• use one belts with hooks, of the same length and of a suitable capacity;
• hook the belts to an overhead crane of suitable capacity;
• position the two hooks at the lifting points of the machine situated on the upper part;
• raise slowly and move with the maximum caution, avoiding even minimum swing, and posi-
tion the machine in its operating zone.
! IMPORTANT: all personnel should keep clear of the suspended load and/or in any
case from the operating range of the overhead crane during the lifting and movement
of the machine.
KG 4550

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3. Installation
3.1 Installation requirements
3.1.1 Atmospheric requirements
- Ambient air temperature: the electrical equipment can operate correctly at air temperatures
from +5 to +40°C and at a mean temperature of no more than +35°C over a 24 hour period.
- Humidity:The electrical equipment of the machine is designed to operate correctly at a humi-
dity between 30 and 95% (without condensation).The damaging effects of condensation can be
avoided by taking the appropriate preventitive steps (eg. in-built heaters, air conditioners, drainage
holes).
- Altitude: the machine is designed to operate at up to 1000 m above sea level.
- Contaminants: the machine is designed to operate in the presence of wood dust in the imme-
diately surrounding area.Where there are other contaminating agents in the immediate vicinity of
the machine (dust, acids, salts, corrosive gases), special agreements between the supplier and user
may be necessary.
3.1.2 Minimum space for use and maintenance
At the set-up of the machine an additional space must be foreseen, to allow the operator to
perform use and maintenance.
3.1.3 Type of support surface for the machine
The floor should be of the industrial type with a minimum resistance of 7 Kg/cm^2.The floor
should be carefully levelled.
3.1.4 Electric power supply
SEE ELECTRICAL DIAGRAM
WARNING:
The voltage change in the electric network can never be more than +/- 5% of the voltage indica-
ted on the plate.
Check the electric network voltage with the proper device; whenever the change is more than
+/- 5% of the voltage indicated on the plate, please contact our Technical Assistance Department.

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3.2 Installation and connections
This paragraph describes the following operations:
* levelling the machine (para. 3.2.1)
* electrical connections (para. 3.2.2)
3.2.1 Levelling of the press
1 - Be sure that the surface where the press is placed is perfectly levelled
2 - Put each equipment plate under each upright
3 - To check the levelling of the press You must use a centesimal level, taking as reference the 4
plates of cylinders support placed close the uprights
If the press will be not levelled, please proceed as follows:
4 - Operate on the screws placed at the base of the uprights to get the levelling in two directions
5 - After the reaching of the levelling in two directions, compensate the distance between the
base of the upright and the counter-plate at floor with suitable thicknesses
6 - Loosen the screws so that the weight of the press is distributed on the plates and not on the
screws.
2
3
4
5
6
WARNING: BEFORE PERFORMING ANY CONNECTION, TEST, MAINTENANCE, LUBRICATION OR CLEA-
NING OPERATIONS, THE MACHINE MUST BE LOCKED OUT WITH THE POWER OFF.
-THE PERSON IN CHARGE FOR THESE OPERATIONS MUST REMOVE THE KEY FROM THE “ TENSION
SELECTOR OFF-ON” LOCK AND KEEP IT IN A POCKET ON HIM.
-BEFORE RESTARTING THE MACHINE, MAKE SURE THAT ALL THE SAFETY DEVICES REMOVED DURING
THE MAINTENANCE OPERATIONS HAVE BEEN PROPERLY RESTORED AND/OR RE-INSTALLED.

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3.2.2 Safety device
Red head pushbuttons for emergency stop. they are set
- on the press control board
- on the control bar
Two-handed press closure command: this guarantees operator safety during the dangerous
closure movement of the mobile platen of the press (P6-P7).
Tilting shutter complete with electrical safety interlock:
In case one of the doors will be open by someone while the machine is performing the working cycle, the
activation of the electrical safety interlocks will stop the machine.
WARNING: IN CASE OF DANGER,THE EMERGENCY MUST IMMEDIATELY BE
DRIVEN BY ONE OF THE FOLLOWING DEVICES:
- THE RED ”EMERGENCY STOP” PUSHBUTTONS, PLACED ON THE CONTROL BOARD
AND ON THE CONSOLLE.
WARNING: BEFORE PERFORMING ANY CONNECTION, TEST, MAINTENANCE, LUBRICATION OR CLEA-
NING OPERATIONS, THE MACHINE MUST BE LOCKED OUT WITH THE POWER OFF.
-THE PERSON IN CHARGE FOR THESE OPERATIONS MUST REMOVE THE KEY FROM THE “ TENSION
SELECTOR OFF-ON” LOCK AND KEEP IT IN A POCKET ON HIM.
-BEFORE RESTARTING THE MACHINE, MAKE SURE THAT ALL THE SAFETY DEVICES REMOVED DURING
THE MAINTENANCE OPERATIONS HAVE BEEN PROPERLY RESTORED AND/OR RE-INSTALLED.

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3.2.3 Electrical connection
Make sure that the supply voltage is the same as indicated in the plate fitted to the insi-
de of the electric cabinet (par. 3.1.4).
Make sure that the supply voltage is the same as indicated in the testing tab on the electrical
panel.To connect the electrical panel, use a flameproof cable with three phase conductors and the
earth cable (in yellow and green).
To connect the cable to the electrical panel of the machine, proceed as follows:
! MAKE SURE THAT THE CABLE IS NOT LIVE
a) Set the main switch IG to position "0" and open the two locks of the door to the electrical panel
using the keys;
b) insert the cable in the electrical cabinet through the cable press at the rear
IG

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c) take the cable (not connected to the power supply!) and connect the three phase conductors
with the terminal board of the main switch on the upper part. Fix the three conductors by tighte-
ning the worm screws.When carrying out this operation, make sure that the bare part of the wire
is completely inserted in the clamp, to prevent contact with the outside
d) connect the conductor with green and yellow casing to the main earth terminal board of the
machine (marked with "PE") situated within the cabinet;
e) block the cable by tightening the cable press;
f) close the door of the electrical cabinet by means of the two locks, using the key, and set the
main switch "IG" to position "1".
THE KEY MUST BE REMOVED FROM THE ELECTRICAL CABINET AND
ENTRUSTED TO A RESPONSIBLE.

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3.2.4 Compressed air connection
The minimum inlet pressure should be 6 Ate.The capacity is 800 Nlt for each working cycle. If
the supply available is insufficient, an air diaphragm of roughly 250 litres should be fitted.
The air inlet is near the lubricator and dry filter, and requires an inlet tube with one inch diame-
ter.
Cracked (burnt) oil and impurities contained in the air can damage the quality of the product by
staining the veneer or PVC.
Water vapours may cause damage to the operation of the electrovalves.
We therefore suggest the following compressed air specifications:
– Particles:The recommended quality level (ISO554: 1976) is 2, corresponding to a maximum
impurity diameter of 1 micron and a maximum density of 1 mg/m3
– Oil content:The recommended quality level is 2, equivalent to 0.1 mg/m3
– Water vapour:The maximum recommended level is 5 mg/m3. Beyond this level, an air drier has
to be used.

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4. Start-up
THE MACHINE IS FITTED WITH TWO MANUAL MECHANICAL STOPS WHICH
BLOCK THE MOBILE PLATEN IN THE CLOSED POSITION. BEFORE OPENING
THE PLATENS, CHECK THAT THE STOPS ARE NOT IN PLACE,TO AVOID DAMA-
GE TO THE MACHINE.
BEFORE OPERATING THE PRESS AND DURING ITS NORMAL WORK,THE OPERA-
TOR MUST ALWAYS CHECKTHAT NO PEOPLE (OR ANIMALS) ARE NEAR THE
MACHINE!