Mbo Rw500 User manual

Rewinder

Translation of the original operating manual

Keep for future reference!

RW500

all forms and types of copyright-protected materials and information that are

currently permitted. No part of the documentation may be copied, otherwise

duplicated,editedortranslatedintootherlanguages,regardlessofthe manner

in which or with which tools this takes place.

Electronically-stored information provided by the manufacturer (CD-ROM, In-

ternet) may be printed out by the user if the created print medium serves the

purpose of use or service of the product described.

Type of machine: Rewinder

Configuration: RW500

Type of document: Translation of the original operating manual

Version: V1.2 Author: Wolfgang Matzner

Status as

of: 8/20/2015 Machine no.:

Language: US English File name: BA_RW500_V1.2_usen

Manufacturer:

MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG

PO Box 1169

71567 Oppenweiler

GERMANY

Tel.: +49 7191 46 0

Fax: +49 7191 46 34

http://www.mbo-folder.com

info@mbo-folder.com

Subject to alterations!

Rewinder RW500

Name plate and

CE marking For all questions relating to your machine, please contact your

MBO agency.

You can find the address on our home page: www.mbo-folder.com.

For the identification of the machine and the most important machine data,

see the name plate on the machine.

Always specify these details for inquiries, service and spare parts orders:

• Commission number

• Type of machine

1 CE marking

2 Type of machine

3 Commission number

4 Year of manufacture

5 Name plate

Illustration 1: Name plate

Rewinder RW500

EC Declaration of Conformity

according to EC Machine Directive 2006/42/EC, Annex II, No. 1 A.

The manufacturer

MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG

Grabenstraße 4-6

71570 Oppenweiler

GERMANY

Oppenweiler, 8/20/2015

hereby declares that the machine described below:

Designation Rewinder

Type RW500

Commissioning no.

complies with the provisions of the following EC directives:

Machinery Directive 2006/42/EC

EMC Directive 2004/108/EC

Harmonized standards applied:

EN ISO 12100:2010

EN 1010-1:2004+A1:2010

EN 1010-4:2004+A1:2009

EN ISO 13849-1:2008

EN 60204-1/2007

Authorized representative for compiling the technical file:

Name Wolfgang Matzner

Address Grabenstrasse 4-6

71570 Oppenweiler

GERMANY

_________________________________

Frank Eckert - Managing Director

Rewinder RW500 1

List of contents

1 About this manual

1.1 Additional documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1.1 Supplier documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Structure of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3 Signs and symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.4 Description of safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1.4.1 Signal words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.4.2 Structure of safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.4.3 Safety sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.5 User assessment of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2 Basic safety instructions

2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 Reasonable foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.3 Obligation and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.4 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.5 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.5.1 Transport, interim storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.5.2 Set-up, commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.5.3 Adjustment and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.5.4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.5.5 Decommissioning, storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.5.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.6 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.6.1 Crushing hazard when handling paper rolls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.6.2 Cutting hazard due to fast-moving webs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.7 Additional hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.7.1 Cutting hazard due to fast-moving webs in a machine combination . . . . . . . . . . . . . 23

2.8 Life time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.8.1 Life time of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.8.2 Service life of the control-technical safety components.. . . . . . . . . . . . . . . . . . . . . . . 24

2.9 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.9.1 Transport, interim storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.9.2 Set-up, commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.9.3 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2Rewinder RW500

List of contents

2.9.4 Setting up/equipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.9.5 Maintenance and repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.9.6 Work on electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.10 Personnel, qualification and duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

2.10.1 Qualification of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.10.2 Duties of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.10.3 Duties of the operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.10.4 Duties of the maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.11 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

2.11.1 Operation and adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.11.2 Operational maintenance (cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.12 Work areas and workstations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

2.12.1 Layout from right to left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.13 Markings and safety messages on the machine . . . . . . . . . . . . . . . . . . . . . . . . . .33

2.13.1 Position and meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.14 Directions for emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

2.14.1 Emergency call numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.14.2 Behavior in case of accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3 Product description

3.1 Important notices about the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

3.1.1 View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.1.2 Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.1.3 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.2.1 Floor plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.2.2 Performance characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.2.3 Acceleration data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.2.4 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.2.5 Shipping and transport data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.2.6 Electrical supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.2.7 Compressed air supply, control air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.2.8 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4 Structure and function

4.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

4.1.1 Components of the rewinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

4.2.1 Compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.2.2 Control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.2.3 Roll lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.2.4 Web break detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Rewinder RW500 3

List of contents

4.2.5 Pneumatic dancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.2.6 Weight force dancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.2.7 Web tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.2.8 Web guide (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.3 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.3.1 Variant RW500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.4 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.4.1 Explanation of the term "guard" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.4.2 Explanation of the term "protective devices" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.4.3 Main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.4.4 EMERGENCY STOP palm button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.4.5 Interlocking movable guards with guard locking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.4.6 Faulty protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.4.7 Checking protective devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.4.8 Checklist for protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5 Operating and display elements, operating modes

5.1 Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.1.2 Main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.1.3 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.1.4 Control panel, web guide (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.1.5 Usage of the touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.1.6 Touchscreen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.1.7 Displaying machine status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

5.1.8 Entering the password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5.1.9 Description of the screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5.1.10 Selecting favorite pages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

5.1.11 <Diagnosis> page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

5.2 Fault displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.2.1 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.2.2 Touchscreen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5.3.1 Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5.3.2 Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6 Transport and interim storage

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

6.1.1 Qualification of personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

6.1.2 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6.2 Packaging of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6.2.1 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6.2.2 Accessories/options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4Rewinder RW500

List of contents

6.2.3 Incoming inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6.2.4 In case of damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6.3 Transporting the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

6.4 Interim storage of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

6.4.1 Outdoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

6.4.2 In a storage room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7 Installation, commissioning

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

7.1.1 Qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.1.2 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

7.2 Installing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

7.3 Making the stationary mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

7.3.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7.3.2 Heed network prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

7.3.3 Observe the design of the stationary mains connection . . . . . . . . . . . . . . . . . . . . . . 91

7.3.4 Making the stationary mains connection on the main control cabinet . . . . . . . . . . . . 92

7.3.5 Connecting the protective equipotential bonding conductor . . . . . . . . . . . . . . . . . . . 93

7.3.6 Checking the protective conductor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

7.4 Commissioning process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

7.5 Conducting a final check of the protective devices . . . . . . . . . . . . . . . . . . . . . . .94

7.6 Conducting an inspection after commissioning . . . . . . . . . . . . . . . . . . . . . . . . . .95

8 Adjustment and operation

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

8.1.1 Qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

8.1.2 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

8.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

8.2.1 Switching the main switch on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.2.2 Press the EMERGENCY STOP palm button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8.2.3 Switching on <Setup / production> operating modes . . . . . . . . . . . . . . . . . . . . . . . 102

8.2.4 Raising/lowering the roll lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

8.2.5 Switching off/on the paper roll brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.2.6 Adjusting the rewind direction of the paper roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.2.7 Pneumatic dancer, set position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8.2.8 Weight force dancer, set position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

8.2.9 Raising/lowering the pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

8.2.10 Move the in-feed shaft in inching mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

8.2.11 Creating production readiness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

8.3 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

8.3.1 Brief instructions for adjusting the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

8.3.2 Insert the core shaft with empty sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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List of contents

8.3.3 Feeding in the web. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

8.3.4 Open/close the nip roller on the in-feed shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

8.3.5 Setting the internal web tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

8.4 Set <Full paper roll> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

8.5 Setting the contact pressure of the pressure arm . . . . . . . . . . . . . . . . . . . . . . . .119

8.6 Identification and handling of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

8.6.1 Troubleshooting/Cause/Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

9 Maintenance

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

9.1.1 Qualification of personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

9.1.2 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

9.2 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

9.2.1 Ordering spare and wear parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

9.3 Spare part list for the protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

9.4 Performing operational maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

9.4.1 Checking protective devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

9.4.2 Check that all protective devices are present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

9.4.3 Cleaning the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

9.4.4 Cleaning the optical sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

9.5 Performing maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

9.6 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

9.7 Performing repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

10 Decommissioning, storage

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

10.1.1 Qualification of personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

10.1.2 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

10.2 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

10.2.1 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

10.2.2 Final decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

10.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

11 Disposal

11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

11.1.1 Qualification of personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

11.1.2 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

11.2 Disposal/recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

6Rewinder RW500

List of contents

Rewinder RW500 7

About this manual

1 About this manual

Everybody who will transport, install, connect, adjust, operate, maintain, re-

pair and dismantle this machine must read this operating manual.

Safe use of the machine is only possible once everybody has understood

the content of and follows all points of the operating manual. This applies

especially to the chapter on safety.

This operating manual contains important notes on how to operate the ma-

chine safely, correctly, and economically.

Following these

notices helps • To avoid hazards.

• To minimize repair costs and downtimes.

• To increase the reliability and service life of the machine.

Supplementation • The operator must add instructions regarding national regulations for

accident prevention to this operating manual.

Retention • This operating manual forms part of the machine. It must be available

on the machine throughout the machine's entire service life.

If you sell the

machine • Give this operating manual to any subsequent owner or user of the ma-

chine.

We reserve the right to make technical changes to improve the machine,

even if these changes are not taken into account in this operating manual.

8Rewinder RW500

About this manual

Additional documents

1.1 Additional documents

In addition to this operating manual, there are these documents about the

machine:

1.1.1 Supplier documentation

1.2 Structure of the operating manual

The table lists the chapters of the operating manual. It also describes the

essential content of these chapters as well as the target groups at whom

the chapters are directed.

Designation Type

MBO part number Use

Wiring diagram

Pneumatic diagram

Spare parts list

Supplier documentation

Table 1: Additional documents

Manufacturer Designation Type

MBO part number Use

Table 2: Supplier documentation

Rewinder RW500 9

About this manual

Structure of the operating manual

No. Chapter Contents Target group

Table of contents The detailed table ofcontents serves as

a search tool •Operator

• Operating personnel

• Maintenance personnel

• Service technicians

1 About this manual Important notes about this operating

manual •Operator

• Operating personnel

• Maintenance personnel

• Service technicians

2 Basic safety

instructions Details about:

• Residual risks and hazards with

intended use.

• Foreseeable misuse.

• Avoidance of the risks.

•Operator

• Operating personnel

• Maintenance personnel

• Service technicians

3 Product description

and product data • Important notices about the product

• Technical data •Operator

• Operating personnel

• Maintenance personnel

• Service technicians

4 Structure and

Function. Description of:

• Structure and function

• Protective devices

•Operator

• Operating personnel

• Maintenance personnel

• Service technicians

5 Operatinganddisplay

elements, operating

modes

Description of the:

• Operating and display elements

• Operating modes

• Operating personnel

• Maintenance personnel

• Service technicians

6 Transport, interim

storage Details about:

• Packaging

• Transportation

• Interim storage

• Transport personnel

• Maintenance personnel

• Service technicians

7 Set-up and

commissioning Details for:

•Set-up

• Commissioning

• Maintenance personnel

• Service technicians

8 Adjustment and

operation Details for:

• Operation

• Adjustment

• Operating personnel

• Maintenance personnel

• Service technicians

9 Maintenance Details for the:

• Operational maintenance

• Maintenance

• Repair

• Operating personnel

• Maintenance personnel

• Service technicians

10 Shutdown, storage

and putting the

machine back into

operation

Details for the:

• Decommissioning

• Storage

• Recommissioning

•Operator

• Operating personnel

• Maintenance personnel

• Service technicians

11 Disposal Details for the environmentally friendly

disposal •Operator

• Maintenance personnel

• Service technicians

Table 3: Structure of the operating manual

10 Rewinder RW500

About this manual

Signs and symbols used

1.3 Signs and symbols used

The signs and symbols in this manual should help you to use the manual

and the machine quickly and safely.

Symbol Explanation

Indicates an instruction for action.

The sequence is not specified.

1) ...

2) ...

3) ...

Numbered instructions for action.

The defined sequence of the instructions for action

makes it easier for you to use the machine correctly and

safely.

Here you will find the result of a sequence of instruc-

tions for action.

<STOP> Push button with the label between the brackets (e.g.

Stop).

Additional information for use of the machine.

Important notice, please observe.

Table 4: Symbols, terms, and abbreviations

Rewinder RW500 11

About this manual

Description of safety messages

1.4 Description of safety messages

Safety messages are marked by a safety sign and a signal word.

1.4.1 Signal words

Thesignalwords drawyourattentiontothe severityofthe hazard. Theyare

structured according to a classification system.

1.4.2 Structure of safety messages

Each safety message is structured as follows:

• Safety sign

• Signal word to identify the hazard level

• Type and source of the hazard

• Possible consequences of the hazard

• Measure(s) for avoiding the hazard

Example:

Signal word Meaning

DANGER Signal word to indicate a hazardous situation with

high risk level which, if not avoided, will result in

death or serious injury.

WARNING Signal word to indicate a possible hazardous situa-

tion with medium risk level which, if not avoided,

could result in death or serious injury.

CAUTION Signal word to indicate a possible hazardous situa-

tion with minor risk level which, if not avoided, could

result in minor or moderate injury or property dam-

age.

Table 5: Signal word meanings

DANGER! WARNING! CAUTION! (Signal word)

Type and source of the hazard.

Possible consequences of the hazard.

Measure(s) for avoiding the hazard.

12 Rewinder RW500

About this manual

Description of safety messages

1.4.3 Safety sign

Depiction Meaning

Prohibition sign

Red border, white background, black symbol.

Safety sign that forbids a behavior that could

cause a hazard.

Warning sign

Yellow background, black symbol.

Safety sign that warns about a hazard.

Mandatory sign

Blue background, white symbol.

Safety sign that prescribes a particular behav-

ior.

Rescue sign

Green background, white symbol.

Safety sign that identifies the rescue path or

the path to a place where you can get help or

find rescue equipment in case of an emer-

gency.

Fire protection sign

Red background, white symbol.

Safety sign, which in case of hazard marks the

location of fire alarm and fire extinguishing

equipment and/or the path to this equipment.

Table 6: Safety sign

Rewinder RW500 13

About this manual

Description of safety messages

1.4.3.1 Warning sign

Depiction Meaning

Warning about a general hazard.

You will see this warning-triangle next to activi-

ties during which several causes can create

hazards.

Warning of hazardous voltage.

You will see this warning-triangle next to activi-

ties during which there is a hazard of electrical

shock, possibly with deadly consequences.

Warning of crushing of body parts.

You will see this warning triangle next to activi-

ties during which there is a hazard of crushing,

possibly with deadly consequences.

Warning against rotating shafts.

You will see this warning triangle next to activi-

ties during which there is a hazard of crushing,

possibly with deadly consequences.

Warning of crushing of hand.

You will see this warning-triangle next to activi-

ties during which there is a hazard of crushing

the hand.

Warning of tipping machine parts.

You will see this warning-triangle next to activi-

ties during which there is a hazard of crushing

due to tipping loads.

Warning against rotating shafts.

You will see this warning triangle next to activi-

ties during which there is an entanglement haz-

ard.

Warning of substances harmful to health.

You will see this warning-triangle next to activi-

ties during which there is a hazard of sub-

stances harmful to health, possibly with deadly

consequences.

Warning of oxidizing substances.

You will see this warning-triangle next to activi-

ties during which there is a hazard of oxidizing

substances, possibly with deadly conse-

quences.

Table 7: Warning sign

14 Rewinder RW500

About this manual

Description of safety messages

Warning of stumbling points.

You will see this warning-triangle next to activi-

ties during which there is a tripping hazard,

possibly with deadly consequences.

Warning of laser beam.

You will see this warning sign in front of activi-

ties during which there is a risk of eye injury

due to laser beam.

Warning of cutting hazard.

You will see this warning sign in front of activi-

ties during which there is a cutting hazard due

to the moving web.

Depiction Meaning

Table 7: Warning sign

Rewinder RW500 15

About this manual

Description of safety messages

1.4.3.2 Mandatory sign

Depiction Meaning

Use hand protection.