Linea - Rev 1.0 2014039-40-41-42 LIDERSAN - EN

INSTRUCTION MANUAL
- Unwinders and Winder Customer :
LIDERSAN SAGLIK VE GIDA

URUNLERI A.S.
Serial nr.:
2014039_40_41_42
Italian : original instructions
The information contained in this manual are the property of the company A.Celli Nonwovens SpA
It is forbidden the reproduction, even in part, without the prior written consent of the company A.Celli Nonwovens SpA
The company A.Celli Nonwovens S.p.A. reserves the right to change the specifications of the product described in this
instruction manual.
Instruction Manual complies with:

Annex I (Art.1.7.4) of Directive 2006/42/EC
This manual should always accompany the machine which is related.
Updated :
19/05/2015 V 1.0
Serial Number: 2014039_40_41_42
Customer Lidersan Saglik
Cap/Chap 1
Machine: Unwinders and Winder
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CHAPTER 1
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Sections Title: Introduction
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CONTENT
CHAPTER 1.
INTRODUCTION ........................................................................................................................ 7
1.1
HOW TO READ THE INSTRUCTION MANUAL ...............................................................................................10
1.2
PICTOGRAMS USED IN THE MANUAL .........................................................................................................12
1.2.1
Obligation signs .............................................................................................................................................. 13
1.2.2
Danger signs ................................................................................................................................................... 13
1.2.3
Prohibition signs.............................................................................................................................................. 14
1.2.4
Personal protective equipment ....................................................................................................................... 14
1.3
GLOSSARY ............................................................................................................................................15
CHAPTER 2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
IDENTIFICATION OF THE MACHINE AND INFORMATION TO THE CUSTOMER .............17
MANUFACTURER'S IDENTIFICATION DATA .................................................................................................19

MACHINE IDENTIFICATION DATA...............................................................................................................19
CUSTOMER'S TASKS ...............................................................................................................................21
INSPECTION ...........................................................................................................................................23
GUARANTEE ..........................................................................................................................................24
CONTACT DETAILS FOR TECHNICAL ASSISTANCE ......................................................................................25
STANDARD REFERENCE ..........................................................................................................................26
ABSTRACT OF DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY ...........................27
CHAPTER 3.
DESCRIPTION OF THE MACHINE .........................................................................................29
3.1
GENERAL DESCRIPTION ..........................................................................................................................31
3.1.1
Identification of the main groups.................................................................................................................... 31
3.1.2
Operating principle ......................................................................................................................................... 35
3.2
TECHNICAL DATA ...................................................................................................................................37
3.2.1
Overall dimensions and mass.......................................................................................................................... 37
3.2.2
Powers and consumption ................................................................................................................................ 38
3.2.3
Technical specifications................................................................................................................................... 41
3.2.4
Actuators......................................................................................................................................................... 44
3.2.5
Environmental operating conditions ............................................................................................................... 45
3.2.6
Noise ............................................................................................................................................................... 46
3.2.7
Vibrations ........................................................................................................................................................ 48
3.2.8
Electromagnetic interferences ........................................................................................................................ 48
3.2.9
Emissions of substances .................................................................................................................................. 49
CHAPTER 4.
4.1
4.2
4.3
4.4
4.4.1
4.4.2
4.4.3
4.5
SAFETY WARNINGS ................................................................................................................................53

TRANSPORTATION ..................................................................................................................................55
UNPACKING ...........................................................................................................................................58
HANDLING .............................................................................................................................................59
Unloading of the goods from the transport .................................................................................................... 59
Lifting the machine groups ............................................................................................................................. 60
Handling of additional equipment .................................................................................................................. 61
STORAGE AND PRESERVATION ................................................................................................................61
CHAPTER 5.
5.1
5.2
5.3
5.3.1
5.3.2
5.4
HANDLING AND TRANSPORT ..............................................................................................51
INSTALLATION .......................................................................................................................63
SAFETY WARNINGS ................................................................................................................................65

PREPARATION OF FOUNDATIONS .............................................................................................................66
MACHINE POSITIONING ...........................................................................................................................67
Anchorage procedure using mechanical foundation bolts.............................................................................. 68
Anchorage procedure by chemical bolts ......................................................................................................... 69
REMOVING BLOCKS ................................................................................................................................71
La presente documentazione di propriet della A.Celli Nonwovens Spa, ogni riproduzione anche parziale, vietata.
This document is the property of A.Celli Nonwovens Spa, any reproduction, even partial, is prohibited.
EN
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5.5
COMPLETION OF THE ASSEMBLY............................................................................................................. 71
5.6
CONNECTION TO POWER SUPPLY ........................................................................................................... 72
5.6.1
Electrical and pneumatic ducts ...................................................................................................................... 75
5.6.2
Electric power supply connection ................................................................................................................... 76
5.6.3
Pneumatic connection .................................................................................................................................... 80
5.6.4
Hydraulic connection ...................................................................................................................................... 81
5.7
COMMISSIONING ................................................................................................................................... 95
CHAPTER 6.
6.1
6.2
6.2.1
6.2.2
6.3
6.4
6.5
6.5.1
6.5.2
6.5.3
6.6
GENERAL SAFETY WARNINGS ............................................................................................................... 101

SPACE REQUIRED FOR OPERATION AND MAINTENANCE .......................................................................... 104
Working area of the machine....................................................................................................................... 104
Operator's working area .............................................................................................................................. 104
LABELS APPLIED THE MACHINE ............................................................................................................. 107
RESIDUAL RISKS.................................................................................................................................. 108
DESCRIPTION OF SAFETY EQUIPMENTS ................................................................................................. 116
Safety equipments........................................................................................................................................ 117
Functional safety .......................................................................................................................................... 118
Fixed and movable guards ........................................................................................................................... 118
PROCEDURES TO BE FOLLOWED IN CASE OF ACCIDENT, BLOCK , DAMAGE OR FIRE .................................. 119
CHAPTER 7.
7.1
7.1.1
7.2
7.2.1
7.2.2
7.2.3
7.3
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.4.5
7.4.6
7.4.7
7.4.8
7.4.9
7.5
7.5.1
7.5.2
7.5.3
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.6.6
7.7
7.7.1
7.7.2
7.7.3
SAFETY ................................................................................................................................... 99
USE AND FUNCTIONING ..................................................................................................... 121
SAFETY WARNINGS.............................................................................................................................. 123

Personal protective equipment (PPE) ........................................................................................................... 124
INTENDED USE .................................................................................................................................... 125
Product Specifications .................................................................................................................................. 126
Dimension of Master Roll and finished reel.................................................................................................. 126
Characteristics of the cardboard cores......................................................................................................... 127
REASONABLY FORESEEABLE MISUSE .................................................................................................... 128
DESCRIPTION OF THE COMMANDS AND CONTROLS ................................................................................ 131
No-Stop Unwinder - Electrical cabinet ......................................................................................................... 131
Winder - Electrical cabinet ........................................................................................................................... 133
Extractor - Electrical cabinet ........................................................................................................................ 135
No-Stop Unwinder - Control desks ............................................................................................................... 137
Winder - Control desks ................................................................................................................................. 157
Handling - Control desks .............................................................................................................................. 163
Pneumatic control box ................................................................................................................................. 168
No-Stop Unwinder - Pneumatic control box ................................................................................................. 170
Winder - Pneumatic cabinet ......................................................................................................................... 172
OPERATOR INTERFACE ........................................................................................................................ 174
Machine configuration ................................................................................................................................. 174
No-Stop Unwinder operator interface pages ............................................................................................... 175
Winder operator interface pages ................................................................................................................. 186
W INDING PARAMETERS ........................................................................................................................ 213
Tension ......................................................................................................................................................... 213
NIP ................................................................................................................................................................ 214
Torque .......................................................................................................................................................... 216
WIT (Wound In Tension) ............................................................................................................................... 217
Draw ............................................................................................................................................................. 218
Load cells ...................................................................................................................................................... 219
TURNING ON THE MACHINE................................................................................................................... 220
Electric system start-up ................................................................................................................................ 221
Starting the hydraulic system ....................................................................................................................... 222
Run modes .................................................................................................................................................... 223
7.7.4
7.8
7.9
7.9.1
7.9.2
7.9.3
7.9.4
7.10
7.10.1
7.10.2
7.10.3
7.11
7.12
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Start of the Machine .....................................................................................................................................224

LOADING MATERIAL TO PROCESS ..........................................................................................................233
STARTING THE WORKING CYCLE ............................................................................................................234
Automatic Cycle ............................................................................................................................................234
Semi-Automatic Cycle ...................................................................................................................................235
Manual Cycle.................................................................................................................................................235
Automatic sequences ....................................................................................................................................236
STOP ..................................................................................................................................................239
Normal Stop ..................................................................................................................................................239
Emergency stop.............................................................................................................................................239
Release and restoring after the emergency. .................................................................................................240
CHANGE OF SIZE ..................................................................................................................................240
DIAGNOSTICS AND ALARMS ...................................................................................................................241
CHAPTER 8.
8.1
8.2
8.2.1
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
8.4
8.4.1
8.4.2
8.5
8.5.1
8.5.2
8.5.3
8.5.4
8.5.5
8.5.6
8.5.7
8.6
8.6.1
8.6.2
8.6.3
8.7
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MAINTENANCE .....................................................................................................................243
SAFETY WARNINGS ..............................................................................................................................245

PROCEDURE FOR LOCKOUT AND TAGOUT .............................................................................................249
Tag, lock, clear and try procedure.................................................................................................................251
ORDINARY AND PREVENTIVE MAINTENANCE ...........................................................................................258
Periodical checking........................................................................................................................................258
Safety device check .......................................................................................................................................261
Maintenance on commercial parts ...............................................................................................................262
Ordinary maintenance for electrical plant ....................................................................................................262
Maintenance of pneumatic plant..................................................................................................................264
Ordinary maintenance for oil-hydraulic plant ...............................................................................................265
LUBRICATION AND GREASING ................................................................................................................275
Automatic lubrication ...................................................................................................................................277
Manual lubrication........................................................................................................................................277
EXTRAORDINARY MAINTENANCE............................................................................................................281
Electrical cubicles ..........................................................................................................................................283
Controls panel ...............................................................................................................................................283
Safety units ...................................................................................................................................................284
Safety limit switches .....................................................................................................................................284
Dismounting of counter-knives .....................................................................................................................286
Replacement of knives ..................................................................................................................................287
Sharpening of knives and counter-knives......................................................................................................290
CLEANING............................................................................................................................................294
Removal of waste and dust ...........................................................................................................................296
Removal of waste formed .............................................................................................................................297
Removal of oils and lubricants ......................................................................................................................298
ARRANGEMENTS FOR STOPPING THE MACHINE FOR LONG PERIODS AND THEN RESTARTING......................298
CHAPTER 9.
TROUBLESHOOTING ...........................................................................................................301
9.1
SAFETY WARNINGS ..............................................................................................................................303
9.2
W INDING DEFECTS AND SOLUTIONS ......................................................................................................303
9.2.1
Telescopic effect ............................................................................................................................................305
9.2.2
Ramps ...........................................................................................................................................................306
9.2.3
Interference rings ..........................................................................................................................................307
9.2.4
J-Line .............................................................................................................................................................308
9.2.5
Stars by the core ...........................................................................................................................................309
9.2.6
Side-skid of the web ......................................................................................................................................310
9.2.7
Troubleshooting for the longitudinal cutting system ....................................................................................310
CHAPTER 10.
DISMANTLING AND DISPOSAL ..........................................................................................325
EN
10.1
10.2
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SAFETY WARNINGS.............................................................................................................................. 327

DISASSEMBLY AND DISPOSAL PROCEDURE............................................................................................ 328
CHAPTER 11.
SPARE PARTS ..................................................................................................................... 329
11.1
HOW TO ORDER SPARE PARTS ............................................................................................................. 331
11.1.1 Type of Spare Parts ...................................................................................................................................... 331
11.1.2 Spare parts ordering instructions ................................................................................................................. 332
CHAPTER 12.
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
12.10
12.11
12.12
12.13
12.14
12.15
12.16
REEL HANDLING ................................................................................................................. 335
INFORMATION...................................................................................................................................... 337
GENERAL INFORMATION ...................................................................................................................... 340
SYSTEM COMPONENTS........................................................................................................................ 342
GENERAL SAFETY PLAN ...................................................................................................................... 344
PACKING INFORMATION ....................................................................................................................... 345
TRANSPORT ........................................................................................................................................ 346
HANDLING........................................................................................................................................... 347
SAFETY MEASURES ............................................................................................................................. 349
MACHINE INSTALLATION....................................................................................................................... 350
MACHINE START UP ............................................................................................................................ 352
AUTOMATIC FUNCTION ........................................................................................................................ 352
TROUBLE SHOOTING ........................................................................................................................... 354
MAINTENANCE .................................................................................................................................... 355
SETTING AND REPLACEMENT OF W ORN OR BROKEN COMPONENTS ..................................................... 357
MACHINE DISMANTLING ....................................................................................................................... 360
ELECTRICAL INSTALLATION .................................................................................................................. 361
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EN
CHAPTER 1.
INTRODUCTION
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The instruction manual and drawings are owned by the A.Celli Nonwovens s.p.a.. drawings, diagrams
and any other document delivered with the machine are the property of the company A.Celli
Nonwovens s.p.a. which reserves all rights and that no can be made available to third parties. It is
therefore forbidden the reproduction (in any form), even partial, of the contents, text or illustrations.
The entire document is protected under copyright law.
The company A.Celli Nonwovens s.p.a. also reserves the right to exercise the rights of industrial
protection.
This instruction book is to be considered an integral part of the machine and it contains all the
necessary instructions to carry out the following operations with no risks whatsoever:
- Transportation
- Installation
- Assembling and dismantling
- Putting into service
- Adjustment
- Machine usage
- Maintenance and repairing operations
- Spare parts
This instruction book provides also:

- the information about the machine;
- the safety precautions to be observed for the safe use of the machine
NOTE
THE ORIGINAL INSTRUCTIONS ARE WRITTEN IN ITALIAN. THE INSTRUCTIONS IN OTHER
LANGUAGES IS A TRANSLATION OF THE ORIGINAL INSTRUCTIONS.
EN
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NOTE
THE MACHINE IS TO BE UTILIZED BY AUTHORISED PERSONNEL ONLY, AFTER BEING FULLY
TRAINED AND ADEQUATELY INFORMED, ACCORDING TO THE KIND OF ACTIVITY TO BE
CARRIED OUT.
THIS INSTRUCTION BOOK HAS BEEN WRITTEN FOR THESE USERS.
THIS INSTRUCTION MANUAL SHOULD BE RETAINED FOR FUTURE REFERENCE. STORE IN A

SAFE PLACE. IN CASE OF LOSS OR WHEN DEEMED APPROPRIATE, REQUEST AN ADDITIONAL
COPY TO THE TECHNICAL SERVICE OF A.CELLI NONWOVENS S.P.A..
THE ORIGINAL INSTRUCTIONS ARE IN ITALIAN. ALL OTHER LANGUAGES ARE TRANSLATIONS
OF THE ORIGINAL INSTRUCTIONS.
1.1
HOW TO READ THE INSTRUCTION MANUAL
This instruction book tells how to use and carry out maintenance works on the machine, in
accordance with safety rules.
The instruction book is made up of 2 Volumes:
- Volume 1: declaration of conformity; technical data of the machine; the documentation concerning
its usage and maintenance and the spare parts list.
- Volume 2: electrical, pneumatic and hydraulic diagrams.
This instruction book is made up of 11 chapters, and their content is described in the preliminary
index.
The folder "\ Drw" is part of the instruction manual and it contains the assembly drawings and
diagrams of the machine. To open the link in a new window with Acrobat Reader click on the link by
pressing the CTRL key.
The sequence of chapters responds to the temporal logic of the machine life.
Terms, abbreviations and pictograms, whose meaning is shown in the following paragraphs are used
to facilitate the text understanding immediacy.
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Procedure for Operator Procedure for Electrical Engineer Procedure for Mechanical Engineer
EN
All the commentaries, warnings and important instructions which must be carefully followed in order to
avoid any possible damage to the machine or injuries to the workers, have been highlighted in bold
characters.
At the top of each page of Volume 1, a number shows the version of the instruction book.
Version 1.0 (V 1.0): it is the first version of the instruction book and comes together with the machine.
Version 1.1 (V 1.1): if during the start-up of the machine some function is changed, in order to be
optimized, and should this affect the information contained in the present instruction book, then
version 1.1 will be released.
The following versions will be issued with progressive and increasing numbers.
The two volumes can be separately updated, this is why their version number may not correspond.
In case of updating, only the changed volume will be sent to the customer.
The higher the number, the more up-to-date is the version.
The paragraph "General safety warnings a pag. 101" is included in Chapter 6 of the manual
(Volume 1). These warnings refer to the machine in general, during its life and operation.
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CHAPTER 1
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The "Safety warnings" paragraph is at the beginning of each chapter. These warnings apply to the
machine and to the operator for the operations related to the chapter.
If necessary, in the paragraph, are reported the safety warnings relating to the operation described in
that paragraph.
The instruction manual is prepared to the time of production. The A.Celli Nonwovens s.p.a. reserves
the right to make changes to the production and to the manual, without entailing the obligation to
update products and prior manuals.
NOTE
ALWAYS READ THE SECTION "SAFETY INSTRUCTIONS" AT THE BEGINNING OF THE CHAPTER,
BEFORE PERFORMING AN OPERATION DESCRIBED IN A PARAGRAPH.
1.2
PICTOGRAMS USED IN THE MANUAL
Symbol
Explanation
Hazardous area. Any area within and/or around a machine in which the presence
of a person constitutes a risk to safety and health of that person
Operator. It is the person informed, qualified and authorized by the buyer who
receives the task to run the machine with active guards through the use of
controls that are placed on the operator panel.
Mechanic Maintenance Engineer. It is the technician qualified and authorized by
the buyer who is able to install, repair, perform ordinary and extraordinary
maintenance, and any setup operation exclusively of mechanical type on the
machine.
Electrical Maintenance Engineer (person trained and instructed as indicated
in EN 50110). It is the technician qualified and authorized by the buyer who is
able to install, repair, perform ordinary and extraordinary maintenance, and any
setup operation exclusively of electrical type on the machine.
Manufacturer's technician with mechanical skills. It is the manufacturer's
technician who must be consulted to perform mechanical operations of complex
and/or detailed type on the machine.
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Symbol
CHAPTER 1
Pag. 13 ( 10 )
Version: 1.0
Explanation
Manufacturer's technician with electrical skills (trained and experienced
person as indicated in EN 50110). It is the manufacturer's technician who must
be consulted to perform electrical operations of complex and/or detailed type on
the machine.
DANGER
Serious or fatal injury
WARNING
Possibility of serious or fatal injury or death
ATTENTION
Possibility of minor or insignificant injury or damage to the machine

Useful information
NOTE
1.2.1 OBLIGATION SIGNS

Symbol
Explanation
Obligation to read the instructions
Protection of hands with gloves mandatory
Wearing overalls for body protection mandatory
Wearing the safety helmet mandatory
Wearing safety shoes mandatory
1.2.2 DANGER SIGNS

Symbol
Explanation
General hazard
Hazard of electric shock, live elements
EN
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Machine: name
Symbol
Explanation
Hot surface hazard
1.2.3 PROHIBITION SIGNS

Symbol
Explanation
Access denied to unauthorized personnel
Do not extinguish fire with water
Do not touch
Do not work on moving members
Do not remove the safety device
No smoking
1.2.4 PERSONAL PROTECTIVE EQUIPMENT

Symbol
Explanation
Required to protect your hands with gloves
Required to wear glasses for eye protection
Required to wear the suit for the protection of the body
Required to wear a protective helmet
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Symbol
CHAPTER 1
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Explanation
Required to wear headphones for hearing protection
Required to wear safety footwear

EN
Required to wear the mask for face protection
Required to wear protective respiratory
1.3
GLOSSARY
Term
Tension
Nip
Description
Force. The tension of a material is obtained with equal and opposite forces that
pull the sheet.
Average linear load between main drum and winding reel, acting along the
direction that connects their centers.
Measure the action necessary to cause a rotation, equal to the force multiplied by
Torque
the perpendicular distance between the line of action of the force and the center
of rotation.
WIT
Wound In Tension. Tension actually applied to the individual turns in the wrapped
reel .
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of the machine and information to the
CHAPTER 2
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EN
CHAPTER 2.
IDENTIFICATION OF THE MACHINE

AND INFORMATION TO THE
CUSTOMER
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Machine: name
CHAPTER 2
Pag. 18 ( 12 )
Version: 1.0
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CHAPTER 2

2.1
Pag. 19 ( 12 )
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MANUFACTURER'S IDENTIFICATION DATA

A.CELLI NONWOVENS S.P.A.
VIA ROMANA OVEST, 252
55016 PORCARI - LUCCA - ITALY
EN
2.2
MACHINE IDENTIFICATION DATA
The serial number of the whole plant is:

2014039
2014040
2014041
2014042
Reference drawing for General layout is :
p9579p_R11.pdf
The plant is composed of the following machines :

Ref.
Description
78100000 No Stop Unwinder - NW
2014039
78100000 No Stop Unwinder - PE
2014040
66300000 Windy Custom
2014041
42000000 Core loader
2014042
52200000 Extractor
2014042
The drawings with 2014039 identify the No Stop Unwinder for NW.
The drawings with 2014040 identify the No Stop Unwinder for PE.
The drawings with 2014041 identify the Winder.
The drawings with 2014042 identify the Extractor.
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CHAPTER 2
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Unwinder - Label plate
Unwinder - Label plate
Winder - label plate
Version: 1.0
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Version: 1.0
EN
Extractor Label Plate
2.3
CUSTOMER'S TASKS
NOTE
THE CUSTOMER MUST INFORM THE A.CELLI NONWOVENS S.P.A. PERSONNEL INSTALLING,
STARTING UP AND SETTING THE MACHINE, OF ALL THE INTERNAL SAFETY AND HEALTH
REGULATIONS.
The Customer is kindly asked to collaborate with such personnel, giving them, in case of need, all the
suitable technical support (tools, equipment, lifting and handling devices).
The assembling, in fact, is often carried out far away from home and it may not be easy, in such
cases, to have all the necessary equipment ready at hand.
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The Customer must make available to the A.Celli Nonwovens s.p.a. personnel Toilet equipped with
showers with hot and cold water and detergents for cleaning the hands and body.
In addition, there must be a suitable place to allow the consumption of food and drink while on the job.
The Customer must appoint a manager to which technicians can refer to in case of need or
emergency. The person in charge must always be present when the A.Celli Nonwovens s.p.a.
personnel are at work at the Customer's plant.
NOTE
THE CUSTOMER MUST ARRANGE AN ADEQUATE AREA WHERE TO LOCATE THE MACHINE,
ACCORDING TO THE INDICATIONS GIVEN IN THE FOUNDATION LAYOUT DRAWING, SUPPLIED
BY THE MANUFACTURER.
The customer must assign specific areas for the unloading, storing, installation and testing
operations of the machine.
Such areas must be guarded with barriers, their access being prevented to everybody, unless A.Celli
Nonwovens s.p.a. authorised personnel, who is responsible for the machine installation, give
permission to enter. In such areas, safety must not be jeopardised by the functioning of other
machines or by the arising of dangerous situations. If so, the machines must be stopped and the
dangerous situations made harmless by the Customer.
If this is not technically possible, the Customer must assume formal responsibility for this and give
adequate information to A.Celli Nonwovens s.p.a. personnel about the risks and how to perform these
operations safety.
The Customer must supply all the requested electricity supply (both power and auxiliary
supplies), according to the specifications indicated in the manual ( Technical data a pag. 37 ).
The customer must supply the requested clean and dry compressed air, according to the
specifications indicated in the order confirmation.
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NOTE
THE CUSTOMER MUST FOLLOW ALL THE INFORMATION AND WARNINGS SPECIFIED IN THIS
INSTRUCTION BOOK OR VERBALLY TRANSMITTED BY TECHNICIANS OF A.CELLI NONWOVENS
S.P.A., WITH REGARD TO SAFELY PERFORMING TRANSPORTATION, INSTALLATION,
ASSEMBLING AND DISASSEMBLING, STARTING UP, SETTING, MAINTENANCE AND REPAIRING
OF THE MACHINE.
2.4
INSPECTION
The inspection includes all actions and tests aimed at certifying the potential reaching of all project
specifications. The machine must reach these specifications in the expected operating conditions.
The inspection is usually carried out at the customer's plant.
Upon completion of commissioning, the machine will be subjected to the tests set at the time the
contract. In addition, the specific controls will be carried out to verify the structures of a security.
Below is the facsimile of the form to perform the safety tests:
Visual check
Result
The protections are installed in accordance with the reference design ?

The fixed and movable guards are installed ?
There are devices of the type lockable energy isolation ?
Emergency stop buttons are installed in accordance with the reference design ?
They are installed and readily visible from control places the indicator lights red
and yellow ?
Are clearly identified control devices ?
It was affixed safety signs in accordance with the reference design ?
Functional check
Switch Tripping the general electricity
General pneumatic shut-off valve
General hydraulic shut-off valve
lighting
Control systems
The beeps and light machine startup .
Result
EN
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Machine: name
CHAPTER 2
Pag. 24 ( 12 )
Functional check
Version: 1.0
Result
Limits of speed ( 10m/min )

Emergency buttons
Bumper cables and emergency
mats
Interlocked movable guards
Bells and warning lights
Training
Result
Did you follow the training for the operators?

Did you follow the training for maintainers ?
Documentation
Result
Label with CE marking

Declaration of Conformity
Manual written in different languages
drawings total
Wiring diagrams
pneumatic diagrams
hydraulic diagrams
Verbal testing electrical installations
Verbal test equipment specifications
2.5
GUARANTEE
The guarantee is valid as specified in the contract (see relevant paragraph). The guarantee covers
the replacement of any possible defective parts in the shortest possible time, according to the
conditions specified in the contract.
The guarantee does not include the travelling expenses of the technicians, nor does it cover those
parts subjected to normal wear and tear (knives, blades, belts, fuses, etc.).
USING ONLY ORIGINAL A.CELLI NONWOVENS S.P.A. SPARE PARTS DURING
THE GUARANTEE PERIOD OF THE MACHINE IS COMPULSORY.
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Pag. 25 ( 12 )
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In case you are not using original components from A.Celli Nonwovens s.p.a. or
from suppliers specifically indicated by the manufacturer, the guarantee shall lapse
immediately. The company A.Celli Nonwovens s.p.a. assumes no responsibility for
damage to persons or property resulting from the use of non-original spare parts.
EN
2.6
CONTACT DETAILS FOR TECHNICAL ASSISTANCE
Through its CUSTOMER CARE Department, A.Celli Nonwovens s.p.a. provides the customer with
suitable assistance to examine and solve any problems which may arise during the use of the
machines.
For any problems, just contact us at the following:
A.CELLI NONWOVENS S.P.A.
VIA ROMANA OVEST, 252
55016 PORCARI - LUCCA - ITALY
Type
Number
Note
Phone
+39 0583 2117932/2117935
(Italy, Middle East, America)
Phone
+39 0583 2117933/2117934
(Europe, Far East, Australia, Africa)
fax
+39 0583 2117990
mail
service@acelli.it
web
www.acellinonwovens.com
Hotline
+39 0583 2117999
H24
The Hotline technical assistance service is active H24.

During office hours, our CUSTOMER CARE Department will answer you (08.00 17.30 GMT+1).
After office hours, a qualified technician will answer. He will be able to give the customer all the
necessary technical support to help solve any possible problems.
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Concerning the specific information for use and functioning of the Hotline service, please contact our
CUSTOMER CARE.
The preliminary contact will be more useful if the customer can provide complete and precise
information, with particular reference to:
- Machine serial number;
- Troubles of the machine;
- Particular conditions in which such troubles have been registered;
- Anomalies noticed with respect to the normal functioning;
- Is it possible to root the cause of the breakdown or damage?
- Did the breakdown or damage happen in the past?
- Did the customer already try to give an answer to the problem?
- Did the customer already introduce corrective actions?
2.7
STANDARD REFERENCE
The machine has been designed and built taking into consideration the particular aspects of
safeguarding the health and safety of workers. To achieve this objective , the manufacturer has
conformed with the state of the current technique, inspired by some of its design choices with the
harmonized standards.
The main directive of reference is the Machinery Directive
2006/42/CE
Were also taken as reference the following directives
2006/95/CE
2004/108/CE
In accordance with the provisions of the Machinery Directive, the machine has been designed and
built in compliance with harmonized standards EN reference and in particular:
Safety requirements for the design and construction of machines for the production
and finishing of the paper. Part 1: Common requirements
Safety requirements for the design and construction of machines for the production
and finishing of the paper. Part 3: Winders and slitters, folding machines
EN1034-1
EN1034-3
They were also applied the principles set out in the following harmonized standard
EN12100
EN 13857
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EN 349
EN 953
EN 13850
EN 13849-1
EN 4413
EN 4414
EN 60204-1
Machinery manufactured in conformity with a harmonized standard, the reference for which has been
published in the Official Journal of the European Union, are presumed to comply with the essential
safety and health protection covered by such a harmonized standard.
2.8
ABSTRACT OF DECLARATION OF INCORPORATION OF PARTLY

COMPLETED MACHINERY
The manufacturer :
Name
A.Celli Nonwovens s.p.a.
Address
Via Romana Ovest, 252 - 55016 Porcari, Lucca - Italy
Declares that the machine described below, fulfills the following essential requirements of the
Machinery Directive 2006/42/EC:
1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7 ANNEX I
Also declares that the relevant technical documentation is compiled in accordance with part B of
Annex VII.
The partly completed machinery (previously identified) fulfills also these directives :
2004/108/CE (Electromagnetic Compatibility)
2006/95/EC (Low tension)
EN
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CHAPTER 2
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Version: 1.0
A.Celli Nonwovens s.p.a. undertakes to transmit (by e-mail), in response to a reasoned request by the
national authorities, relevant information on the partly completed machinery.
THE PARTLY COMPLETED MACHINERY MUST NOT BE PUT INTO SERVICE UNTIL THE FINAL
MACHINERY INTO WHICH IT IS TO BE INCORPORATED HAS BEEN DECLARED IN
CONFORMITY WITH THE PROVISIONS OF THE MACHINERY DIRECTIVE 2006/42/EC.
MACHINE DESCRIPTION
Model :
Uninders + Winder
Type :
781-663-420-522
Serial Nr. :
2014039-40-41-42
Year of construction :
2015
Serial Number: 2014039_40_41_42

Sections Title: Description
of the machine
CHAPTER 3
Pag. 29 ( 22 )
Version: 1.0
EN
CHAPTER 3.
DESCRIPTION OF THE MACHINE
Serial Number: 2014039_40_41_42

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CHAPTER 3
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Version: 1.0
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3.1
of the machine
CHAPTER 3
Pag. 31 ( 22 )
Version: 1.0
GENERAL DESCRIPTION
3.1.1 IDENTIFICATION OF THE MAIN GROUPS

The plant is composed of the following machines:
UNWINDER NO STOP BY REVOLVER
Pos.
Group
Description
781M100022D
Frames group
781L000022X
Frames group
781J9000XXS
Chucks 6"
781E8000XXX
Chucks 6"
EN
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of the machine
Pos.
Group
Description
781O200022X
Paper roll 167
781F1000XXD
Chucks adjustment
781J9000XXD
Chucks 6"
781J800022D
Cross cut
781L700022X
Cross cut with toothed blade
10
781L200022D
Dancing roll
11
781L500022X
Cross cut Frames
12
781E7000XXX
Revolver rotation
13
78308000XXX
Potentiometer
14
781F9000XXX
Laser for check diameter
15
781M500022D
Safety guard
16
781L300022X
Paper roll 127
17
781M000022X
Cross cut group mobile detents
UNWINDER NO STOP BY REVOLVER
Version: 1.0
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of the machine
Pos.
Group
Description
781M300022S
Frames group
781L000022X
Frames group
781J9000XXS
Chucks 6"
781E8000XXX
Chucks 6"
781O200022X
Paper roll 167
781F1000XXS
Chucks adjustment
781J9000XXD
Chucks 6"
781J800022S
Cross cut
781L700022X
10
781L200022S
Dancing roll
11
781L900022X
Cross cut Frames
12
781E7000XXX
Revolver rotation
13
78308000XXX
Potentiometer
14
781F9000XXX
Laser for check diameter
15
781P700022S
Safety guard
16
781L800022X
Web threading path
17
781L400022S
Web slides
18
781L300022X
Paper roll 127
19
781M600022S
Walkway group
20
781M000022X
Cross cut group mobile detents
CHAPTER 3
Pag. 33 ( 22 )
Version: 1.0
EN
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WINDER
Pos.
Group
Description
663F700022X
Windy frames group
663N800022X
Drive drum for axial helper
663N500022D
663G300022D
663H100022D
Shaft loading device
6632900022X
6" expandable shaft
6631800022X
Expandable cut roll
6628500022X
Load cell roll
66386000XXX
D.150 knife independent lock.
10
663H300022X
Web slides
11
663D3000XXD
Cams group
12
663D100022D
Spool storage
13
6636200022X
Trim suction device
14
663H0000XXX
Main drive
15
663C500022D
Sus roll carriages
16
663C100022D
Sus roll
Version: 1.0
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of the machine
Pos.
Group
Description
17
663C900022D
Arm for reel unloading
18
663G600022X
Knives beam
19
6639200022X
Safety mechanical sensor
20
663F900022D
S-Wrap roll
21
663H600022X
Paper roll 198
22
663F800022D
Bowed rolls d.175 group
23
663G500022D
Safety guard
24
66391000XXX
Encoder
25
663G0000XXD
Secondary power drive assembly
26
663C300022X
Frames group
27
663H700022X
Elettorstatic bar
28
663F400022X
Counter-knives dust removal system
29
663F400022X
Counter-knives dust removal system
CHAPTER 3
Pag. 35 ( 22 )
Version: 1.0
3.1.2 OPERATING PRINCIPLE

3.1.2.1
NON STOP UNWINDER
The Non Stop Unwinder with Revolver is a machine for carrying out the Master Rolls of material. In
particular, the present unwinder born to carry reels of non-woven fabric continuously, without
interruption of the production cycle.
The unwinder is composed from a section of unwinding with 2 stations and a cutting section.
The product carried out passes through a dancer group that controls the tension via a lever system
controlled by pneumatic cylinders.
When the reel in progress must be replaced, the machine rotates and brings into the working position
a new reel, previously prepared. The system takes care of matching the new web with the one in
progress and to cut it. This operation allows to not stop the plant to replace the finished reel.
The reel is held in rotation by effect of an electric motor mounted in axis.
EN
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The cycle of unwinding and doffing is fully automatic and can be done at a constant speed without
going to affect the production cycle of the non-woven fabric placed downstream of the machine.
The cutting system of the product is constituted by a retractable toothed blade.
3.1.2.2
WINDER
The Winder is a machine for winding in Master Roll the materials produced in the form of web
continuously with indefinite length. In particular, this Winder is designed to wind non-woven fabric
material on rolls which are then subsequently processed to obtain finished products used in various
industrial sectors among which we mention : articles on hygiene and health , filtration systems,
products for the automotive sector, items for civilian use, products used in agriculture and in the
construction industry, and in general technical articles .
Inside of the Winder, the product is processed by a winding system, typically a winding roller, which is
pressed against the Master Roll being formed around a special winding shaft.
The Master Roll is kept in rotation due to the tangential stress exerted on its periphery from the
winding roller. The shaft on which is formed the Master Roll lays on guides and it is held against the
winding roller by means of suitable supports. Once the Master Roll has been completed, the web
material is cut and a new winding shaft is inserted close to the winder roller .
The winding cycle and exchange (doffing) is fully automatic and can be done at a constant speed
without going to affect the production cycle of the nonwoven fabric.
SLITTO SYSTEM
The cutting unit "Slitto" is composed by independent cutting groups, each one with its knife and
counter-knife.
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EN
The cutting units slide on guides by means of recirculating ball bearings and to adjusting the cut
position is used a rack and pinion system.
The counter-knives are made from the section mounted on motorized expandable shaft.
Compressed air is directed to the knife holder by one collector that control both movements of
advancing and approaching.
NOTE
MORE INFORMATION ARE WRITTEN IN THE USE CHAPTER " INTENDED USE A PAG. 125 "
3.2
TECHNICAL DATA
3.2.1 OVERALL DIMENSIONS AND MASS

The overall dimensions of the machine refer to the assembly drawing:
p9579p_R11.pdf
Technical data
Units
Value
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CHAPTER 3
Machine: name
Pag. 38 ( 22 )
of the machine
Version: 1.0
Technical data
Units
Value
Length
mm
30'500
Width
mm
11'000
High
mm
5'000
Gross weight
Kg
150'000
3.2.2 POWERS AND CONSUMPTION

ELECTRICAL DATA
Technical data
Electric power supply (are not permissible range larger
than +/- 10%)
U.M.
Value
400
Number of phases
3 ph
Auxiliary
Vac
230
Field
Vdc
24
Hz
50
Frequency (Not larger than +/- 1% of nominal frequency

continually, and than +/-2 % for short time)
Type of connection of the grounding of the power supply
Safety level according to EN 60529/10.91. for electrical
cabinets of power
TN
IP
55
Regulations reference
IEC 60204-1
Electrical cabinet room presence
No
Radiation
No
Vibrations, quake
No
special installations
No
EMC
No
Laser
Yes
Output power cables electrical cabinet
From down
PLC
Siemens S7
Data transmission network
Profibus DP MPI
Data communication network from A.Celli to Customer
Ethernet TCP/IP
PLC development software
Step 7
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Pag. 39 ( 22 )
of the machine
Technical data
Version: 1.0
U.M.
Supervision software
Value
WinCC
Desktop + Industrial
Supervision PC
Monitor
EN
PNEUMATIC DATA
The data in the following table shows the air consumption during the different working steps.
Machine
Steps
U.M.
Value
Winder
Threading
Nl/min
4'500
Normal functioning
Nl/min
600
Doffing cycle
Nl/min
1'600
Threading
Nl/min
2'500
Normal functioning
Nl/min
600
Doffing cycle
Nl/min
1'800
Corecutter
Each cycle
Nl/min
1'250
No Stop Unwinder
Threading
Nl/min
2'800
Normal functioning
Nl/min
700
Doffing cycle
Nl/min
1'300
Threading
Nl/min
4'500
Normal functioning
Nl/min
700
Doffing cycle
Nl/min
2'000
Rewinder
Winder
3.2.2.2
ELECTRIC WIRING DIAGRAM
The wiring diagram of reference for the NW Unwinder is :

2014039_GB.pdf
The wiring diagram of reference for the PE Unwinder is :
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Pag. 40 ( 22 )
of the machine
2014040_GB.pdf
The wiring diagram of reference for the Winder is:

2014041_GB.pdf
The wiring diagram of reference for the Extractor is:

2014042_GB.pdf
3.2.2.3
PNEUMATIC DIAGRAM
The pneumatic diagram of reference for the NW Unwinder is :

2014039_PD.pdf
The pneumatic diagram of reference for the PE Unwinder is :

2014040_PD.pdf
The pneumatic diagram of reference for the winder is:

2014041_PD.pdf
The pneumatic diagram of reference for the Extractor is:

2014042_PD.pdf
3.2.2.4
CHAPTER 3
HYDRAULIC DIAGRAM
The hydraulic diagram of reference for the winder is:

2014041-S.pdf
2014041-L.pdf
NOTE
Version: 1.0
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Pag. 41 ( 22 )
of the machine
Version: 1.0
MORE INFORMATION ARE WRITTEN IN THE INSTALLATION CHAPTER " CONNECTION TO

POWER SUPPLY A PAG. 72 "
3.2.3 TECHNICAL SPECIFICATIONS

3.2.3.1
NO STOP UNWINDER - SPECIFICATIONS
EN
Technical data
Unit
Value
Master Roll (min - max)
mm
500 1'500
Web width
mm
1'000 2'200
Mechanical speed
m/min
850
Production speed
m/min
800
Threading speed
m/min
10
Cross cut type
Toothed blade
Longitudinal cut type
Master roll weight (max)
kg
1'200
Minimum width of cut
mm
Trim exhauster
No
Centralized lubrication
No
Number of shafts supplied
shaft
mm
6"
Transmission system
AC Motors
Motor side
Right
Operator side
Left
Control panel side
Left
Machine frame color
RAL 9002
Control desk, control box, and electrical
RAL 7035
cabinet color
Taper effect
No
Variable nip
No
Compressed air (Clean and dry)
bar
Cable ducts
In aerial ducts
Unwinder axial alignment (+/-75mm)
Yes
Tension control
Dancer roll
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of the machine
MOTORS INSTALLED
Quantity
Description
Nr. 1
Revolver
Nr. 1
Cut group
Nr. 1
Press roll
Nr. 2
Mandrels
3.2.3.2
NO STOP UNWINDER - SPECIFICATIONS
Technical data
Unit
Value
Master Roll (min - max)
mm
1'200
Web width
mm
1'000 2'200
Mechanical speed
m/min
850
Production speed
m/min
800
Threading speed
m/min
10
Cross cut type
Toothed blade
Master roll weight (max)
kg
2'300
mm
Trim exhauster
No
No
shaft
mm
6"
Transmission system
AC Motors
Motor side
Left
Operator side
Right
Control panel side
Right
Machine frame color
RAL 9002
Control desk, control box, and electrical

cabinet color
RAL 7035
Version: 1.0
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CHAPTER 3

Technical data
Pag. 43 ( 22 )
of the machine
Unit
Value
Taper effect
No
Variable nip
No
bar
Version: 1.0
Cable ducts
In aerial ducts
Unwinder axial alignment (+/-75mm)
Yes
Tension control
Dancer roll
MOTORS INSTALLED
Quantity
Description
Nr. 1
Revolver
Nr. 1
Cut group
Nr. 1
Press roll
Nr. 2
Mandrels
3.2.3.3
WINDER - SPECIFICATIONS
Technical data
Unit
Value
Mechanical speed
m/min
850
Production speed
m/min
800
Threading speed
m/min
10
Cross cut type
Toothed blade
Expandable shaft with cutting shells
Cut units n
10
mm
Trim exhauster
Yes - up to fan
No
4 - Expandible
shaft
mm
6"
Transmission system
AC Motors
Motor side
Right
EN
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Pag. 44 ( 22 )
of the machine
Technical data
Unit
Value
Operator side
Left
Control panel side
Left
Machine frame, control desk and control
RAL 9002
box color
Electrical cabinet color
RAL 7035
Taper effect
Yes
Variable nip
Version: 1.0
bar
Yes (setting pressure by operator panel)
Cable routing
In aerial ducts
Shaft storage
Yes
Shaft launcher
Yes
S-Wrap
Yes - Press roll
SUS
Yes
INSTALLED MOTORS
Quantity
Description
Nr. 1
Leading roll and bowed roll transmission
Nr. 1
Driving roll transmission
Nr. 1
Cut Group
3.2.4 ACTUATORS
The machine has various actuators to perform the movements required to operate the Machine. The
actuators are constituted by electric power, pneumatic and hydraulic systems.
Here are the references to the drawings in which they are called cylinders, motors and all the
elements that move the parts of the machine, complete with technical specifications.
No Stop Unwinder reference drawing:
2014039.pdf
No Stop Unwinder reference drawing:
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Pag. 45 ( 22 )
of the machine
Version: 1.0
2014040.pdf
Winder reference drawing:

2014041.pdf
2014042.pdf
EN
3.2.5 ENVIRONMENTAL OPERATING CONDITIONS

The machine must be installed, used and kept in a covered working environment under controlled
microclimatic, environmental and lighting conditions, which are in keeping with the legislative
parameters for safety and hygiene in the working areas in force in the country of installation.
Technical data
U.M.
Value
Working temperature
+15 / +40 C
Stocking temperature:
+25 / +55 C
Relative humidity
>80%
Max working altitude (*)
1000
(*) In the event of higher altitudes contact the manufacturer.

3.2.5.1
EXPLOSIVE ATMOSPHERE
The machine must not be used in potentially explosive atmospheres.

3.2.5.2
LIGHTING
CAUTION
THE MACHINE IS EQUIPPED WITH A LIGHTING SYSTEM IN THE AREA OF THE
SLITTO TO ALLOW THE OPERATOR THE POSITIONING OF THE KNIVES AND
COUNTER-KNIVES. IN GENERAL, TO WORK, THE MACHINE USES THE
ILLUMINATION PROVIDED TO THE INSTALLATION SITE. THE MACHINE MUST
NEVER BE OPERATED IN DARK AREAS.
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3.2.6 NOISE
This chapter contains information on the "noise" produced by the machine, as required by the
European Directive 2006/42/EC, and amendments.
The measurement is done in the working position of the Operator, close to the control panel and in
any working and control position of the machine. It is done also in other points around the machine.
The referenced standard is EN 13023.
LEQ <= LEQ DB (A)
LPC <= LPC DB (C)
Meaning of symbols:
LEQ : Equivalent continuous sound pressure level at the Operator position.
LPC : peak level of C-weighted sound pressure level at the Operator position.
3.2.6.1
MEASUREMENT
From the evaluation of noise produced by the machine, the weighted sound pressure level "A" in the
workplace appears to be less than 83 db (A).
Description
LEQ : Equivalent continuous sound pressure level
at the Operator position.
LPC : Peak level of C-weighted sound pressure
level at the Operator position.
LWA : A-weighted sound power level.
U.M.
Value
dB
<85
Pa
dB
<63 (130dB compared to 20

Pa)
<83
The evaluation was performed according to operating procedures that have allowed to consider a
random error of +/-1.0 dB, and was performed under real operating conditions of the Operator, taking
into consideration the direction of origin of the disturbing effect.
For carrying out the measurements, it was used a precision sound level meter conforming to class 1
of EN 60651/1994 for sound level meters with overload indicator, and to standard EN 60804/1994 for
supplements .
The instrument used to perform the measurement is an integrating sound level meter identified as
follows:
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Sound level meter

Manufacturer
SVANTEK
Model
SVAN 958_SV 12L_SV22
Type
Sound Level Meter SVAN 958 A s/n 15433 with preamplifier SV12L s/n
18951 and microphone SV22 s/n 4013187
Serial nr.
15433_18951_4013187
Calibration nr.
CT-SLM-0194-2010 del 12/2010
To calibrate the sound level meter was used as a calibrator identified below.
Calibrator
Manufacturer
Delta OHM srl
Model
HD 9001A
Type
HD 9001A Calibrator
Serial nr.
03017310
Calibration nr.
CT-CAA-0077-2010 of 12/2010
The technical characteristics of the integrating sound level meters SVAN 958_SV 12L_SV22 and
calibrator HD9101 follow the standards :
- CEI IEC 60651
- CEI IEC 60804
- CEI EN 61672-1
- CEI EN 61672-2
- CEI IEC 60942 - Calibrator
The measurements were performed in compliance with European standards.
It should be noted that:
The value provided refers to the noise of the machine and not the exposure of the Operator;
The daily personal noise exposure of an Operator depends on various factors such as: exposure
time, the use or not of personal protective equipment, the terms and conditions of use of the machine,
the presence of other machines or noise sources, the state of maintenance of the equipment,
installation conditions, etc..;
EN
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The provided value is a useful reference for the user, in order to assess the risk associated with the
introduction of the machine in the workplace and the need or not to undertake any measures to
reduce the exposure of workers.
Required to wear headphones for hearing protection.
WARNING
THE OPERATOR MUST WEAR A HEADSET FOR HEARING PROTECTION WITH
15 DB MINIMUM ATTENUATION DURING MACHINE USE.
IF THE MACHINE IS INSTALLED IN A REVERBERATING ENVIRONMENT OR

WITH OTHER NOISE SOURCES, IT COULD BE NECESSARY TO INCREASE
THE ATTENUATION LEVEL OF THE HEADSETS FOR HEARING PROTECTION.
With regard to personal protective equipment to refer to Directive 89/686/EEC "Personal protective
equipment" and subsequent amendments.
The A.Celli Nonwovens s.p.a. is available, when requested, to assist in the analysis and search for a
solution to the problems that may arise in respect of that risk.
3.2.7 VIBRATIONS
The machine, during normal operation, is not a source of dangerous or annoying vibrations for the
Operator.
The operator, during the intended use does not come into contact with machine parts subjected to
vibrations.
3.2.8 ELECTROMAGNETIC INTERFERENCES

There are no electromagnetic interferences.
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3.2.9 EMISSIONS OF SUBSTANCES

There are no emissions of ionizing and non-ionizing radiation.
During normal operation, the machine does not emit liquids, gases or other debris. The machine has
been designed and built to prevent the emission of substances, vapors or gases hazardous to
humans.
In relation to the specifications of the processed product can be powders emissions of polypropylene
and polyethylene based. The emission of dust is always a function of the type of material processed.
NOTE
IT IS NECESSARY THAT THE USER PERFORM SPECIFIC ENVIRONMENTAL ANALYSIS TO
ASSESS THE CONCENTRATION AND THE RISK FOR THE OPERATORS.
EN
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of the machine
Version: 1.0
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Sections Title: Handling
and transport
CHAPTER 4
Pag. 51 ( 12 )
Version: 1.0
EN
CHAPTER 4.
HANDLING AND TRANSPORT
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CHAPTER 4
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4.1
and transport
CHAPTER 4
Pag. 53 ( 12 )
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SAFETY WARNINGS
NOTE
READING THIS CHAPTER ASSUMES, FOR THE PURPOSES OF A SAFE USE OF THE MACHINE,
THE KNOWLEDGE OF WHAT IS CONTAINED IN CHAPTER "GENERAL SAFETY WARNINGS A
PAG. 101".
DANGER
RISK OF FALLING LOADS. STAY CLEAR OF THE LOAD.
NEVER LEAVE A LOAD SUSPENDED IN THE AIR.
WARNING
PREVENT ACCESS TO UNAUTHORIZED AND/OR UNQUALIFIED PERSONNEL
TO THE MACHINE OR PACKAGING HANDLING AREA.
THE PHASES OF THE HANDLING OR PACKAGING OF THE MACHINE MUST

BE PERFORMED BY QUALIFIED PERSONNEL IN THE CONDUCT OF CRANES
AND FORKLIFTS.
PLAN AND ORGANIZE THE OPERATIONS SEQUENCE BEFORE STARTING

THE LIFTING OPERATIONS.
TO MOVE THE MACHINE OR PACKAGE, USE LIFTING EQUIPMENT (BELTS,

CRANES, FORKLIFT ...) IN ACCORDANCE WITH EC STANDARDS.
EN
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FOR THE MACHINE HANDLING OR THE PACKAGING TRANSPORT USE

SUITABLE EQUIPMENTS (BELTS, CRANE, FORKLIFT) REGULARLY
MAINTAINED AND SERVICED.
THE LIFTING OF THE MACHINE OR PACKAGING MUST HAVE A CAPACITY

GREATER THAN THE WEIGHT OF THE LOAD.
CAUTION
PLACE PIECES OF WOOD BETWEEN THE SLINGS AND THE CONTACT
SURFACES THAT HAVE SHARP EDGES SO AS NOT TO DAMAGE THE SLINGS
OR THE COATING.
IN THE CASE WHERE THE SIZE OF THE MACHINE OR THE PACKING DOES
NOT ALLOW THE VISUAL TO THE OPERATOR ASSIGNED TO THE HANDLING,
IT IS NECESSARY TO USE AN ADDITIONAL OPERATOR ON THE GROUND TO
HELP HIM IN THE OPERATIONS. THE GROUND OPERATOR MUST GIVE
COMMANDS TO THE OPERATOR INVOLVED IN THE CONDUCT OF LIFTING
EQUIPMENT.
Obligation to protect hands with gloves.
Obligation to wear a suit to protect the body.
Obligation to wear a safety helmet.
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Obligation to wear safety shoes.
4.2
TRANSPORTATION
EN
The machine is shipped from the manufacturers to the customers using the most suitable means of
transportation. This determines the way in which the packaging and the transportation of the
groups/elements are carried out.
The machine is disassembled into its core components according to the following general rules:
- Considering the limits set for road transportation via truck and sea by the international
regulations, as to dimensions (as shown in the table below) and weight.
- Finding out each time about the legislation in force that can differ from country to country.
- The main obstacle, with this kind of machines, is usually given by their overall dimensions rather
than their weight. In any case, this must be verified for each single loading.
- Trying to meet the limitations listed in the a.m. points, the general rule is that of disassembling
the machine as least as possible with respect to its pre-assemblage at the manufacturers.
Once the machine has been disassembled into transportable parts, maximum care must be taken in
order to ensure that:
- The moving parts of machinery must be locked. Accessories and components supplied shall be
packed in crates and locked to the truck bed with pieces of wood and straps.
- Fragile parts, liable to be damaged during transportation, must be adequately protected against
accidental collision with other parts.
- Those machined parts that require particular care in order to maintain their proper functionality,
must be protected either with a film of grease or with any other adequate covering (i.e. pluri-ball,
polystyrene or similar).
Wooden crates and any other loose item that is part of the shipment, must be arranged in such a
manner so as not to represent any possible danger for the operators, during transportation and
unpacking stages.
The structure of the crates must be reinforced in the supporting areas and on the cover. Moreover,
special signs describing the handling instructions (grip areas, stacking support surface, weight, etc.)
must be affixed.
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CHAPTER 4
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and transport
Pos.
Description
Containment Ceiling for anti-crushing
Side walls with high thickness
Supporting frame
Rest area protected
Chains
Handhold
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Description
Floor-standing
Rest area protected
Belts
10
Handhold
and transport
CHAPTER 4
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If the machine is transported by sea or air, it will be packed in wooden crates. The inner parts of the
machine must be locked with wooden blocks attached to the crate bed with special nails or cap
screws.
The lifting points (chains, ropes or forks) are indicated on the wooden crate.
Externally to the housing or on the crate there is a cardboard label showing the destination data:
name, address, number of packages/crates, total weight, identification number of the packaging/crate.
For sea transport must take into account the type of container. The parts that are not painted are
protected against corrosion.
EN
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4.3
CHAPTER 4
Pag. 58 ( 12 )
and transport
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UNPACKING
NOTE
UPON ARRIVAL CHECK (VISUALLY WITH THE CARRIER) THE INTEGRITY OF THE PACKAGING
AND REPORT ANY ANOMALIES FOUND TO A SUPERVISOR.
ANY DAMAGE TO THE CONTAINING CRATE COULD, IN FACT, RAISE DOUBTS ON THE
INTEGRITY OF ITS CONTENT.
ANY DAMAGES OCCURRED DURING THE UNLOADING STAGE INSIDE THE INSTALLATION SITE,
ARE NOT COVERED BY WARRANTY.
CAUTION
DISPOSE OF WASTE PACKAGING IN ACCORDANCE WITH THE LAWS OF THE
COUNTRY OF INSTALLATION OF THE MACHINE.
Remove all guarding devices used to protect the machine during transportation, making sure not to
damage the machine itself.
Remove all clamping devices and guards used for transportation.
Thoroughly clean all those machine parts that might have been soiled during transportation and
handling.
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4.4
and transport
CHAPTER 4
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HANDLING
4.4.1 UNLOADING OF THE GOODS FROM THE TRANSPORT
NOTE
THE CUSTOMER MUST PERFORM THE UNLOADING OF GOODS FROM TRANSPORTS.
FOR THE MOVEMENT OF THE CRATES, IT NEEDS TO USE APPROPRIATE EQUIPMENT, IN

RELATION TO THE SIZE AND WEIGHT OF EACH OF THEM.
THE INFORMATION CAN BE FOUND IN THE "PACKING LIST" WHICH IS COMPILED BY OUR
SHIPPING DEPARTMENT AT THE TIME OF PACKING. THE "PACKING LIST" IS COMPRISED OF
MULTIPLE DOCUMENTS, ONE FOR EACH CRATE. ON THE CRATE THERE IS THE "PACKING
LIST" REFERS TO THAT CASE.
The operations must be carried out taking into account:

- type of crating
- weight of the load to be lifted
- barycentre of the load
- lifting and transport methods (overhead travelling crane, forklift, etc.)
The materials must be stored in closed areas, protected against adverse weather conditions, and on
tiled surfaces. The crates cannot be superposed.
EN
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4.4.2 LIFTING THE MACHINE GROUPS
NOTE
ON EACH GROUP PACKED, READY TO BE MOVED, HAS BEEN REPORTED A SHEET WITH
WEIGHT OF THE GROUP AND IMAGE OF HOW IT SHOULD BE HANDLED. THE SHEET LISTS
INFORMATION TO FACILITATE THE PROPER POSITIONING OF HOOKS AND LIFTING BELTS.
ONCE YOU OPEN THE PACKAGING, THE HANDLING OF GROUPS OF THE MACHINE FOR THE
INSTALLATION AND ASSEMBLY OF THE MACHINE ITSELF REQUIRE THE SUPERVISION OF
A.CELLI NONWOVENS S.P.A. TECHNICIANS. IT IS THE USER'S DUTY TO TAKE CARE THAT THE
PRODUCTS ARE HANDLED CAREFULLY, USING SUITABLE LIFTING DEVICES IN ORDER TO
PRESERVE THE ORIGINAL TERMS OF QUALITY.
WARNING
THE CENTER OF GRAVITY OF THE GROUP OR OF THE MACHINE DEPENDS
ON THE POSITION OF THE MOVING PARTS.
DURING THE PHASES OF THE MACHINE OR PACKAGE HANDLING, RESPECT

THE POSITION OF THE FORKS OF THE FORKLIFT OR LIFTING BELTS.
DURING THE USE OF A FORK LIFT, RESPECT THE SPEED AND SLOPE
ALLOWED.
CAREFULLY SLING ALL THE COMPONENTS THAT MUST BE MOVED,

AVOIDING ANY SUDDEN MOVEMENT OR SWINGING.
If you are using a crane, mount on the machine the "U" hooks to attach the lifting belts.
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4.4.3 HANDLING OF ADDITIONAL EQUIPMENT

All the accessories and small components can be moved by hand and placed on the side of the crate
or truck.
EN
CAUTION
THE PIECES THAT EXCEED 25 KG (15 KG FOR WOMEN) SHOULD BE LIFTED
BY AT LEAST 2 OPERATORS.
4.5
STORAGE AND PRESERVATION
CAUTION
THE MATERIALS MUST BE STORED IN CLOSED AREAS, PROTECTED
AGAINST ADVERSE WEATHER CONDITIONS, AND ON TILED SURFACES.
THE CRATES CANNOT BE SUPERPOSED.
NO STORING IN AN OPEN PLACE.
IN THE CASE OF STACKING OF COMPONENTS LOCKED TOGETHER BY

STRAPS OR CABLES.
The packed machine must be stored in environments protected from weather and sun.
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The storage time should be reduced to the essential; for machines protected by a "vacuumed"
wrapping the storage time is 12 months, while those protected only with a plastic sheet the time must
be minimized (EEC or neighbouring countries). In case of long-term storage, periodically check the
conditions of all the machine components.
For more information on delivery times and storage requirements, please contact the assistance
service.
The manufacturer does not guarantee the integrity of the content for times greater than those
recommended.
NOTE
THOSE PARTS THAT HAVE BEEN DAMAGED AS A CONSEQUENCE OF CARELESS STORAGE,
ARE NOT COVERED BY WARRANTY.
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CHAPTER 5
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EN
CHAPTER 5.
INSTALLATION
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5.1
CHAPTER 5
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SAFETY WARNINGS
NOTE
PAG. 101".
DANGER
DURING THE MACHINE HANDLING AND INSTALLATION IT IS FORBIDDEN TO
APPROACH THE WORK AREA.
IT IS FORBIDDEN TO CARRY OUT HANDLING OPERATIONS FOR

INSTALLATION WITHOUT THE SUPERVISION OF A TECHNICIAN OF A.CELLI
NONWOVENS S.P.A..
THE STEPS TO BE TAKEN DURING HANDLING AND INSTALLATION MUST BE

COORDINATED BY A.CELLI NONWOVENS S.P.A. TECHNICIAN WHO GIVES
ORDERS TO OTHER TECHNICIANS.
CAUTION
IT IS FORBIDDEN TO CARRY OUT INSTALLATIONS IN ENVIRONMENTS
HAVING DIFFERENT CONDITIONS FROM THE ONE INDICATED IN THE
PARAGRAPH "ENVIRONMENTAL OPERATING CONDITIONS A PAG. 45".
EN
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5.2
PREPARATION OF FOUNDATIONS
Useful information on the distribution of the dynamic loads and the position of the machine fixing
points can be found in this drawing.
The machine is fixed onto the floor using either mechanical or chemical anchor bolts.
References drawing:
p9705p_R02.pdf
NOTE
FOUNDATIONS MUST BE PREPARED BY THE CUSTOMER BASED ON THE REFERENCE
DRAWING SENT BY A.CELLI NONWOVENS S.P.A..
THE FLOOR WHERE THE MACHINE WILL BE INSTALLED MUST NOT SUFFER FROM ANY
VIBRATION CAUSED BY OTHER MACHINES.
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5.3
CHAPTER 5
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MACHINE POSITIONING
NOTE
THE KNOWLEDGE OF WHAT IS CONTAINED IN CHAPTER 4 "CHAP 4 HANDLING AND
TRANSPORT A PAG. 51".
ONCE YOU OPEN THE PACKAGING, THE HANDLING OF GROUPS OF THE MACHINE FOR THE
INSTALLATION AND ASSEMBLY OF THE MACHINE ITSELF REQUIRE THE SUPERVISION OF
A.CELLI NONWOVENS S.P.A. TECHNICIANS. IT IS THE USER'S DUTY TO TAKE CARE THAT THE
PRODUCTS ARE HANDLED CAREFULLY, USING SUITABLE LIFTING DEVICES IN ORDER TO
PRESERVE THE ORIGINAL TERMS OF QUALITY.
THE FIXING PROCEDURE MUST BE CARRIED OUT BY A.CELLI NONWOVENS S.P.A.

TECHNICIANS.
DEFINE THE MACHINE CENTRE LINE, TRACING IT ON THE FLOOR WHERE THE MACHINE WILL
BE PLACED.
CAUTION
FAILURE TO COMPLY WITH THE INSTRUCTIONS WILL RESULT IN THE
TERMINATION OF THE GUARANTEE AND/OR THE PAYMENT OF THE COST
NECESSARY TO RESTORE THE COMPLYING CONDITIONS.
LEAVE ENOUGH SPACE FOR ESCAPE ROUTES DURING MAINTENANCE

WITH ELECTRICAL PANEL OPEN.
NOTE
EN
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LEAVE AT LEAST 50 CM OF SPACE BETWEEN THE EXHAUST VENT AND THE WALLS FOR AIR
CIRCULATION IN THE CABINET.
OBSERVE THE POSITIONING OF THE MACHINE ACCORDING TO THE LAYOUT PROVIDED. AT

THE TIME OF DESIGN PRECAUTIONS WERE TAKEN FOR THE OPERATOR TO HAVE THE
NECESSARY SPACE FOR THE FREE MOVEMENT AROUND THE MACHINE IN SAFETY, DURING
THE PHASES OF MAINTENANCE AND CONTROL OF THE LINE.
The conditions of the floor shall be suitable as to ensure sufficient strength to support the weight of
the machine and accessories.
Before positioning the machine it is necessary and essential to check the conditions of the floor where
the machine will be positioned.
The support structure must not deform compromising the strength and safety of the machine itself.
The machine must be perfectly vertical and level.
Where the floor conditions are not in accordance with what required, it is absolutely necessary to
make appropriate adaptation and/or recovery actions (e.g., laying of specific foundations and/or use
of specific platforms which may be provided by manufacturer of the machine).
5.3.1 ANCHORAGE PROCEDURE USING MECHANICAL FOUNDATION BOLTS

Drill the holes where the bolts will be anchored, according to the dimensions specified in the reference
drawing.
Place the foundation plates with their pre-installed bolts onto the floor. Do not tighten the bolts. When
doing this, always refer to the centre line mentioned in the previous point.
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Foundation plates must be levelled with a spirit level (0,05 mm on 1m length) by loosening or
tightening the adjusting screws provided with the plates and by interposing a metal thickness between
the final part of the screw and the floor.
Fill the holes with cement, in order to block the foundation screws into the floor. Tighten the screw
nuts, following the indications on the drying times of the mortar.
EN
NOTE
TYPE OF CEMENT TO BE USED: RCK = 25 N/MM
Once the plates have been fixed onto the floor, make sure once again that the alignment and the
levelling have not undergone any shifting. If so, acceptable conditions can be reset by means of
adjusting screws.
Fill the interstices between the floor and the foundation plates with self-levelling cement, leaving a 50
mm thick kerbstone all around.
Once the mortar has dried up, the tie nuts can be fastened thus completing the fixing stage.
Clean the support bases of the machine from any cement leftovers.
Take all the machine sections to the installation place and place them carefully onto the foundation
plates.
5.3.2 ANCHORAGE PROCEDURE BY CHEMICAL BOLTS

Drill a hole with the diameter and depth according to the following table.
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bolt
M12
M16
M20
M24
Tension Load (kN) (*)
6,5
9,8
14,5
18
hole (mm)
14
18
22
28
Depth (mm)
100
125
170
220
Torque max. (Nm)
40
80
150
200
Quantity of resin (ml)
8,5 - 10
16,5 - 19
30 - 34
60 - 66
(*) With reference to a.m. tension loads, an adequate coefficient of safety must be applied to the
material where the anchorage is carried out.
Remove dust and any other remains from the hole.
Fill the hole with resin (use a resin gun) - starting from the base and gradually moving up.
Minimum cartridge temperature: +5C.
Insert the screwed bar, making it rotate by impulses. A small overflow of resin proves that the hole
has been properly filled.
NOTE
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DO NOT STRESS THE ANCHORAGE DURING HARDENING.
Before putting the anchorage in traction, wait for the prescribed time
Usage Time allowed
Floor temperature
Open Time allowed (min)
+5C
20
150
+10 C
12
90
+20 C
50
+25 C
45
+30 C
40
(min)
CAUTION
READ THE MATERIAL SAFETY DATA SHEET OF THE CHEMICAL USED.
ORGANIZE ANY ACTION TO PREVENT AND / OR REMEDY IN THE EVENT OF
ACCIDENTAL CONTACT.
NOCIVO - HARMFUL - MINDERGIFTIG - NOCIF

FOR PROPER INSTALLATION OF ANCHORS FOLLOW THE INSTRUCTIONS OF
THE MANUFACTURER OF THE PLUG.
5.4
REMOVING BLOCKS
To ensure a safe transport of the machine, have been installed mechanical blocks on the groups of
the machine. It is the responsibility of the A.Celli Nonwovens s.p.a. Technicians remove them.
5.5
COMPLETION OF THE ASSEMBLY
The technicians of A.Celli Nonwovens s.p.a. ensure the :
EN
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- Completion of the installation.

-
Testing and Connecting the machine to the energy sources.
Testing & Commissioning of the machine.
5.6
CONNECTION TO POWER SUPPLY
The wiring and connections of which is responsible for the company A.Celli Nonwovens s.p.a. are
designed, constructed and installed in accordance with the European standards EN 60204-1.
- Each connection is treated as a single circuit and connected to one of the Earth points.
Example of single circuit
- The power equipment is separated or shielded from the control equipment.

- All terminals for the incoming supply connection are clearly identified (see the electrical
diagrams and the cables list).
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EN
Example of terminals
Example of relays
- Main disconnecting switch devices, for the prevention of unexpected start-ups, are provided.
They are suitably placed and readily identifiable.
Example of main switch
- All live parts (electric cables, electronic cards, etc.) are located inside enclosures with the
minimum degree of protection against direct contact.
- All live parts are completely covered with insulation, which can only be removed by destruction.
Such insulation can withstand the mechanical, chemical, electrical and thermal stresses, to
which it can be subjected under normal service conditions
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Example of cables with shield
- All live parts are disconnected inside the enclosures, which before being opened, disconnect
the inner circuit, except the PELV circuits (Protective Extra Low Voltage - at low voltage <24V,
<60V) that are always under tension.
- All conductors (power / control circuits) except earth neutral conductors and the transformers
are protected against over current by protective devices suitably chosen.
- An overload protection of motors is provided.
- All parts of the protective bonding circuit have been designed so that they are capable of
withstanding the highest thermal and mechanical stresses that can be caused by an earth-fault
of those parts.
- All exposed conductive parts of the electric equipment and the machine are connected to the
protective bonding circuit.
- All the machine parts that can cause a hazardous condition, when actuated at the same time,
are interlocked against wrong manoeuvres.
- For emergency stop functions and all other safety-related stop functions the use of hardwired
electromechanical components has been preferred, or, as alternative, by Safety PLC.
- Terminals on terminal blocks are clearly identified and correspond with markings on the
diagrams. Conductors are identifiable at each termination in accordance with the technical
documentation.
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- All parts have been placed and oriented in order that they can be identified without moving
them.
- Insulated conductors and cables have self-extinguishing properties.
- All wirings are secured against accidental loosening.
- Conductors and their connection, external to the electric equipment enclosures - boxes,
cabinets or panels - are positioned in suitable ducts.
- Wiring of frequently moving parts are made with conductors suitable for flexing service. Cables
subjected to movement, are supported in such a way that there is not any damaging.
- Required measures have been taken to minimise the probability of hazards, in the case that
failures or disturbances in the electrical equipment can cause dangerous condition for the
operator, the machine or the work in progress.
- Control circuits with different principles of operation or differing types of devices have been
adopted in order to reduce the probability of faults giving rise to hazards.
- All control devices mounted on the machine, on the control desk and on the control boxes are
readily accessible for service and maintenance.
- Push buttons and indicator lights are colour-coded in accordance with the European standards
EN 60204-1.
- The man-machine interfaces are clearly and durably marked, in consideration of their
functions.
5.6.1 ELECTRICAL AND PNEUMATIC DUCTS

According to the arrangement of the various components to create channels suitable for containing
the electrical connections and possibly also the pneumatic connections referring to the wiring and
pneumatic diagram provided attached with the instruction manual.
WARNING
MAKE SURE THAT THE CABLES AND PIPES ARE WELL SPREAD ON THE
FLOOR: CHECK THAT THERE ARE NO CHOKING OR PINCHING OF THE
PIPES.
MAKE SURE THAT THE CABLES AND PIPES ARE NOT CRUSHED OR
PINCHED BY SHARP OBJECTS.
EN
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ALL PIPES MUST BE POSITIONED AND/OR LOCKED IN ORDER TO AVOID

THE WHIP EFFECT IN CASE THEY ARE BROKEN.
PLACE ALL CABLES AND PIPES IN THE DEDICATED DUCTS.
NOTE
THE DUCT LINES SHOULD BE MADE IN FULL COMPLIANCE WITH THE REGULATIONS IN THE
COUNTRY OF INSTALLATION OF THE MACHINE.
5.6.2 ELECTRIC POWER SUPPLY CONNECTION

- No-Stop Unwinder - wiring diagram number:
2014039
No-Stop Unwinder electrical connection:
400V/50Hz
The general electrical cabinets of the system are identified with the following labels:
For the electric connection of the machine, refer to the electric diagram and to the drawing of the
operator positions.
The wiring diagram of reference for the NW Unwinder is :
2014039_GB.pdf
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- No-Stop Unwinder - wiring diagram number:

2014040
No-Stop Unwinder electrical connection:
400V/50Hz
EN
operator positions.
The wiring diagram of reference for the PE Unwinder is :
2014040_GB.pdf
Winder Wiring diagram number:

2014041
Winder electrical connection:
400V/50Hz
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operator positions.
Winder Wiring diagram:
2014041_GB.pdf
Extractor - Wiring diagram number:

2014042
Extractor electrical connection:
400V/50Hz
operator positions.
Extractor Wiring diagram :
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Pag. 79 ( 36 )
Version: 1.0
2014042_GB.pdf
Operator position drawing :

PO2014039-40-41-42.pdf
EN
WARNING
TO PERFORM ELECTRICAL OPERATIONS, IT IS RECOMMENDED TO AVAIL
OF A TRAINED AND SKILLED OPERATOR, OR SOMEONE TRAINED AND
INSTRUCTED BY THE SKILLED OPERATOR :
OR
BE SURE TO MAKE THE CORRECT CONNECTION TO THE THREE-PHASE

WITH GROUNDED NEUTRAL INDUSTRIAL MAINS.
BEFORE TAKING THE LINE CABLES TO THE ELECTRICAL PANEL OF THE

MACHINE MAKE SURE THAT VOLTAGE HAS BEEN REMOVED FROM THE
LINE.
THE POWER LINE MUST BE MADE IN ACCORDANCE WITH THE LAWS OF

ELECTRICAL ENGINEERING AND WITH THE STANDARDS IN FORCE IN THE
COUNTRY OF INSTALLATION.
PROTECT THE POWER SUPPLY LINE AGAINST OVERVOLTAGE.
PROTECT THE LINE AGAINST OVERCURRENT WITH DEVICES PROPERLY

COORDINATED AND LIMITING SHORT CIRCUIT CURRENT.
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THE POWER LINE MUST BE FITTED WITH A GROUND WIRE TO BE

CONNECTED TO THE TERMINAL WITH THE SYMBOL PE. THIS CONNECTION
SHOULD BE AS SHORT AS POSSIBLE.
VERIFY THAT IN THE FEED POINT AT WHICH THE MACHINE MUST BE

CONNECTED THERE IS AVAILABILITY OF ELECTRICAL POWER THAN IS
GREATER OR AT LEAST ENOUGH WITH RESPECT TO THE MAXIMUM POWER
ABSORBED BY THE MACHINE (SEE TECHNICAL DATA A PAG. 37 ).
MAKE SURE THAT GROUNDING CONDUCTORS ARE NOT SUBJECTED TO

MECHANICAL STRESS, OR SUBJECT TO RISK OF CORROSION.
NOTE
FOLLOW THE INSTRUCTIONS CONTAINED IN THE WIRING DIAGRAM.
5.6.3 PNEUMATIC CONNECTION

No-stop Unwinder pneumatic diagram number:
2014039
No-Stop Unwinder pressure air supply : 6 bar
Connecting air supply No-Stop Unwinder: 2"
For pneumatic connection of the machine, refer to the pneumatic diagram and to the drawing of the
operator positions.
The pneumatic diagram of reference for the NW Unwinder is :

2014039_PD.pdf
No-stop Unwinder pneumatic diagram number:

2014040
No-Stop Unwinder pressure air supply : 6 bar
Connecting air supply No-Stop Unwinder: 2"
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operator positions.
The pneumatic diagram of reference for the PE Unwinder is :

2014040_PD.pdf
EN
Winder pneumatic diagram number:
2014041
Winder pressure air supply : 7 bar
Connecting air supply Winder: 2"
operator positions.
Winder pneumatic diagram:

2014041_PD.pdf
Extractor pneumatic diagram number:

2014042
Extractor pressure air supply : 7 bar
Connecting air supply Extractor : 2"
Extractor pneumatic diagram:
2014042_PD.pdf

PO2014039-40-41-42.pdf
5.6.4 HYDRAULIC CONNECTION

For hydraulic connection of the machine, refer to the hydraulic diagram and to the drawing of the
operator positions.
The hydraulic diagram of reference for the winder is:
2014041-S.pdf
2014041-L.pdf
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PO2014039-40-41-42.pdf
CAUTION
IF AN OIL LEAK IS NOTICED, IMMEDIATELY REPAIR IT BEFORE TURNING ON
THE MACHINE.
5.6.4.1
BASIS
A rational assembly and correct installation are essential factors for correct operation by an oilhydraulic system over time. The following notes give some general suggestions and warnings.
5.6.4.2
GENERAL WARNINGS
The reliability of any machine or oil-hydraulic plant is a function of its quality, the state of the
transmission fluid, and the absence of impurities in the circuit. Do not forget that the fluid lubricates
the system components.
It is therefore important to foresee:
- during the design state: continuous oil filters, sized according to the class and type of system
and the required performance. Filtering must be at least 60 (see: the function of filtering).
- during the assembly stage: the main connection operations must be carried out in a clean, nondusty environment, immediately removing waste of any kind that could enter the circuit. The
pumps and all oil-hydraulic devices are always delivered with the openings closed by protective
caps, which should only be removed at the time of connection. With the device mounted, it is
always a good idea to ad a bit of hydraulic oil to ensure protection of internal parts until the
hydraulic system is filled. Pickle the pipes and clean the system.
- during operation: careful filter maintenance, cleaning and/or replacing the cartridges frequently.
5.6.4.3
PIPES AND FITTINGS
Cold-drawn steel pipes without welding seams must be used in oil-hydraulic systems, in compliance
with international standards.
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Fittings should be selected based on the features of the system, and especially the running pressure
and pipe diameter.
The following are normally used:
- up to DN 40, 3-part fittings with cutting ring (for lowstress systems and with no vibration).
- up to DN 40, 3-part fittings with welded spigot and tapered seal with O-ring (in heavy-duty
systems and for the most severe use).
- beyond DN 40, flange connections.
The pipe diameter must be chosen in relation to the maximum oil capacity in each section of the
circuit, which may be considerably higher than the pump capacity, and the following maximum speeds
must not be exceeded :
- 1 - 1.5 m/s in intake pipelines.
- 1.5 - 4 m/s in pipelines returning to the tank.
- 4 - 8 m/s in delivery pipelines.
Depending on the running pressure (the minimum speeds must be observed in low-pressure systems
to limit load losses, and higher speeds are admissible in high-pressure systems) and according to the
type of system (high speeds, for example, are admissible in mobile machines or for jog operation,
while low speeds are recommended in continuously-running operating machines).
It is especially important the intake pipes and those returning to the tank be oversized. The intake
pipe must be as short and straight as possible, avoiding sharp bends, throttles and narrowing that
could easily interfere with correct operation of the pumps. The pipes must be pickled, passivated and
then washed with oil. Pickling is necessary to eliminate rust and crusting and especially welding
shreds, etc.
It is normally permitted to use solutions based on "Betona" or similar salts as the pickling fluid.
In this case, passivation and washing are no longer necessary.
Pickling may be avoided when the welds are performed in an inert atmosphere, or are pocket-type. In
any case, the pipelines must be cleaned thoroughly. During installation, the pipes must be
appropriately held in place by an adequate number of supports; for this purpose, plastic brackets are
universally adopted, normally made of polyamide or polypropylene.
It is recommended to establish the number of supports based on the following average anchoring
distances:
- 1500 mm for pipes under pressure.
- 3000 mm for low-pressure pipes (returns and drainage).
EN
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In connections between oil-hydraulic system, make sure that the pipes and devices can be easily
dismantled whenever necessary.
Thus provide fittings on the openings of the devices and in the pipe nodes, to allow any section of
pipeline to be rapidly removed. The pipes must not block access to the equipment, especially in points
containing adjustment hand wheels or setting or control devices.
For threaded connections, give preference to special Teflon bands, sold on the market under various
brand names.
When assembling flexible hoses, avoid those with a too-small radius and torsion stress (see figure
below): flexible hoses must be sized for pressures of twice the maximum running pressure, to take
into account the inevitable pressure jumps.
The drainage attachments of the oil-hydraulic motors and the various valves must be suitably fitted to
the tank to prevent oil leaks.
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EN
WRONG
RIGHT
Example of wrong and correct flexible pipes connection
5.6.4.4
OIL TANK
The oil tank must be sized in relation to:

- installed power;
- pump capacity;
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- amount of heat generated during operation;

- type of system and service;
- etc.
As a general rule, we suggest allowing for an oil capacity 2 - 4 times the pump capacity for prime
minute (according to the running pressure and application). For example, if the pump has a capacity
of 25 l/min., it is recommended to use a tank with a capacity between 50 and 100 liters. This rule is
suggested by considerations of heat dispersions of internal oil circulation within the circuit. In special
cases, it is necessary to reduce the size of the tank due to space limitations or other reasons; it may
be a good idea to include a forced-circulation cooling system in radiators or coolants. The use of
coolants (generally heat exchangers between the hot oil and the circulating water) is recommended in
circuits that develop a considerable level of heat, and always in continuous-operation systems with a
high installed power. It should be kept in mind that the oil temperature in the tanks should never
exceed the cautious limit of 50-60C, or no more than 60-70 C at the most, while the ideal running
range is considered to be between 40 and 50 C. Of course, the tank capacity must also take into
account the amount of oil that can be absorbed by the circuit during special operating stages.
In small systems, the pumps are normally located above or inside the oil tank. In systems with pumps
having a considerable capacity, or with pistons pumps for high pressures, it is best for the tank to be
placed above the pump so that intake always takes place downwards.
The shape of the tank is normally polygonal, with a ratio of between 1:1:1 and 1:2:3 among the
corners. However, it may be any shape, and in mobile machines and large plants it is often cylindrical.
It is important for the tank to always be built so as to allow easy accessibility for periodic cleaning.
The tanks must be thoroughly cleaned and painted internally using a paint resistant to hot oil.
The tank must be hermitically sealed, except for the air vent to allow air circulation (in oil level
movements), which must be protected by an appropriate air filter and prevent dust and impurities from
entering the tank.
The pipelines returning the oil from the circuit must extend inside the tank, with the end beneath the
minimum oil level, to avoid the formation of foam. Also make sure that the return flow of oil to the tank
does not disturb the suction of the pump: it is this recommended to space the two ends, and to not
aim the return jet toward the intake opening. In tanks of a certain capacity, internal membranes are
also used to separate the oil return area and the pump intake area, to impede the creation of a
whirlpool and to allow a certain degree of sedimentation, making it easier to decant solid, suspended
particles and any water that may be present.
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Place a drain on the bottom of the tank, in an appropriate position to spurge water deposits and empty
the tank for maintenance. To facilitate emptying, the bottom of the tank should be raised above the
ground, and tilted towards the drain if possible.
The oil tank must always allow the oil level to be checked, and bear an indication of the minimum and
maximum prescribed levels. The maximum level is in relation to possible oil leaks, and the minimum
level must ensure that no air can be taken in through the pump intake.
5.6.4.5
THE FUNCTION OF FILTERING
Among the main causes of breakdowns and problems in oil-hydraulic systems, we can point out:
blockage of equipment due to gripping or breakage of parts due to wear, and the ageing of the fluid
that transmits the hydraulic power, thus losing all of its chemical and physical properties.
It has by now been ascertained that the main cause of all of these problems is due to the presence of
particles and microparticles that continuously circulate in the fluid, and cause wear.
These microparticles, if left to circulate in the system, act as an abrasive mixture, scratching the
surfaces they come into contact with and dragging additional contaminants into the cycle. The
damage is the greater the more sophisticated the equipment installed.
The filter and, generally, the function of filtering is thus responsible for eliminating these particles and
microparticles to ensure maximum efficiency and the maximum life-span of an oil-hydraulic system.
The choice and number of filters is obviously based on the type of system and equipment to be
protected: generally speaking, even in modest-sized system the minimum acceptable filtering level is
not below 60 .
As far as the arrangement of the filters in the circuit is concerned, we may consider the following
possibilities :
- In standard industrial plants the minimum filtering accepted is not lower than 60 .
- In industrial plants with proportional valves it is necessary to contemplate a filtering degree of
10-20 .
- In circuits with servovalves it is necessary to contemplate a filtering degree of at least 5 .
Concerning their circuit position you have the following possibilities:
- intake mount (thus on the pump intake conduit);
- return mount (thus on the conduit returning to the tank);
- on-line mount (thus on the line under pressure, upstream from delicate equipment);
EN
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It is especially important for the filter to be easily accessible for periodic cleaning, which must be
prescribed to maintenance on a weekly basis. Use filters with visual and/or electrical clog indicators to
facilitate control.
5.6.4.6
PUMPS AND MOTORS
The various types of oil-hydraulic pumps and motors may require special assembly standards,
specified in the manufacturer's instructions (for example, certain types of pistons pumps must be fed
from above).
Some general rules, however, may be considered valid in most cases.
First of all, coupling to the firs motor must be done preferably using an elastic coupling. Should you
wish to use a different type of transmission, ask the manufacturer: few pumps allow axial or radial
loads. Observe the rotation direction of the pump (or motor) which is always indicated by an arrow on
the pump body.
Do not remove the pump for any reason: changes in the rotation direction or position of the openings
(when possible) must be made by the manufacturer (unless expressly authorized by the latter).
The intake conditions of all pumps are an especially important factors, and it is essential to facilitate
the flow of oil as much as possible, especially by using oversized pipes.
Some types of pumps and motors have drainage fitting: on their body, to drain internal oil leaks, which
must be connected appropriately to the tank.
5.6.4.7
VALVES AND DISTRIBUTORS
All oil-hydraulic pumps are volumetric pumps, and thus must normally be protected in delivery with a
maximum pressure valve, set to a value below the maximum value allowed for the pump. Unless the
pump is self-adjusting (resetting the capacity at a certain pressure), with adequate internal
protections.
Normally, at least one maximum pressure valve is therefore always present in any oil-hydraulic circuit,
in addition to any other valves to control the pressure, direction and flow.
When installing these devices, plan for the possibility of having to remove them or parts of the circuit
with the least trouble: this must be kept in mind not only in tracing the paths of the pipes and fittings,
but also in placing the individual devices inside the system, especially for those valves that require
easy access for setting.
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In all systems, the appropriate fittings must be allowed in suitable positions for the necessary
pressure gauges, thus not only on the main pump delivery but also in those sections of the circuit
where it may be best to control the pressure. Between the pressure gauge and the line, always
include a shut-off valve so that the pressure gauge may be cut out when a reading is not necessary:
this serves to extend the life of the gauge itself.
It is also generally a good idea to include shut-off valves to isolate valves, groups or actuators, to
facilitate start-up and system maintenance.
5.6.4.8
HYDRAULIC OIL
In oleohydraulic circuits oil is the means transmitting power and at the same time lubricating the
equipments: for a good maintenance of the plant oil must be of good quality, with a high viscosity
index and with antifoaming and antioxidant addition agents, in compliance with the international
classifications (i.e. API MS, VDMA 24818, DIN 51524 and 515251). In particular, we suggest the use
of mineral oils of the group H -LP according to DIN 51525 (part 2), but the most common and used
standard (in Europe) is ISO VG.
Oil viscosity must be chosen according to the kind of oleohydraulic pumps and motors used and in
compliance with the working temperature of the plant. It is therefore necessary to check the directions
given by the maker for pumps and motors.
In diagram here below we inserted the average viscosity/temperature curves for the commonly used
oils in three groups of different viscosity; in the chart below you can find the relative initials of the
various suppliers.
Generally, we can consider that the most part of modern oleohydraulic pumps and motors works at its
best when using oil with a viscosity ranging from 35-40 cSt at 50C. Since the average working
temperature of hydraulic circuits is about 50C, the most used oil corresponds to curve "C" of chart
below that shows the kind of oil/supplier (that is with a viscosity of 35-43 cSt at 50C).
Of course, it being understood the direction of 40 cSt at 50C, if the working temperature should result
higher than 50-55C, it will be necessary to use an oil with a different viscosity, that will be suggested
by the fluid suppliers themselves. If there should be working conditions with a lower temperature, it
will be convenient to use the oils shown by curves "B" or A, according to the real working
temperature.
Therefore you can also use less (10-15 cSt at 50C) or more viscous fluids (until 58-72 cSt at 50C),
keeping in mind that we generally use less viscous fluids for low pressures (to limit load loss) and
more viscous fluids for high pressures (to reduce inner blows-by).
EN
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Remember that the use of too viscous fluids can cause difficulties in the starting-up at room
temperature because the most part of the oleodynamic pumps do not work regularly at normal speeds
with a higher viscosity than 290-365 cSt.
Diagram Viscosity/Temperature
Line
DIN 51524-2
H - LP 32
H - LP 46
H - LP 68
Viscosity cSt at 50C
16 20
24 28
31 39
AGIP
OSO 32
OSO 46
OSO 68
IP
Hydrus 32
Hydrus 46
Hydrus 68
BP
Energol HLP 32
Energol HLP 46
Energol HLP 68
CASTROL
Hyspin AWS 32
Hyspin AWS 46
Hyspin AWS 68
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Line
ESSO
Nuto H 32
Nuto H 46
Nuto H 68
MOBIL
DTE 24
DTE 25
DTE 26
SHELL
Tellus 32
Tellus 46
Tellus 68
CHEVRON
EP Hydraulic Oil 32
EP Hydraulic Oil 46
EP Hydraulic Oil 68
EN
These guidelines are purely indicative, thus in special operating conditions we suggest you contact
our technical department and the oil manufacturer.
Of course, different oils must be used in special running conditions; for example, there are special oils
for outdoor plants running at very low temperatures, especially where a progressive start-up is not
allowed, but the system must be ready to run promptly at any time (for example in cable-car systems),
as well as when inflammable oils are required, etc.
Special attention must be paid to the running temperature, which acts as a catalyst for pollution and
chemical-physical degradation. In particular, the temperature encourages the formation of oxygenated
compounds such as aldehydes, chetones, acids and water (which may be indicated as the products
of hydrocarbon degradation). The oxidation speed may be considered more or less constant up to a
temperature of 60 C, and doubles from this point on at each oil temperature increase of 10 C:
- the production of these oxides forms sludge and sediments in the oil.
- a strong catalytic action is provided by copper, thus where possible it is best to avoid using this
metal.
The running temperature must therefore normally be kept between 40 and 50 C, and it is best for it
not be exceed 60 C; in no case should it ever exceed 70 C, since this temperature may cause
damage to seals. It is also necessary to keep in mind that a new mineral oil, as recommended by the
oil companies, always contains a certain number of pollutant particles,; this pollution is due to the
handling of the fluid during shipping and packing.
Only in special cases is it possible to find fluids with a high purity level, for example those responding
to the specification MIL-H-58068. Before adding oil to the circuit, the user must carefully clean the
fluid; in any case, we recommend filling the tank using mobile filtering units.
The oil should be changed regularly every 4'000 hours.
However, it is recommended to submit oil samples to analysis to check the integrity of its chemicalphysical properties, as the above duration in purely indicative and depends not only on the system
characteristics and the service but also on climate conditions and the accuracy of filtering and
maintenance.
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An top-ups of the oil must be made using oil of the same brand, to avoid various functional problems.
5.6.4.9
FIRE-RESISTANT FLUIDS
Mineral oils have fairly low flame and spontaneous combustion temperatures; many once lit, continue
to burn and expand the flame, thus extending the danger zone.
Thus where fluid leaks may help to create a fire hazard, special products are used that are more
resistant to fire, and which are improperly defined as "inflammable fluids".
Below are just a few suggestions about using the two most widely-used categories:
- Fluids based on phosphorous esters.
- Water-glycol solutions.
We recommend that you consult a qualified manufacturer for the various applications.
Fluids based on phosphorous esters are:
- highly resistant to combustion with low flame propagation;
- good lubricating power;
- fair rust-proof characteristics;
- a limited viscosity index;
- high specific weight;
- incompatible with rubber and paint.
Among their disadvantages are their toxicity and high pollution rate.
Thus when using these fluids, hydraulic systems must adopt special precautions:
- use of flexible hoses and seals made of suitable elastomers (especially Viton, or P.T.F.E., or
even butile within certain limits);
- no use of paint inside the tank or on any surfaces that might come into contact with the fluid
(except in very special cases and after contacting specialized manufacturers);
- continuous and especially accurate filtering of the system, due to the high density of the fluid;
- appropriate sizing of components and pipelines, due to the higher kinetic viscosity.
Fluids based on phosphorous esters emit high running temperatures (even above 100 C), have an
excellent resistance to ageing and require no special maintenance beyond a periodic check of the
water content, which makes these fluids especially aggressive even in small percentages.
Fluids based on water-glycol are solutions with a water content of 40-50%, glycol or propylene glycol
and polyethylene glycols.
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Their resistance to combustion derives from their water content, and thus it is necessary to check the
mix composition periodically in order to top up the water as needed: their main disadvantage is a
relatively high alteration due to evaporation.
They have : a high viscosity index, a fair lubricating power, good anti-rust properties, are incompatible
with pains and high density, but only for elastomers.
EN
Thus when using these fluids, we recommend that you:
- check the compatibility with the seals, which is normally verified at least for the static seals in
the valves;
- use larger tanks (with volumes of 8-10 times the pump capacity);
- include an efficient thermostatic control of the fluid temperature, which should be kept around
40-50 C; avoid temperatures above 65 C.
- size the system for limited flow speeds (max. 3 m/sec.)
- reduce the pump rotation speed, which should not exceed 1'000 - 1'200 r.p.m. (we do not
advise the use of gear pumps)
- reduce the maximum running pressure, which should be limited to 100 - 120 bars.
Finally, cadmium-coated components should not be used.
5.6.4.10 CLEANING THE SYSTEM
In new systems it is impossible to completely eliminate contaminating substances, even by adopting
the precautions described above. It is therefore necessary to thoroughly clean a new system before
using it.
To prevent polluted oil from damaging the system components, a few precautions should be taken:
- by-pass the utilities, motors and cylinders, and control valve banks;
- fully open all taps and throttles mounted on the line;
- isolate buffers from the rest of the circuit;
- if possible, include two batteries of filters in cascade formation in the conduit returning to the
station, with a filtering power of 125 , 25 and 10 , respectively, so that filtering is in any
case lower than during operation.
The power station itself may be used to clean the system if the above precautions are taken.
For large or considerably important systems, however, a special flow station must be used, with
motor-driven pump units and an independent tank.
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The cleaning fluid must be selected from among high-quality mineral oils, in collaboration with a
qualified manufacturer, and must be compatible with the seals and running fluid because it is
generally possible that not all of the cleaning fluid will be removed from the system.
We recommend a flow speed in the pipes of 5-6 m/sec.
The flow should take place with the oil hot (approx. 40 C).
It is not possible to set a standard time; in any case, cleaning should not be done for less than 40-50
consecutive hours. The clog level of the filter cartridges should be checked, indicating the degree of
cleaning gradually reached by the system.
5.6.4.11 STARTING THE SYSTEM
When starting the motor-driven pump units, take the following precautions. These are essential in
order to immediately ensure the necessary lubrication of the internal parts:
- Make sure that any valves or gates on the intake and delivery side are open.
- Make sure that the pump is free to turn manually, without encountering excessive resistance,
and that the rotation direction of the motor coincides with that of the pump.
- Fill the pump body with the fluid used in the circuit through the drainage hole; if this is not
possible, through the delivery conduit.
- Vent the maximum pressure valve located on the delivery conduit. The pumps must normally be
started in a vacuum. In any case, contact the manufacturer to see if different instructions are
given.
- Start the electric jog motor to assist the engaging of the pump, indicated by a pressure gauge
that should be present in delivery and by the change in the noise of the pump, which becomes
quieter when engaged.
If possible, it is a good rule to have the pump run for a certain period of time at reduced speed, to
break in the system.
While filling the system, air must be purged, as pressure from air causes functioning problems and
speeds up wear.
To facilitate this operation, special air release valves may be placed on the pump delivery, or special
rapid-lock valves can be placed on the stations and special panels. The air closed within the pipelines
may be eliminated by loosening the fittings on the top side of the system and inserting purge taps; for
the cylinders, use the breather screws provided.
Air release is indicated by the appearance of foam: when a continuous, clear flow comes from the
fitting or breather, the air has been eliminated.
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Once the system has been filled and the air released, check the oil level in the tank and top up if
necessary, then put the system gradually under pressure. Set and fine-tune the adjustment valves.
It is best for this to be done at full running temperature.
The system may now be inspected.
Make sure that no foam forms in the tank: this indicated air infiltration in the pump intake (as long as
the return pipe to the tank remains immersed in oil, as indicated above).
When oils with a certain viscosity are used and the environmental temperature is very low, there could
be functioning problems and loud pump noise during start-up due to the high oil viscosity. In this case,
the oil should somehow be preheated before start-up (for example, using a heating element) or the
pump speed reduce: in small systems, you can also heat the oil by having the pump run for a certain
time in short circuit under average pressure before running the system.
After a few hours of operation, clean the filters, check the oil level in the tank again and carefully
check all fitting seals.
5.7
COMMISSIONING
DANGER
BEFORE CONNECTING THE MACHINE TO THE POWER SOURCE, CHECK
THAT THE MAIN SWITCH IS ON "OFF" OR ON "0".
WARNING
THE KEYS TO OPENING THE DOORS OF THE ELECTRICAL CABINET MUST
BE DELIVERED AND STORED BY THE PLANT MANAGER AND KEPT OUT OF
THE REACH OF THE OPERATORS.
EN
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CAUTION
BEFORE STARTING THE MACHINE, ALWAYS CHECK ALL CONNECTIONS
AND CHECK THE CONNECTIONS WITH THE PREVIOUS OR FOLLOWING
MACHINES.
The plant set-up, before starting, must include at least the following precautional tests :
- Check if the right lubricants come in the correct quantity and in the proper containers and if the
different points of the machine are correctly lubricated.
- Check all electrical connections, using the diagrams and the cable list.
- Check the correct positioning and the functioning of all sensors and all limit-switches
(mechanical and electrical); These controls must be executed manually under conditions of
maximum safety for the operator (when possible: have the machine working at slow speed or
impulse speed, min. conditions of pressure, etc.)
- Check the pneumatic and/or hydraulic connections to be sure that there are no leaks in the
plant.
After ensuring the previous checks had positive results, check the actual safety conditions, by
simulating a loadless automatic working cycle of the machine (without the product).
If the machine requires fine-tuning operations, these must be carried out by the technicians of A.Celli
Nonwovens s.p.a..
Operate on:
- Regulation and calibration of the pneumatic and/or hydraulic actuators, by means of the
pneumatic and/or hydraulic diagram
- Calibration of the electric motor drives, following the instruction books in appendix
- Check the efficiency and correct functioning of the sensors.
- Check the mechanical limit-switches and the potentiometers.
If the working conditions of the simulated cycle do not need any further changes , it is then possible to
start the motors and synchronise the speed of the different sections of the machine according to their
use.
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The operator can now start the operation of feeding the product through the machine, starting a first
production cycle. A gradual increase in the operating speed of the machine, starting from low values
(approx. 1/3 of the maximum performance) allows the operator to keep the various functions under
control in safe working conditions.
EN
NOTE
PLEASE, REFER TO THE LUBRICANTS LIST " LUBRICANT LIST A PAG. 278 "
After the checks and the subsequent fine-tuning the machine is ready to start the production cycle.
For the first switching on and for the checks to be carried out refer to "Chap 7 Use and Functioning
a pag. 121".
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Sections Title: Safety
CHAPTER 6
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EN
CHAPTER 6.
SAFETY
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6.1
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GENERAL SAFETY WARNINGS
DANGER
The machine must be used exclusively for the purpose for which it was designed.
Refer to this manual.
Before you start to work on the machine, the operator is required to follow a proper
training in order to familiarize himself with all aspects, technical and safety of the
machine. Refer to this manual.
It is forbidden to work on the machine with procedures, or operators or operators

with only qualifications other than those specified in this manual. Access to the
machine and the surrounding areas is allowed only to authorized and qualified
personnel who are fully aware of all the safety measures and techniques of the
machine.
Do not change the operating conditions of the machine without the prior written
consent of A.Celli Nonwovens s.p.a.. The interlocks are required for correct
operation of the machine and reduce the risks.
It is forbidden to disable or modify in any way the safety devices on the machine.
Penalty is the lapse of the guarantee.
In the event of failure of a safety component immediately contact Technical Service
to order the spare part.
In case of alarm, before to continue with normal operations it is necessary that the
causes of the alarm are identified and removed.
DANGER UNEXPECTED START.
EN
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The operator to run the machine can only execute the reset command from the operator panel to
restart the machine.
IT MUST NOT ENTER IN THE WORKING AREA OF THE MACHINE TO
ELIMINATE FAILURES OR MALFUNCTIONS. CALL THE MECHANICAL AND
ELECTRICAL MAINTENANCE TECHNICIANS.
It is forbidden to carry out the maintenance, cleaning, repair, inspection or

adjustment with the machine switched on or otherwise without first disconnected
and locked the machine. See " Procedure for Lockout and Tagout a pag. 249 ".
THE KEYS USED FOR THE EXCLUSION OF SAFETY DEVICES MUST NOT
REMAIN ON THE MACHINE BUT MUST BE MAINTAINED BY RESPONSIBLE
STAFF OF THE PLANT AND KEPT OUT OF REACH OF THE OPERATORS.
ATTENTION FOR CLOTHING OF ANYONE WHO WORKS ON THE MACHINE. IT

IS FORBIDDEN THE USE OF CLOTHES WITH HANDLES THAT CAN BE
ATTACHED TO THE MACHINE PARTS. IT IS FORBIDDEN THE USE OF TIES
AND OTHER LOOSE PIECES OF CLOTHING. IT IS FORBIDDEN TO CARRY
BULKY RINGS OR BRACELETS THAT CAN ENTANGLE HANDS TO MACHINE
PARTS.
DANGER - ELECTRICAL
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OR
HAZARD OF ELECTRIC SHOCK. NEVER THROW WATER OR LIQUID ON THE

ELECTRICAL PANEL OR ON THE CONTROL PANEL.
IN CASE OF FIRE, USE ONLY FIRE EXTINGUISHERS CO2. OTHER

EXTINGUISHERS COULD DO IRREPARABLE DAMAGES TO THE ELECTRICAL
COMPONENTS.
WARNING
IMMEDIATELY WIPE OFF ANY OIL LEAKS AROUND THE MACHINE, AS THEY
MAY REPRESENT A SERIOUS RISK OF AN ACCIDENT FOR THOSE WHO ARE
OPERATING AROUND. SEE "REMOVAL OF OILS AND LUBRICANTS A PAG.
298."
NOTE
BEFORE MAKING THE MACHINE FUNCTIONAL READ THE INSTRUCTIONS CONTAINED IN THIS
MANUAL AND CAREFULLY FOLLOW THE INDICATIONS INCLUDED IN IT.
THIS INFORMATION MUST BE SCRUPULOUSLY OBSERVED AND PRESERVED. IN CASE OF

SALE OF THE MACHINE TO THIRD PARTIES, IT MUST BE TRANSFERRED IN FULL AND
LEGIBLE.
THE MANUFACTURER DISCLAIMS ANY LIABILITY FOR DAMAGE TO PROPERTY OR PERSONS

OR TO THE MACHINE CAUSED BY METHODS OF TRANSPORT, HANDLING, INSTALLATION,
OPERATION AND MAINTENANCE OTHER THAN THOSE INDICATED IN THIS MANUAL.
EN
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6.2
CHAPTER 6
Pag. 104 ( 22 )
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SPACE REQUIRED FOR OPERATION AND MAINTENANCE
6.2.1 WORKING AREA OF THE MACHINE

The working area of the machine is identified by the perimeter delimited by fixed guards that surround
it. Access to the work area of the machine is restricted to trained personnel. Access to the work area
is possible only through the doors, which are interlocked with guard locking. For their position refer to
the drawing:
781M500022D.PDF
663G500022D.PDF
781P700022S.PDF
6.2.2 OPERATOR'S WORKING AREA
CAUTION
MUST LEAVE AT LEAST ONE METER BETWEEN THE MACHINE AND OTHER
LARGE ITEMS TO ENABLE THE OPERATOR TO SAFELY PERFORM
OPERATIONS, MAINTENANCE OR DISMANTLING OF THE COMPONENTS.
ACCESS TO THE INSIDE OF THE PROTECTIONS IS ONLY POSSIBLE UNDER

CERTAIN CONDITIONS OF MACHINE STATUS.
PO2014039-40-41-42.pdf
Area
Job
AREA (1)
Start-up and operation of the machine

Cleaning machine, Cabinet and push-button
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Area
CHAPTER 6
Pag. 105 ( 22 )
Version: 1.0
Job
Control of the working cycle
AREA (2)
Placement of the Master Roll on the Unwinder

Removing shaft of the finished Master Roll from the Unwinder
Handling the finished reel in output from Winder
Handling the Master Rolls awaiting processing
AREA (3)
Troubleshooting Alarms
Adjustments and restore of working conditions
Web thread up on Unwinders and Winder
Positioning of the knives for the production
AREA (4)
Ordinary maintenance
Extraordinary maintenance
AREA (5)
Control of the working cycle
AREA (1)
Machine is running
- Area outside of the fixed guards.

- Access to this area of work is allowed to Operators: people trained on the operation and
security of the machine.
AREA (2)
Machine is running
- Area inside of the fixed guards but external to the fixed guards of the individual machines.
- Access to this area of work is allowed to operators:
- People trained on the operation and security of the machine.
EN
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- Persons authorized to use lifting equipment and make lifting operations.

AREA (3)
Machine is running with safety doors opened.
- Area inside to the safety guards of the individual machines. The access to this area of work is
protected by a guard interlocked the opening of which disables only some functions.
- Access to this area of work is allowed only to electrical or mechanical maintenance engineers:
- Technicians trained on the operation and security systems of the machine.
- Skilled technicians or technicians trained by experts, able to recognize the dangers arising
from maintenance on electrical circuits or mechanical components.
- Technicians able to recognize, isolate and neutralize the sources of power direct and / or
accumulated.
AREA (4)
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- Area inside to the safety guards of the individual machines. The access to this area of work is
protected by a fixed guards and a guard interlocked the opening of which disables only some
functions. The access to this area of work is allowed after a "Lock-out - Tag-out" procedure.
- Access to this area of work is allowed only to electrical or mechanical maintenance engineers:
- Technicians trained on the operation and security systems of the machine.
- Skilled technicians or technicians trained by experts, able to recognize the dangers arising
from maintenance on electrical circuits or mechanical components.
- Technicians able to recognize, isolate and neutralize the sources of power direct and / or
accumulated.
AREA (5)
Machine is running
- Walkways and stairs.

- Access to this area of work, is allowed to Operators: technicians trained on the operation and
security systems of the machine.
6.3
LABELS APPLIED THE MACHINE
Some safety labels, that indicate the type of risk in that area, have been applied on the machine
where necessary. Their positions are shown below:
Safety sign
Meanings
Position on the Machine
Electrical Hazard
Electrical panel and junction boxes
You may not use water to extinguish fires
Electrical panel
Danger hot surface
Surfaces of electric motors
General Hazard
Area operator
EN
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Machine: name
Safety sign
Pag. 108 ( 22 )
Meanings
Version: 1.0
Position on the Machine

Transit area and load on Unwinder of the
Danger presence of suspended loads
Master Rolls, inside and outside of the

safety guards. Discharge area of the
reels from the Rewinder.
Area of contact between the Master Roll
Attention to the hands
and Unwinder. Area dedicated to the

extraction and introduction of cores.
Area within the fixed guards. The signal
No entry for unauthorized persons
is applied to the interlocked doors for

access to this area.
It is forbidden to carry out the

maintenance, cleaning, repair, inspection
or adjustment with the machine turned on
Area dedicated to web thread up on

Unwinder. Area inside the safety guards.
The signal is applied to the interlocked
doors for access to this area.
It is forbidden to turn off or change in any

way the safety components on the
machine. Penalty of forfeiture of the
Area inside the safety guards. The signal
guarantee. In the event of failure of a
is applied to the interlocked doors of
safety component immediately contact
access to that area and the fixed guards.
the technical service A.Celli Nonwovens

s.p.a. to order spare parts.
Sign risk
6.4
RESIDUAL RISKS
NOTE
RISK AREAS ARE INDICATED IN THE DRAWING:
PO2014039-40-41-42.pdf
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THE RISK TYPE IS IDENTIFIED BY WARNING SIGNS.
FOR RESIDUAL RISK IS DEFINED AS A POTENTIAL DANGER, IMPOSSIBLE TO ELIMINATE OR

PARTIALLY REMOVED, WHICH CAN CAUSE DAMAGE IF THE OPERATOR INTERVENES USING
METHODS AND WORK PRACTICES THAT ARE INCORRECT.
EN
FAILURE TO OBSERVE THE FOLLOWING SAFETY PRECAUTIONS MAY RESULT IN SERIOUS
PERSONAL INJURY AND DAMAGE TO PROPERTY!
DANGER
DANGER OF ENTANGLEMENT OR ENTRAPMENT.
This danger exists as the machine is made of fast rotating components. In order to limit the
consequent risks, appropriate mechanical safety guards have been planned. Their functionality must
always be protected and guaranteed.
Do not remove safety guards while the machine is running.
Do not operate on components in motion.
The residual risk of entrainment or entrapment can occur when the user accesses within the fixed
guards, including the shelters and the machine.
DURING OPERATION OF THE MACHINE CONSIDER EACH ALARM AND
OPERATE WITH THE UTMOST CARE.
DANGER - ELECTRICAL
The electrical equipment is functioning properly at an ambient temperature within +5 and +40 , with
a relative humidity between 30 and 95% (non-condensing).
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The electrical equipment is protected against solid objects and water. The pulpit of command, control
cabinet and control panels have a minimum protection class IP 43.
The motors, both in AC and DC, have a minimum protection class IP 23.
The machine has been built according to the instructions given by the European standards EN 60204
-1.
- In order to reduce all the electrical hazards must be strictly observe the following safety rules:
OR
THE ELECTRICAL TECHNICIANS SHOULD HAVE THE ELECTRICAL

REQUIREMENTS OF THE LAW IN FORCE IN THE COUNTRY OF
INSTALLATION OF THE MACHINE AND MUST HAVE READ THE WIRING
DIAGRAM AND THIS HANDBOOK.
MAINTENANCE AND ADJUSTMENT OPERATIONS WITH THE ELECTRICAL

PANEL OPEN ARE ALLOWED ONLY TO QUALIFIED ELECTRICAL
PERSONNEL, AFTER IDENTIFYING WITH CERTAINTY THE PARTS UNDER
VOLTAGE.
DO NOT TAMPER PROTECTION AGAINST DIRECT OR INDIRECT CONTACT

WITH PARTS UNDER TENSION, NOR GROUND EQUIPMENT.
THE CABINET CONTAINS HAZARDOUS LIVE ELECTRICAL COMPONENTS.

SHOULD IT BE NECESSARY TO CARRY OUT TESTS WITH THE ELECTRICAL
CABINET UNDER TENSION, THE FOLLOWING GUIDE LINES MUST BE
FOLLOWED :
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- Remove all jewellery (Rings, necklaces and bracelets).

- Take note of all instruments and working conditions.
- Wear suitable clothes and individual safety device.
- Wear insulating shoes.
- Make sure to stop any mechanical operation.
- When possible, work on an insulating basement.
BEFORE STARTING ANY OPERATION REQUIRING AN INTERLOCK DEVICE
OR ANY OTHER SAFETY DEVICE MADE INACTIVE, MAKE SURE THAT THE
ELECTRIC SECTIONING IS ALWAYS EFFECTIVE.
IF THE TYPE OF MAINTENANCE OR ADJUSTMENT DOES NOT ALLOW TO

DISCONNECT THE POWER SUPPLY IT IS RECOMMENDED TO IDENTIFY WITH
CERTAINTY THE ACTIVE PARTS OF THE MAINTENANCE AND ALL THE
POINTS OF POSSIBLE POWER SUPPLY.
REALIZE THE CONDITION OF DOUBLE INSOLATING PROTECTION AGAINST

LIVE PARTS ON WHICH OPERATING.
KEEP STRICTLY THE DISTANCE OF 15 CM BETWEEN THE LIVE PARTS OF

THE INTERVENTION AREA AND PARTS OF THE BODY NOT COVERED BY
INSULATION.
WARNING
SLIPPING AND FALLING HAZARD
EN
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Walkways and ladders are made with no-slip materials.
AREAS OF WALKWAYS TO ACCESS TO THE MACHINE,

WALKWAYS AND STAIRS. CLEAN REGULARLY AND KEEP
TIDY.
FRICTION OR ABRASION HAZARD
No accessible parts of the machine have any sharp edges, sharp angles, or rough surfaces likely to
cause injury. The remaining abrasion hazard can occur when the operator enter inside safety fences,
between guards and Machine.
IMPACT HAZARD
The danger of head impact exists for the operator entering the machine area to carry out maintenance
interventions, especially in the areas beneath the mechanical devices.
CUTTING HAZARD
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PARTICULAR ATTENTION MUST BE PAID BY THE

OPERATORS WORKING IN THE AREAS NEAR THE
CUTTING DEVICES OR NEAR SHARP EDGES. THESE
MAINTENANCE OPERATIONS HAVE TO BE CARRIED OUT
WHEN THE MACHINE IS NOT WORKING. DURING
MAINTENANCE OF THE KNIVES IS MANDATORY TO WEAR
GLOVES TO PROTECT YOUR HANDS. IF PRESENT, USE
THE SPECIAL EQUIPMENT FOR REMOVING AND HANDLING
THE KNIVES. SEE THE CHAPTER "CHAP 8 MAINTENANCE
A PAG. 243".
FIRE HAZARD
At least one fire extinguisher must be placed near the machine.
Check the good condition of the hydraulic plant. Hydraulic oil bursts into flames when it reaches the
temperature of about 200C.
Keep the machine and the surrounding area clean.
EN
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Welding or flame cutting operations must be authorized and performed under the control of the staff in
charge of the fire service.
All personnel must be thoroughly informed about the company emergency procedures in case of fire
and/or explosion, including evacuation plans and rules of prevention and protection against these
hazards.
High temperature, combined with dust, paper wastes and sparks can cause a fire.
CUTTING HAZARD. DURING MAINTENANCE OF THE KNIVES IS MANDATORY

TO WEAR GLOVES TO PROTECT YOUR HANDS. IF PRESENT, USE THE
SPECIAL EQUIPMENT FOR REMOVING AND HANDLING THE KNIVES.
DANGER FROM NOISE.
It is forbidden to stand near the machine without the protective equipment of hearing.
WARNING
THERMAL HAZARD.
High temperature on the outer surfaces of the electric motors. Wait until the cooling of the component
prior to performing maintenance.
DANGER OF CONTACT WITH OIL AT HIGH TEMPERATURES.
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Wait until the oil cooling before performing disassembly of the piping.
THE RESIDUAL RISK OF BURNS MAY OCCUR IN THE SPLICING AND CROSSCUTTING AREAS OF REWINDER.
EN
CAUTION
BIOLOGICAL HAZARD.
If dangerous chemical products are used to clean and wash encrusted areas, read the toxicology
cards beforehand.
Wear individual protective devices as indicated on the safety card.
DANGER DUSTS AND CHEMICALS
The cut of the product may result in the emission of dust into the surrounding environment. Do not
stay longer than is necessary in dusty areas.
Obligation to protect the airway.
HIGH PRESSURE FLUID EJECTION HAZARD.
The hydraulic system has been realized according to the regulations in force on the subject, above all
as far as piping and connections are concerned. Metal piping (electro-galvanized steel) have been
mostly used, for their high mechanical strength and in order to avoid any breaking risks due to
accidental collisions or abrasions. Only when it was strictly necessary, friction flexible pipes at high
resistance have been used.
The pneumatic system has been realized according to the standards in force.
DUST AND CHEMICAL AGENTS HAZARD.
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ACCORDING TO THE PRODUCT WORKED, DURING THE CUTTING PHASE OF

THE WEB MAY OCCUR EMISSIONS OF DUST INTO THE SURROUNDING
ENVIRONMENT. REFER TO THE DATA SHEET FOR THE PRODUCT WORKED.
IF HARMFUL DO NOT STAY LONGER THAN NECESSARY IN DUSTY AREAS.
Obligation to protect the airway.
6.5
DESCRIPTION OF SAFETY EQUIPMENTS
To ensure the safety of the machine there are several devices interfaced with:
- Software interlocks.
- Mechanical interlocks.
- Indicating special conditions.
- Preventing access to certain areas.
These devices are three different types :
- Safety devices.
- Functional safeties.
- Safety fixed and moveable guards.
To identify their position on the Machine, refer to drawings :
PO2014039-40-41-42.pdf
2014039.pdf
2014040.pdf
2014041.pdf
2014042.pdf
781M500022D.PDF
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CHAPTER 6
Pag. 117 ( 22 )
Version: 1.0
663G500022D.PDF
781P700022S.PDF
6.5.1 SAFETY EQUIPMENTS

In order to avoid any possible injuries due to wrong maneuvering, interlocking safety devices have
been installed.
- Main electrical disconnecting switch, manual and lockable.
- Main pneumatic disconnecting valve, manual and lockable.
- Emergency mushroom-shaped buttons.
- Safety unit to control the integrity of the emergency circuit.
Main Electrical disconnecting switch Main Pneumatic disconnecting valve Emergency push button
- Emergency stop with feet and/or hand control.

- Emergency stop trip wire switches.
- Audible warning device signaling various phases of the machine when operating.
- Audible warning device signaling emergency conditions.
- Visible warning device signaling various phases of the machine when operating.
- Visible warning device signaling emergency conditions.
IN ACCORDANCE WITH EN 13849-1, THE EMERGENCY CONTROL SYSTEM
ENSURES A PERFORMANCE LEVEL "D".
EN
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Emergency stop with feet and/or hand
Visible warning device for
Visible warning for
control
operating
emergency
- On hydraulic and pneumatic actuators that control dangerous movements are installed in closed
center solenoid valves or block valves to prevent an unexpected start-up in case of power
failure, as reported in the attached diagrams.
6.5.2 FUNCTIONAL SAFETY

On the machine can be installed the following control devices:
- Sensors for detecting the position of the movable parts.
- Reed Sensors.
- Photocells for web presence.
- Load cells for Reel presence.
- Interlocks on the doors of access to the workspace.
6.5.3 FIXED AND MOVABLE GUARDS

The machine is fenced with fixed guards. There are interlocked doors that allow entry only in the work
area with the machine stopped or running at low speed. Their openness involves the cutting of the
auxiliary energy.
On the Machine there are:
- Fixed guards on some moveable parts, removable only with the aid of tools.
- Bellows for protection against dust installed in the sliding guides.
- Repair wire mesh.
- Repair in Lexan.
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CHAPTER 6
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Version: 1.0
PROCEDURES TO BE FOLLOWED IN CASE OF ACCIDENT, BLOCK ,

DAMAGE OR FIRE
In case of injury , you should always :

- Stop the machine by pressing the closer emergency button.
- Close the isolating valve air inlet.
- Remove the person who has had an accident and make certain of his condition. In relation to
the severity of the accident to call the emergency personnel.
- If the person is entangled with the clothes in the machine parts cut clothes to free him.
- Inform respective authorities.
In the event of a machine block or as a result of any malfunction or failure, you should always :
- Turn off the machine by pressing the emergency button.
- Locate and remove the cause of the shutdown or malfunction.
- After restoring normal operative condition you can proceed to the normal restart.
In the event of a release of smoke or signs of fire anywhere on the machine, you should always :
- Turn off the machine by pressing the emergency button.
- Warn personnel to firefighting procedures.
- Proceed to extinguish fire using fire extinguishers only to CO2.
- Contact your technical support service.
EN
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Sections Title: Use
and Functioning
CHAPTER 7
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Version: 1.0
EN
CHAPTER 7.
USE AND FUNCTIONING
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Sections Title: Use
and Functioning
Version: 1.0
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7.1
Sections Title: Use
and Functioning
CHAPTER 7
Pag. 123 ( 122 )

Version: 1.0
SAFETY WARNINGS
NOTE
PAG. 101".
THE READING OF THIS CHAPTER ASSUMES, FOR THE PURPOSES OF THE SAFE USE OF THE
MACHINE, THE KNOWLEDGE OF WHAT IS CONTAINED IN THE SECTION "RESIDUAL RISKS A
PAG. 108".
BEFORE RUNNING THE MACHINE, CHECK THE PIPING AND PLUMBING.

VISUALLY CHECK THAT THERE ARE NO LEAKS IN THE SYSTEM THROUGH
THE READING OF GAUGES IN THEIR BOXES. CHECK THE ILLUMINATION OF
THE "AUXILIARY INSERTED" AND TEST LAMPS FROM THE MAIN
ELECTRICAL PANEL.
EVERY TIME THE MACHINE IS STARTED OR BEFORE STARTING THE WORK

CYCLE, CHECK THE EFFICIENCY OF THE SAFETY DEVICES.
DANGER
BEFORE STARTING THE MACHINE, CHECK THAT NO OPERATOR IS INSIDE
THE AREA FENCED BY FIXED GUARDS (WORKING AREA OF THE MACHINE).
WARNING
IT IS PROHIBITED TO USE THE MACHINE BY UNQUALIFIED, INCOMPETENT,
NOT SOBER OR DRUG ADDICTED PERSONNEL.
EN
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Version: 1.0
ALLOW FREE FROM OBJECTS (BOXES, TOOLS, CABLES) THE ACCESS WAY
TO THE CONTROL PANELS AND IN PARTICULAR TO EMERGENCY BUTTONS
TO DISCONNECT PNEUMATIC, ELECTRICAL AND PNEUMATIC SYSTEMS.
THE OPERATORS MUST HAVE AN EASY ACCESS TO ALL THE SAFETY
DEVICES ON THE MACHINE FROM ANYWHERE THEY COMES FROM.
CAUTION
THE MACHINE MUST BE OPERATED AND MAINTAINED BY SKILLED
OPERATORS AUTHORIZED BY THE CUSTOMER WHO HAVE PARTICIPATED
IN TRAINING COURSES CONDUCTED BY THE MACHINE MANUFACTURER
TECHNICIANS.
OBSERVE THE WORKSPACES AROUND THE MACHINE, SO THAT THE

OPERATOR EASILY REACHES THE EMERGENCY BUTTON.
7.1.1 PERSONAL PROTECTIVE EQUIPMENT (PPE)
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Sections Title: Use
CHAPTER 7
Pag. 125 ( 122 )
and Functioning
Version: 1.0
INTENDED USE
NOTE
THE LIMITS OF THE MACHINE IN TERMS OF ENERGY CONSUMPTION AND ARE REPORTED IN
CHAPTER 3, TECHNICAL DATA A PAG. 37.
The machine is designed for unwinding reels of plastic material, continuously : both films that
nonwoven fabric. Both unwound materials are sent to another Machine that deals with the sticking of
the two products.
The laminated material is cut, trimmed and wound on cardboard cores, ready for subsequent
processing.
The limits of use of the machine are described in section " Technical data a pag. 37 ".
NOTE
THE MACHINE HAS BEEN DESIGNED FOR THE PRODUCTS DESCRIBED IN THE SECTION
"PRODUCT SPECIFICATIONS A PAG. 126" WITH THE OPERATING LIMITS DESCRIBED IN THE
SECTION "CHAP 3 DESCRIPTION OF THE MACHINE A PAG. 29." ANY USE OF THE MACHINE
OTHER THAN THOSE DESCRIBED IN THE SECTION "INTENDED USE" IS CONSIDERED
"MISUSE". IN THESE CASES, THE MANUFACTURER DECLINES ANY LIABILITY FOR ANY
DAMAGE CAUSED TO PERSONS OR PROPERTY AND CONSIDERS VOID ANY WARRANTY ON
THE MACHINE ITSELF.
THE MANUFACTURER IS NOT RESPONSIBLE FOR DAMAGES CAUSED BY USING THE MACHINE
IN WAYS OTHER THAN THOSE DESCRIBED IN PARAGRAPH "TECHNICAL DATA A PAG. 37".
THE MACHINE IS INTENDED FOR PROFESSIONAL USE ONLY BY SKILLED OPERATORS AND
DRIVERS TRAINED IN THE PROPER USE OF THE MACHINE, THE METHOD OF ADJUSTMENT
AND BEHAVIOR TO BE FOLLOWED IN THE EVENT OF A MALFUNCTION.
THE OPERATOR OF THE MACHINE MUST BE PERFORMED BY A SINGLE PERSON WHO

CARRIES OUT ITS TASK FROM THE WORK SITE NEAR THE MAIN COMMAND AND CONTROL
PULPIT.
EN
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and Functioning
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THE OPERATOR MUST ENSURE THAT WHEN RUNNING THE MACHINE THERE IS NOBODY
WITHIN THE AREA FENCED BY RIGID METAL GUARDS AND INTERLOCKED DOORS.
ONLY DURING THE ADJUSTMENT OPERATION, CONTROL AND MAINTENANCE, PERSONNEL,

SPECIFICALLY TRAINED AND AWARE OF THE RISKS AND CORRECT MODE OF BEHAVIOR, CAN
ACCESS WITHIN THE SAFETY GUARDS FOR CONTROLS OR OPERATIONS TO BE
PERFORMED.
USE THE MACHINE ONLY WITH THE ORIGINAL ACCESSORIES OR AUTHORIZED BY THE
MANUFACTURER.
7.2.1 PRODUCT SPECIFICATIONS

Technical data
U.M.
Value
Fiber type
PP ; PE
Product formation technology
Spunbond (PP)
Cohesion technology
Calendred
8 30 (PP)
Basic weight
g/m
Web tension
N/m
20 200
Density
kg/dm
Finish technology
10 20 (PE)
Tear resistance
Thickness
mm
7.2.2 DIMENSION OF MASTER ROLL AND FINISHED REEL

Technical data
U.M.
Value
Web width
mm
1'000 2'200
Master Roll max diameter
mm
Min slitting width
mm
Reel min. diameter (min - max)
mm
500 1'500 (PP)

1'200 (PE)
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7.2.3 CHARACTERISTICS OF THE CARDBOARD CORES

For the perfect working of the A.Celli Nonwovens s.p.a. machines, it is necessary to use cardboard
cores that have at least the below-mentioned requirements:
- The cardboard cores must be of top quality.
- The 3 cores must have a tolerance on the internal diameter of: 76 +0 +0,7 mm
- The 6 cores must have a tolerance on the internal diameter of: 152 +0 +0,7 mm
- Roundness deviation or ovalization: the deviation must be smaller or equal to 0,5 mm. The
UNI 10328 (*) set of rules regulate the measurement mode of this value. It is the maximum
range of the sensitive device placed at a core end, while it is rotating of 360.
- Straightness deviation or curving: the deviation must be smaller or equal to 1 mm every
metre in length of the core. The UNI 10328 (*) set of rules regulate the measurement mode of
this value. It is the range, in millimetres, collected by the sensitive device in the centre of the
core, while it is rotating of 360.
- Compression strength: the strength of the cardboard cores must be no smaller than 900 N out
of 10 cm. The UNI 10328 (*) set of rules regulate the measurement mode of this value.
- Crush resistance: the cardboard cores shall have a resistance to crushing as per the table
below.
inner of the core
Thickness
Minimum Crush Resistance
(mm)
(mm)
(N/100mm)
76
1000
76
12
1650
152
750
152
12
1200
172
700
172
12
1100
- The cardboard cores must be normalized in a drying oven, so that the residual humidity shall
not be higher than 9%. The UNI 10328 (*) set of rules regulate the measurement mode of this
value.
EN
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- Conservation: the cardboard cores must be preserved in a dry place, so as to avoid the
humidity reabsorption. It is also important to preserve the cores inside packages, or inside
wooden frames, so as to allow them to be packed one on the other, without damaging the
straightness of the cardboard cores.
We recommend the customer to cautiously choose the supplier of the cardboard cores, requiring at
least the above-mentioned characteristics. It is also important for the customer to check these values,
making sure that these values are guaranteed by the supplier according to the UNI 10328 (*) rules
that regulate these tests.
(*) - The UNI 10328 rules are divided into seven sections, as follows:
Rule
Description
UNI 10328/1
Tests on paper or cardboard cores. Terms and definitions.
UNI 10328/2
UNI 10328/3
UNI 10328/4
UNI 10328/5
UNI 10328/6
UNI 10328/7
7.3
Tests on paper or cardboard cores. Sampling and criteria for the

acceptance of the parcel.
Tests on paper or cardboard cores. Conditioning.
Tests on paper or cardboard cores. Determination of the humidity
content. Drying process in stoves.
Tests on paper or cardboard cores. Determination of dimensions.
Tests on paper or cardboard cores. Determination of roundness or
straightness deviation.
Tests on paper or cardboard cores. Determination of the compression
strength.
REASONABLY FORESEEABLE MISUSE
DANGER
IT IS FORBIDDEN TO TAMPER THE SECURITY SYSTEMS OF THE MACHINE
OR ANY EQUIPMENT USED TO CONTROL THE MANUFACTURING PROCESS
(EG, POSITION SENSORS, LIMIT SWITCHES, FLOW SWITCHES, PRESSURE
SWITCHES ...).
Serial Number: 2014039_40_41_42

Sections Title: Use
CHAPTER 7
Pag. 129 ( 122 )
and Functioning
Version: 1.0
DANGER OF PINCHING AND DRAGGING. IT IS FORBIDDEN TO REMOVE THE

FIXED GUARDS AND PROTECTIVE GUARD WITH THE MACHINE RUNNING.
NEVER START THE MACHINE WITH GUARDS REMOVED.
IT IS STRICTLY FORBIDDEN CLIMBING ON FRAMES AND GUARDS, BENDING

INTO DANGER AREAS AND CREEPING INTO OR UNDERNEATH RUNNING
MACHINES.
NO MAINTENANCE INTERVENTION OR ADJUSTMENT HAS TO BE

UNDERTAKEN ON ANY PART OF THE MACHINE WITHOUT FIRST
DISCONNECTING AND LOCKING THE MACHINE - POWER SUPPLY
INTERFACE (SEE "PROCEDURE FOR LOCKOUT AND TAGOUT A PAG. 249").
WARNING
EN
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 130 ( 122 )

and Functioning
Version: 1.0
Do not change the operating conditions of the machine without the prior written
consent of A.Celli Nonwovens s.p.a.. The interlocks are required for correct
operation of the machine and reduce the risks.
CAUTION
IT IS PROHIBITED TO PROCESS MATERIALS OTHER THAN THOSE
MENTIONED IN THE INTENDED USE. IT IS ALSO PROHIBITED PROCESS
FIBERS WHICH MAY INTRODUCE RISKS OF BIOLOGICAL NATURE AND / OR
CARCINOGENIC AND FABRICS WITH FLAME TEMPERATURE BELOW 100 C.
IT IS ABSOLUTELY FORBIDDEN TO BRING INTO THE MACHINE METALLIC

MATERIALS, HARD MATERIALS, FLAMMABLE MATERIALS AND ANY OTHER
MATERIAL THAT COULD DAMAGE THE CARRING ROLLERS AND IDLER
ROLLERS OR PRODUCE FRAGMENTS, SPLINTERS, DUST OR VAPORS
DURING REWINDING THAT CAN AFFECT, FLOOD OR POISON ANYONE IN
THE VICINITY OF THE MACHINE.
IT IS REASONABLY FORESEEABLE MISUSE TO USE PART OF THE WORKING

AREA AS A STORE FOR MATERIALS NO LONGER NECESSARY FOR
PROCESSING.
DO NOT COVER WITH OBJECTS OR WALLS THE SLOTS ON THE

ELECTRICAL PANEL USED FOR THE CIRCULATION OF COOLING AIR.
Serial Number: 2014039_40_41_42

Sections Title: Use
CHAPTER 7
Pag. 131 ( 122 )
and Functioning
Version: 1.0
DO NOT INSTALL ON A MACHINE PC SOFTWARE OR HARDWARE OTHER

THAN THAT SUPPLIED BY THE MACHINE MANUFACTURER.
DO NOT LEAVE THE MACHINE UNATTENDED WHILE IT IS TURNED ON OR

WHILE IT IS RUNNING THE AUTOMATIC CYCLE.
EN
298."
USE ONLY CORES OF THE QUALITY DESCRIBED IN THE SECTION

"CARDBOARD CORES SPECIFICATIONS A PAG. 127".
7.4
DESCRIPTION OF THE COMMANDS AND CONTROLS
For the arrangement of the cabinet and the control box refer to the drawing :
p9579p_R11.pdf
For the position of electrical components inside cabinet refer to the wiring diagram:
2014039_GB.pdf
2014040_GB.pdf
2014041_GB.pdf
2014042_GB.pdf
7.4.1 NO-STOP UNWINDER - ELECTRICAL CABINET

The electrical cabinet of No-Stop Unwinder (+ECU) is composed with a modular system.
- If the electrical cabinet is inside a control room will be locked the door to the room.
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 132 ( 122 )

and Functioning
Version: 1.0
- If the electrical cabinet is on field near the machine will be locked the doors of the cabinet so do
not have a free access to the electrical components.
ECU Box
Position
Description
Main circuit breaker
Function
Machine-power supply interface used to switch on/off the
electrical supply.
UPS Auxiliaries
Switch used to enable or to disable the external power
400VAC 3ph
supply by UPS system for 24 V circuit.
Auxiliaries - on
Lamp test
Drive - disabled
Blue lamp indicating that the power circuit of the auxiliaries is

on.
White push button used to verify the efficiency of all lamps
on the relative control panel.
Red warning lamp indicating the corresponding disabled
drive status.
Serial Number: 2014039_40_41_42

Position
Sections Title: Use
Description
CHAPTER 7
Pag. 133 ( 122 )
and Functioning
Version: 1.0
Function
Switch used to enable or to disable the converter of the
Drive -
corresponding motor so as to avoid any unexpected start
disable/enable
whenever a mechanical maintenance intervention is carried

out on that specific machine section.
Emergency - on
Yellow warning lamp indicating the emergency stop

intervention on the relative control panel.
Mushroom-shaped button used to stop the machine in case
of emergency. When pushed, the machine starts braking
Emergency stop
rapidly. In order to re-start the machine, remove all faulty or

dangerous conditions and turn the mushroom shaped device
clockwise to restore the normal working conditions.
7.4.2 WINDER - ELECTRICAL CABINET

The electrical cabinet of Winder (+ECW) is composed with a modular system
- If the electrical cabinet is inside a control room will be locked the door to the room.
- If the electrical cabinet is on field near the machine will be locked the doors of the cabinet so do
not have a free access to the electrical components.
EN
Serial Number: 2014039_40_41_42
CHAPTER 7
Machine: name
Sections Title: Use
Pag. 134 ( 122 )

and Functioning
ECW
Ref.
Description
Auxiliaries - on
Lamp test
Drive - disabled
Drive - disable/enable
Emergency - on
Emergency stop
MAIN CIRCUIT BREAKER

Machine-power supply interface used to switch on/off the electrical supply.
AUXILIARIES - ON
Blue lamp indicating that the power circuit of the auxiliaries is on.
Version: 1.0
Serial Number: 2014039_40_41_42

Sections Title: Use
CHAPTER 7
Pag. 135 ( 122 )
and Functioning
Version: 1.0
LAMP TEST
White push button used to verify the efficiency of all lamps on the relative control panel.
DRIVE - DISABLED
Red warning lamp indicating the corresponding disabled drive status.
EN
DRIVE - DISABLE / ENABLE
Switch used to enable or to disable the converter of the corresponding motor so as to avoid any
unexpected start whenever a mechanical maintenance intervention is carried out on that specific
machine section.
EMERGENCY - ON
Yellow warning lamp indicating the emergency stop intervention on the relative control panel.
EMERGENCY STOP
Mushroom-shaped button used to stop the machine in case of emergency.
When it is pushed, the machine starts braking rapidly. In order to re-start the machine, remove all
faulty or dangerous conditions and turn the mushroom shaped device clockwise to restore the normal
working conditions.
7.4.3 EXTRACTOR - ELECTRICAL CABINET

The electrical cabinet of Extractor (+ECE) is composed of a module with interlocked doors.
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 136 ( 122 )

and Functioning
Ref.
Description
Auxiliaries - on
Lamp test
Emergency - on
Emergency stop
Version: 1.0
MAIN CIRCUIT BREAKER

Machine-power supply interface used to switch on/off the electrical supply.
AUXILIARIES - ON
Blue lamp indicating that the power circuit of the auxiliaries is on.
LAMP TEST
EMERGENCY - ON
EMERGENCY STOP
working conditions.
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 137 ( 122 )

Version: 1.0
7.4.4 NO-STOP UNWINDER - CONTROL DESKS

NON WOVEN
7.4.4.2
NO-STOP UNWINDER - CONTROL DESK +CDU

EN
Control Desk CDU
Position
Description
Function
Reel centring -
Three-position centre-off luminous selector used to align axially
Operator side/Drive
the reel through the lateral movement of the unwinder.
side
The lamp is on when the unwinder is centred.
Serial Number: 2014039_40_41_42

Machine: name
Description
Revolver rotation
11
Tension insertion
15
16
Pag. 138 ( 122 )
Sections Title: Use
Position
CHAPTER 7
and Functioning
Version: 1.0
Function
Three-position centre-off black selector used to rotate the
revolver clockwise or counter-clockwise.
Luminous push button used to enable the tension automatic
control.
Front area chuck jog
- Unwind/Wind
chucks, currently in their unwinding position, at jog speed.
Rear area chuck jog
- Unwind / wind
chucks, currently in their reel loading position, at jog speed.

Blue luminous push button used to activate the automatic cycle
for the ejection of the finished reel and the loading of a new reel.
18
Start automatic cycle
When the cycle conditions are active for the reel doffing to be
carried out, this button starts blinking.
Once it has been pushed, it lights on during all the automatic
cycle.
Green luminous push-button which activates the working run.
By pushing this button, from the threading run status, the
machine will start with reference to the parameters of the
acceleration edge managed by the driver, until it reaches
19
Work speed
the speed set by the Operator.

By pushing this button, with the machine stopped, a horn
sounds at least for 3s, the warning lamp of the button blinks
and the rotating alarms are activated. Afterwards the horn stops
sounding and in the next three seconds the operator confirms
the action by pushing the button again.
Red push button used to stop the Unwinder according to the
20
Stop
21
Line start
White luminous push button used to start the Line
22
Line stop
Red push button used to stop the Line.
23
26
Local command
request
Horn quiet
normal braking procedures.
Luminous push-button at customers disposal.

Yellow push button used to silence the horn after any signalling
of emergency or hazard.
Serial Number: 2014039_40_41_42

Position
27
Sections Title: Use
Description
Revolver safety
barrier reset
CHAPTER 7
Pag. 139 ( 122 )
and Functioning
Version: 1.0
Function
Yellow luminous push button used to reset the condition of the
revolver safety barrier.
The warning lamp is on when the alarm condition must be reset.
29
Speed increase
Black push button used to increase the speed of the line.
30
Speed decrease
Black push button used to decrease the speed of the line.
31
In line request
Luminous push-button at customers disposal.
Slide guard -
Three-position centre-off green luminous selector used to lock or
Open/Close
to unlock the platform gate.
33
34
Lamp test
35
Emergency - on
White push button used to verify the efficiency of all lamps on

the relative control panel.
Yellow warning lamp indicating the emergency stop intervention
Mushroom-shaped button used to stop the machine in case of
emergency. When it is pushed, the machine starts braking
36
Emergency stop

7.4.4.3
Position
NO-STOP UNWINDER - CONTROL DESK +CBG1
Description
Function
EN
Serial Number: 2014039_40_41_42

Machine: name
Position
Pag. 140 ( 122 )
Sections Title: Use
Description
CHAPTER 7
and Functioning
Version: 1.0
Function
Green luminous three-position centre-off selector used to
Threading in
activate or deactivate the locking/unlocking device of the
Revolver safety gate
Revolver gate.
Unlock / Lock
The lamp is on when the gate is unlocked and it is possible to

enter.
7.4.4.4
NO-STOP UNWINDER - CONTROL DESK +CBU1
Position
Description
Emergency stop
Chuck O.S.
Lifting platform
Chuck / Lifting platform Enable
EMERGENCY STOP
working conditions.
CHUCK O.S. - CLOSE / OPEN
Push button used to open or close the chuck on operator side.
LIFTING PLATFORM - UP / DOWN
Pushbutton to move the lifting platform up or down.
Serial Number: 2014039_40_41_42

Sections Title: Use
CHAPTER 7
Pag. 141 ( 122 )
and Functioning
Version: 1.0
CHUCK / LIFTING PLATFORM ENABLE

Push button used to enable the movements of the chuck and lifting platform.
7.4.4.5

EN
Position
Description
NW Reel centring -
Operator side/Drive
side
PE Reel centring -
Operator side/Drive
side
Function
Three-position centre-off selector used to align axially the reel
through the lateral movement of the NW Unwinder.
Three-position centre-off selector used to align axially the reel

through the lateral movement of the PE Unwinder.
- Unwind/Wind
chucks, currently in their unwinding position, at jog speed.
Slack
Dandy roll insertion
Black push button used to reset the web tension after the
threading operation. It is active until it is pressed.
Luminous pushbutton used to activate the dandy roll.
Serial Number: 2014039_40_41_42

Machine: name
Pag. 142 ( 122 )
Sections Title: Use
Position
Description
Tension insertion
Lamp test
CHAPTER 7
and Functioning
Version: 1.0
Function
control.
White push button used to verify the efficiency of all the lamps of
Threading in safety
activate or deactivate the locking/unlocking device of the central
gate centre side
gate.
Unlock / Lock

enter.
11
Emergency - on

12
Emergency stop

clockwise to restore the standard working conditions.
Serial Number: 2014039_40_41_42

7.4.4.6
Sections Title: Use
CHAPTER 7
Pag. 143 ( 122 )
and Functioning
Version: 1.0
NO-STOP UNWINDER - CONTROL DESK +CBU3A
EN
Position
Description
Cut group - Up /
Down
Press roll in cut

position
Cross cut
Revolver rotation
Tension insertion
Lamp test
Function
Three-position centre-off luminous selector used to move the
cross cut group to its working position or to bring it to its rest
position.
Black pushbutton used to bring the press roll of the cut group to
its working position, so as to paste the sheet of the new reel with
the one of the unwinding reel.
Black push button activating the web cross cut.
control.
Serial Number: 2014039_40_41_42

Machine: name
Position
Pag. 144 ( 122 )
Sections Title: Use
Description
CHAPTER 7
and Functioning
Version: 1.0
Function
Work speed

10
Stop
11
Emergency - on

12
Emergency stop

7.4.4.7
Position
Description
Emergency stop
Chuck D.S.
Chuck enable
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 145 ( 122 )

Version: 1.0
EMERGENCY STOP
working conditions.
CHUCK T.S. - CLOSE / OPEN
Push button used to open or close the chuck on Drive side.
CHUCK ENABLE
Push button used to enable the movements of the chuck.
EN
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
Pag. 146 ( 122 )

and Functioning
FILM
7.4.4.8
CHAPTER 7
NO-STOP UNWINDER - CONTROL DESK +CDU
Ref.
Description
Load Reel Slide Guard - Open
Reel centering
Version: 1.0
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
Ref.
Description
Load Reel Slide Guard - Close
Revolver rotation
10
11
Tension insertion
12
13
14
15
16
Rear area chuck jog
17
18
Automatic cycle Start
19
Work speed
20
Stop
21
Line Start
22
Line Stop
23
Local command request
24
25
Unwinder footboard safety gate
26
Horn quiet
27
Emergency reset
28
29
Speed increase
30
Speed decrease
31
In line request
32
33
34
Lamp test
35
Emergency on
36
Emergency stop
CHAPTER 7
Pag. 147 ( 122 )

Version: 1.0
EN
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 148 ( 122 )

and Functioning
Version: 1.0
LOAD REEL SLIDE GUARD - OPEN

Push button used to open the slide guard for the load of the reel.
REEL CENTERING - DRIVE SIDE / TENDER SIDE
Three-position, centre-off luminous selector, used to align axially the Reel through lateral
displacement of the Unwinder.
The lit lamp indicates "Unwinder centered".
LOAD REEL SLIDE GUARD - CLOSE
Push button used to close the slide guard for the load of the reel.
REVOLVER ROTATION - CLOCKWISE / COUNTER CLOCKWISE
Three-position, centre-off black selector, used to move the revolver in clocwise or counter clockwise.
TENSION INSERTION
Luminous push button used to activate the product tension function, during work speed.
FRONT AREA CHUCK JOG - UNWIND / WIND
Three-position, centre-off black selector, used to rotate in jog mode the chucks, that are actually in
unwinding position.
REAR AREA CHUCK JOG - UNWIND / WIND
Three-position, centre-off black selector, used to rotate in jog mode the chucks, that are actually in
Reel loading position.
AUTOMATIC CYCLE
Luminous blue push button used to start the automatic cycle regarding the sequence that foresee the
finished reel ejecting and the new core loading.
When the reel reaches the diameter or the length set, this button starts blinking : once it has been
pushed it lights on during all the automatic cycle.
Serial Number: 2014039_40_41_42

Sections Title: Use
CHAPTER 7
Pag. 149 ( 122 )
and Functioning
Version: 1.0
WORK SPEED
Green luminous push-button activating the working run.
By pushing this button, the machine will start from threading run status according to the parameters
of the acceleration ramp, until the speed set by the operator is reached.
By pushing this button, with the machine stopped, a horn will sound at least for 3s as the warning
lamp of the button blinks and the rotating alarms are activated. In the following three seconds after the
horn has silenced, the operator confirms the action by pushing the button once again.
STOP
Red push button used to stop the Machine according to the normal braking procedures.
LINE START
Luminous push button used to start the Line
LINE STOP
Red button used to stop the line.
LOCAL COMMAND REQUEST
Luminous push button available for the Customer.
UNWINDER FOOTBOARD SAFETY GATE - LOCK / UNLOCK
Green luminous three-positions centre-off selector used to lock or to unlock the Unwinder safety gate
to access to the footboard.
HORN QUIET
Yellow push button used to silence the horn after any signalling of emergency or hazard.
EMERGENCY RESET
Yellow luminous push button used to reset the condition of emergency stop before the machine is restarted according to its standard working conditions.
The warning lamp is on when the alarm condition must be reset.
EN
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 150 ( 122 )

and Functioning
Version: 1.0
LINE SPEED INCREASE

Black push button used to increase the line speed.
LINE DECREASE SPEED
Black push button used to decrease the line speed.
IN LINE REQUEST
Luminous push button available for the Customer.
LAMP TEST
EMERGENCY - ON
EMERGENCY STOP
working conditions.
7.4.4.9
Position
Description
Emergency stop
Chuck O.S.
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
Position
Description
Lifting platform
Chuck / Lifting platform Enable
CHAPTER 7
Pag. 151 ( 122 )

Version: 1.0
EMERGENCY STOP
working conditions.
CHUCK O.S. - CLOSE / OPEN
Push button used to open or close the chuck on operator side.
LIFTING PLATFORM - UP / DOWN
Pushbutton to move the lifting platform up or down.
CHUCK / LIFTING PLATFORM ENABLE
Push button used to enable the movements of the chuck and lifting platform.
EN
Serial Number: 2014039_40_41_42

Machine: name
CHAPTER 7
Pag. 152 ( 122 )
Sections Title: Use
and Functioning
Version: 1.0
7.4.4.10 NO-STOP UNWINDER - CONTROL DESK +CBU3
Position
Description
Tension insertion
Slack

- Unwind/Wind
Lamp test
Function
Luminous push button used to enable the working of the rider
roll.
control.
threading operation. It is active until it is pressed.
Three-position centre-off black selector used to start the parent
reel on the Unwinder by jog impulses, either clockwise or
anticlockwise.
Threading in safety
activate or deactivate the locking/unlocking device of the central
gate centre side
gate.
Unlock / Lock

enter.
Serial Number: 2014039_40_41_42

Sections Title: Use
Position
Description
11
Emergency - on
CHAPTER 7
Pag. 153 ( 122 )
and Functioning
Version: 1.0
Function
12
Emergency stop

7.4.4.11 NO-STOP UNWINDER - CONTROL DESK +CBU3A
Position
Description
Cut group - Up /
Down
Press roll in cut

position
Function
Three-position centre-off luminous selector used to move the
cross cut group to its working position or to bring it to its rest
position.
Black pushbutton used to bring the press roll of the cut group to
its working position, so as to paste the sheet of the new reel with
the one of the unwinding reel.
EN
Serial Number: 2014039_40_41_42

Machine: name
CHAPTER 7
Pag. 154 ( 122 )
Sections Title: Use
and Functioning
Position
Description
Function
Cross cut
Black push button activating the web cross cut.
Revolver rotation
Tension insertion
Lamp test
Version: 1.0

control.
Work speed

10
Stop
11
Emergency - on

12
Emergency stop

Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 155 ( 122 )

Version: 1.0
EN
Position
Description
Emergency stop
Chuck D.S.
Chuck enable
Position
1
Description
Function
Unwinder - web
Three-position centre-off black selector used to activate the web
thread up
thread up on Unwinder.
Serial Number: 2014039_40_41_42

Machine: name
CHAPTER 7
Pag. 156 ( 122 )
Sections Title: Use
and Functioning
Version: 1.0
7.4.4.14 NO-STOP UNWINDER - CONTROL DESK +CBG1
Position
Description
Function
Threading in
Revolver safety gate
Revolver gate.
Unlock / Lock

enter.
7.4.4.15 NO-STOP UNWINDER - CONTROL DESK +CBG2
Position
Description
Unwinder - Safety
gate for thread up

belt
Unlock/Lock
Function
Unwinder gate on drive side.
enter.
Serial Number: 2014039_40_41_42
CHAPTER 7

Sections Title: Use
Pag. 157 ( 122 )
and Functioning
Version: 1.0
7.4.5 WINDER - CONTROL DESKS

7.4.5.1
WINDER - CONTROL DESK +CDW
EN
CDW
Position
Description
Shaft loader
Upstroke /
Downstroke
Function
Three-position, centre-off black selector used to lift or to lower
the spool loader.
Serial Number: 2014039_40_41_42

Machine: name
Position
10
Supports
Lock / Unlock
Spool feeding arms

Up / Down
Horizontal carriages
Press / Eject
13
14
15
20
Version: 1.0
Function
Three-position, centre-off black selector used to lock the winding
spools when they are on the loader or to unlock them when they
have been placed on their winding position.
Three-position, centre-off black selector, used to raise or to
lower the spool feeder and to bring and position them in their
winding seat.
Three-position centre -off black selector used to move the
horizontal carriages, either to press them against the driving roll
or to move them away from it.
Three-position centre-off black selector used to lock the winding
shaft clamps
spool on the horizontal carriages when these are in their winding
Rest / Close
position or to unlock it when it has been completely wound.
Shaft detents
Three-position centre -off black selector used to raise the
horizontal carriages
detents, which stop the reel or to push it in its storage and / or
Up / Down
removal position.
Cut group
Three-position, centre-off black selector, used to move up /
Up / Down
down the cross cut group.
Axial helper
Luminous push button used to activate or deactivate the axial
On / Off
helper.
Chucks
Three-position centre-off luminous selector used to open or to
Open / Close
close the chucks.
Upstroke /
Downstroke
12
and Functioning
Reel relieving roll

11
Pag. 158 ( 122 )
Sections Title: Use
Description
CHAPTER 7
Cross cut
Three-position, centre-off black selector used to raise or to lower

the reel relieving roll.
Luminous push button used to do the cross cut of the web.
The lamp is on when the cross cut cycle is active.
Unloaders
Three-position, centre-off black selector used to move the
Receive / Eject
Unloader Table in receive or eject position.
Unloader detents
Receive / Eject
detents on Unloader Table in receive or eject position.
Reel unloading
Eject / Receive
unloading arms in receive or eject position.
Ejector on truck
Black push-button used to move the ejector on truck.
Serial Number: 2014039_40_41_42

Position
Sections Title: Use
Description
Manual /
21
semiautomatic /
automatic
CHAPTER 7
Pag. 159 ( 122 )
and Functioning
Version: 1.0
Function
Green luminous selector with three stable positions used to
choose the working mode of the winder.
Luminous blue push button used to start the automatic cycle
regarding the sequence that foresee the finished reel ejecting
and the new core loading.
22
Automatic Cycle
When the cycle conditions are reached, this button starts

blinking.
Once it has been pushed it lights on during all the automatic
cycle.
By pushing this button, the machine will start from threading
run status according to the parameters of the acceleration
ramp, until the speed set by the operator is reached.
23
Work speed
By pushing this button, with the machine stopped, a horn will

sound at least for 3s as the warning lamp of the button blinks
and the rotating alarms are activated. In the following three
seconds after the horn has silenced, the operator confirms the
action by pushing the button once again.
Red push button used to stop the winder according to the
24
Winder stop
25
Line start
White luminous push button used to start the Line
26
Line stop
Red push button used to stop the Line.
Local command
Luminous push-button used to indicate the local machine as
request
speed reference.
27
White push button used to check all lamp efficiency of the
30
Lamp test
32
Speed increase
Black push button used to increase the speed of the line.
33
Speed decrease
Black push button used to decrease the speed of the line.
34
Line request
36
Horn quiet
relative control panel.
Luminous push-button used to indicate the external machine as

speed reference.
Yellow push button used to silence the horn after any signalling
of emergency or hazard.
EN
Serial Number: 2014039_40_41_42

Machine: name
Description
37
Emergency - on
38
Emergency stop
7.4.5.2
Pag. 160 ( 122 )
Sections Title: Use
Position
CHAPTER 7
and Functioning
Version: 1.0
Function
emergency.
WINDER - CONTROL DESK +CBW1
CBW1
Position
Description
Knife area safety
gate
Lock / Unlock
Function
Green luminous center-off selector used to lock/unlock the knife
area safety gate.
Serial Number: 2014039_40_41_42

Position
Sections Title: Use
Description
CHAPTER 7
Pag. 161 ( 122 )
and Functioning
Version: 1.0
Function
By pushing this button, the machine will start from threading
run status according to the parameters of the acceleration
ramp, until the speed set by the operator is reached.
Work speed
By pushing this button, with the machine stopped, a horn will

sound at least for 3s as the warning lamp of the button blinks
and the rotating alarms are activated. In the following three
seconds after the horn has silenced, the operator confirms the
action by pushing the button once again.
5
6
7
10
Winder stop
Red push button used to stop the winder according to the

Expandable shaft
Luminous push button used to lock or unlock the expandable
Lock / Unlock
shaft.
Press roll
Two position selector used to open or close the press roll.
Trim exhauster
Black two-stable-position switch used to activate or deactivate
On / Off
the trim removal system.
Slack
threading operations. It remains active as long as it is pushed.
Trim Knives
Luminous push button used to activate the slitting units for trim.
insertion
When lamp is on knives are activated.
Threading air
Black push-button activating the air blowers and simplifying the
blowers
web threading operations.
12
Lamp test
13
Knife insertion
14
Tension insertion
15
Emergency - on
16
Emergency stop
White push button used to check all lamp efficiency of the

relative control panel.
Luminous push button used to activate the slitting units.
Luminous push button used to activate the product tension
function.
emergency.
EN
Serial Number: 2014039_40_41_42

Machine: name
7.4.5.3
Pag. 162 ( 122 )
Sections Title: Use
and Functioning
CBW2
Position
Description
Winder safety gate - unlock/lock
Winder safety gate - locked
WINDER SAFETY GATE - LOCK / UNLOCK

Key selector used to unlock or to lock the Winder safety gate.
WINDER SAFETY GATE LOCKED
Green luminous lamp.
It lights on when the winder safety gate is locked.
7.4.5.4
Position
Description
CHAPTER 7
Function
Version: 1.0
Serial Number: 2014039_40_41_42

Position
1
Sections Title: Use
and Functioning
CHAPTER 7
Pag. 163 ( 122 )

Version: 1.0
Description
Function
Winder safety
Luminous push button used to reset the safety bumper After
bumper reset
restoring working conditions.
7.4.6 HANDLING - CONTROL DESKS

7.4.6.1
CONTROL DESK +CBCL1
Position
Description
Caricatore anime
Canale di scarico
Function
Selettore nero a tre posizioni con ritorno al centro usato per
????????????????????'
????????????????????'
EN
Serial Number: 2014039_40_41_42

Machine: name
Position
Supporto
6
Carroponte in
posizione
???????????????????????
???????????????????????
Supporto sostegno
Pulsante luminoso bianco usato per
asta
???????????????????????
Collegato /

???????????????????????
????????????????????'
Support
Black three-positions centre-off selector used to select the shaft
Shaft / Core
or the core support.
Shaft support
15
anima
Supporto fuori bordo
Version: 1.0
Function
Scollegato
14
and Functioning
Supporto sostegno
Supporto
10
Pag. 164 ( 122 )
Sections Title: Use
Description
CHAPTER 7
Upstroke /
Downstroke
Black three-positions centre-off selector used to lift or down the

shaft support.
Shaft
Black three positions selector with centre-off used to inflate or
Inflating / Deflating
deflate the shaft.
17
Clamp - Close
Black push-button used to close the clamp.
18
Clamp - Open
Black push-button used to open the clamp.
16
Extraction head
19
Upstroke /
Downstroke
20
Black three-positions centre-off selector used to move the

extraction head upstroke and downstroke.
Extraction head
Black three positions selector with centre-off used to move
Forward / Backward
forward or backward the extraction head.

Blue luminous push button to activate the automatic cycle nr. 3
21
Extractor cycle 3
of extractor.
When the cycle conditions are met, this button flashes. Once
pressed, stays on for the duration of the automatic cycle.
Serial Number: 2014039_40_41_42

Position
Sections Title: Use
Description
CHAPTER 7
Pag. 165 ( 122 )
and Functioning
Version: 1.0
Function
22
Extractor cycle 2
of extractor.
23
Extractor cycle 1
of extractor.
24
Manual / Auto
Safety gate of Core
26
introduction area
Lock / Unlock
29
Emergency on
Three-position centre-off green selector used to select the

extractor working mode.
Green luminous center-off selector used to lock/unlock the
safety gate to enter into core introduction area.
30
Emergency stop

7.4.6.2
Position
HANDLING - CONTROL DESK +CBCL2
Description
Function
EN
Serial Number: 2014039_40_41_42

Machine: name
Position
Pag. 166 ( 122 )
Sections Title: Use
Description
CHAPTER 7
and Functioning
Version: 1.0
Function
Safety gate
Lock / Unlock

Handling safety gate.
enter.
7.4.6.3
Position
7
EXTRACTOR - CONTROL DESK +CBE1
Description
Function
Truck exit reel
Black three-positions centre-off selector used to rotate the
rotation - Wind
finished reel in order to wind or unwind the tail.
Truck ejector
Black push-button used to set the position of the ejector: receive
Receive / Eject
or eject position.
Serial Number: 2014039_40_41_42

Position
9
Sections Title: Use
and Functioning
CHAPTER 7
Pag. 167 ( 122 )

Version: 1.0
Description
Function
Truck reel keeper
Black three-positions centre-off selector used to open or close
Open / Close
the truck reel keeper.

Black three-positions centre-off selector used to move the truck
10
Truck
of the extractor forward and backward.
Forward / Backward
The truck will move from its present position towards and away
from the Machine.
14
Support
Black three-positions centre-off selector used to select the shaft
Shaft / Core
or the core support.
Shaft support
15
Upstroke /
Downstroke
Black three-positions centre-off selector used to lift or down the

shaft support.
Shaft
Black three positions selector with centre-off used to inflate or
Inflating / Deflating
deflate the shaft.
17
Clamp - Close
Black push-button used to close the clamp.
18
Clamp - Open
Black push-button used to open the clamp.
16
Extraction head
19
Upstroke /
Downstroke
20
Black three-positions centre-off selector used to move the

extraction head upstroke and downstroke.
Extraction head
Black three positions selector with centre-off used to move
Forward / Backward
forward or backward the extraction head.

21
Extractor cycle 3
of extractor.
22
Extractor cycle 2
of extractor.
23
Extractor cycle 1
of extractor.
EN
Serial Number: 2014039_40_41_42

Machine: name
Description
24
Manual / Auto
26
27
28
29
Pag. 168 ( 122 )
Sections Title: Use
Position
CHAPTER 7
and Functioning
Version: 1.0
Function
Three-position centre-off green selector used to select the
extractor working mode.
Shuttle safety
Yellow luminous push button used to reset the safety bumber of
bumper reset
shuttle.
Laser crash barrier
Yellow luminous push button used to reset the safety crash
reset
barrier.
Comands
Two position selector used to enable or disable the manual
Enable / Disable
movements.
Emergency on

30
Emergency stop

7.4.7 PNEUMATIC CONTROL BOX

The solenoid valves and pressure regulators with gauges on the pneumatic system, are part of the
pneumatic control box, which is separated from the electrical section.
This section explains the features of the pressure regulators installed outside of the pneumatic control
boxes, so that the operator can optimize the control and improve the functioning of the machine.
Some pressure regulators, however, are installed within the pneumatic control boxes, and they being
adjusted during start-up by A.Celli Nonwovens s.p.a. technicians. The calibration of these regulators
may only done by skilled and trained mechanics.
On all pneumatic control boxes, on the side of the box, on the collector of the main power air supply,
is located a pressure regulator which regulates the operating air pressure for the line to which it is
dedicated.
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 169 ( 122 )

Version: 1.0
EN
Line regulation pressure : 6-7 bar
Serial Number: 2014039_40_41_42

Machine: name
CHAPTER 7
Pag. 170 ( 122 )
Sections Title: Use
and Functioning
Version: 1.0
7.4.8 NO-STOP UNWINDER - PNEUMATIC CONTROL BOX

7.4.8.1
Position
NO-STOP UNWINDER - PNEUMATIC CONTROL BOX +PBU3
Description
Value
Function
This pressure reducer is used to adjust the working
Press roll up
45
pressure of the press roll in upper position.

The correspondent gauge shows this pressure.
Tank
56
pressure inside the tank.

The corresponding manometer shows this pressure.
Press roll down
45
pressure of the press roll in lower position.

The correspondent gauge shows this pressure.
Serial Number: 2014039_40_41_42

Position
Sections Title: Use
Description
and Functioning
Value
CHAPTER 7
Pag. 171 ( 122 )

Version: 1.0
Function
Cross cut
45
pressure of the cross cut system.

The corresponding gauge shows this pressure.
EN
7.4.8.2
Position
NO-STOP UNWINDER - PNEUMATIC CONTROL BOX +PBU31
Description
Value
Function
Dancer roll
13
pressure of the dandy roll.

The corresponding manometer shows this pressure.
Serial Number: 2014039_40_41_42

Machine: name
Pag. 172 ( 122 )
Sections Title: Use
and Functioning
7.4.9 WINDER - PNEUMATIC CABINET

7.4.9.1
Position
WINDER - PNEUMATIC CONTROL BOX +PBW1
Description
CHAPTER 7
Value
Function
Version: 1.0
Serial Number: 2014039_40_41_42

Position
Sections Title: Use
Description
Shaft loading arms
relieving
CHAPTER 7
Pag. 173 ( 122 )
and Functioning
Value
Version: 1.0
Function
This pressure reducer is used to adjust the shaft
12 bar
loading arms relieving working pressure.

Press roll
23 bar
pressure of the press roll.

Knives advance
22,5 bar
pressure of the knives during their advancement

movement.
Knives approach
34 bar
pressure of the slitting knives against the counterknives.

Counter-knives
locking
This pressure reducer is used to adjust the locking

5 bar

Adjusted
Shaft loading arms
according
to panel
Adjusted
according
to panel
Adjusted
Reel sustention
pressure of the counter-knives bands.
according
to panel
This gauge shows the pressure of the supports for

shaft loading.
This gauge shows the pressure of the cylinders of

horizontal carriages.
This gauge shows the pressure of the reel relieving

system.
EN
Serial Number: 2014039_40_41_42

Machine: name
7.5
Sections Title: Use
CHAPTER 7
Pag. 174 ( 122 )

and Functioning
Version: 1.0
OPERATOR INTERFACE
7.5.1 MACHINE CONFIGURATION

The machine configurations pertaining to the operator are implemented through the operator panel.
On the control unit you can find four users levels, all of them protected by password.
Each user can only access those functions reserved to him/her. In particular, the Operator will not be
able to access those keys reserved to the Superuser and/or the Shift Supervisor and/or the
Maintenance worker
Rule
Competence
SUPERUSER
Reserved to A.Celli Nonwovens Spa technicians
SHIFT
SUPERVISOR
Shift supervisor
MAINTENANCE
Reserved to for maintenance workers
OPERATOR
Standard Operator
NOTE
THE FIRST THREE LEVELS ARE TIME PASSWORDS; THE OPERATOR ONE, ON THE OTHER
HAND, NEVER EXPIRES.
NOTE
THE OPERATOR CAN ACCESS TO THE INTERFACE PAGES FOR CHECKING AND CHANGING
THE PRODUCTION CYCLE.
Serial Number: 2014039_40_41_42

Sections Title: Use
CHAPTER 7
Pag. 175 ( 122 )
and Functioning
Version: 1.0
7.5.2 NO-STOP UNWINDER OPERATOR INTERFACE PAGES

7.5.2.1
LAYOUT OF THE PAGES
UPPER PART
On the top of each page there are some indicators informing the operator about the machine setting
modes, the name of the page, date and time.
Upper part
Button/Field Description
1
Speed of the Line
Angular position of Revolver
Dancer roll position
Doors, if opened or not
Safety status, if activated or not

Mode of functioning :
- Manual
- Semi-Auto
- Auto
Alarm status
Furthermore, by touching the icons on the screen, it is possible to enter the corresponding panel
pages.
8
Control page
Diagnostic page
10
Alarm page
EN
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 176 ( 122 )

and Functioning
Version: 1.0
11
Motor page
12
Maintenance page
CENTRAL PART
In the middle of each page, and according to their type, there are all those setting functions reserved
to the operator or the data relating to the instantaneous functioning of the machine.
Central part
LOWER PART
In the lower part of the page you can find the references to the keys to be used to select the desired
functions, specific to that single page.
Lower part
7.5.2.2
MOTOR PAGE
This page shows the current parameters of motors :

- Speed
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 177 ( 122 )

Version: 1.0
- Torque
- Temperature
EN
Button/range Login
1
7.5.2.3
Drives reset fault acknoledge
ALARM PAGE
This page shows all the alarm messages sent by the machine in chronological order.
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 178 ( 122 )

and Functioning
Version: 1.0
Alarm page
Button
Description
Button for resetting the PLC alarms
Button for accessing the alarm log
Button for resetting the Drive alarms
Alarm display area
ACKNOWLEDGING AN ALARM
To reset an alarm condition, proceed as follows:
- Display all the alarm messages, if more than one, in the Alarm page.
- Notify authorised and trained personnel who will see to removing the causes.
- Acknowledge the alarm by pressing the ACK button.
- Return to the desired page.
NOTE
ALARMS ARE 2 DIFFERENT TYPES
By pressing the " ACK" , the alarm is acknowledged . With alarm went out and recognized the
corresponding text disappears.
At this point, the alarm is saved and will be visible in the Alarm History page.
In case of alarm or fault on a drive, you have to understand the cause and then reset using the reset
button dedicated.
Serial Number: 2014039_40_41_42

Sections Title: Use
CHAPTER 7
Pag. 179 ( 122 )
and Functioning
Version: 1.0
EN
Alarm History page
This page lists all the alarms, both the active ones and those that have been resolved.
Alarm History page
Serial Number: 2014039_40_41_42

Machine: name
7.5.2.4
Sections Title: Use
Pag. 180 ( 122 )

and Functioning
CONTROL PAGE
Button/range Description
1
Push button to select manual mode
Push button to select semi-automatic mode
Push button to select automatic mode
Grammage setting
Reel for start the automatic doffing cycle
Unwinder 1 or 2 setting page

Push button to select the reel diameter reading mode.
- Manual
- Auto
CHAPTER 7
Reel for start the manual doffing cycle
When the operation mode is active, the button is colored.
Version: 1.0
Serial Number: 2014039_40_41_42

7.5.2.5
Sections Title: Use
and Functioning
CHAPTER 7
Pag. 181 ( 122 )

Version: 1.0
USERS PAGE
EN
Button/range
Login
User setting and password
Logon
Logout
Serial Number: 2014039_40_41_42

Machine: name
7.5.2.6
Sections Title: Use
CHAPTER 7
Pag. 182 ( 122 )

and Functioning
Version: 1.0
DIAGNOSTICS PAGE
These pages indicate the movements of all the machine parts.
In the event of a component malfunctioning, go to this page and press the key that corresponds to the
malfunctioning movement.
The diagnostics page relative to the selected component will appear on the screen.
Use the arrows below to scroll through the steps of the cycle and identify the unfulfilled condition.
So that the selected movement can be performed, the necessary conditions must be checked:
- If the condition is fulfilled, the indicator is green.
- If the condition is not fulfilled, the indicator is red.
Every indicator must be green for the actuator to move.
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 183 ( 122 )

Version: 1.0
EN
7.5.2.7
RESERVED PAGE
On this page you can change the machine parameters.

SETTING PAGE
1-2-3
Setting the external of the core according to the shaft .
Number of revolution before cut
Setting the length of the junction.
Contact time of the clamping.
7-8-9
Buttons to access the other setup pages.
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
Pag. 184 ( 122 )

and Functioning
SETTING FOR REVOLVER PAGE
Button
Description
Move the group in Home position.
CHAPTER 7
Move the group by JOG.

The group moves until the button is pressed.
Setting of the working parameters.
Switch on or switch off the drive
Move the group to the specified position.
Button for the management of safety
It stops the actual movement.
8-9
Go to setting pages
10
Open the Alarm page
11
Button for returning to the previous page
Version: 1.0
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 185 ( 122 )

Version: 1.0
SETTING FOR CUT GROUP PAGE
EN
Button
Description
Move the group in Home position.
Move the group by JOG.

The group moves until the button is pressed.
Setting of the working parameters.
Switch on or switch off the drive
Move the group to the specified position.
Button for the management of safety
It stops the actual movement.
8-9
Go to setting pages
10
Open the Alarm page
11
Button for returning to the previous page
NOTE
THIS PAGE IS USED BY A.CELLI NONWOVENS S.P.A. TECHNICIANS DURING START-UP.
Serial Number: 2014039_40_41_42
CHAPTER 7
Machine: name
Sections Title: Use
Pag. 186 ( 122 )

and Functioning
Version: 1.0
NOTE
THIS PAGE IS USED BY SOFTWARE DURING START-UP, TO LOAD THE SET-UP PARAMETERS.
THIS PAGE IS PROTECTED BY PASSWORD.
THE OPERATOR LEVEL IS AUTOMATICALLY RESTORED AFTER 60S AFTER THE INSERTION OF
THE PASSWORD.
At the pressure on the key, the field appears for

entering the password.
Enter it from the keyboard and confirm with OK.
Press the button again to access the page.
7.5.3 WINDER OPERATOR INTERFACE PAGES
NOTE
THE CONTROL OF THE SPEED OF WINDING CAN BE DONE IN TWO WAYS: TENSION OR DRAW.
TENSION
When the control mode is set to TENSION, the Winder automatically varies its speed so that the
tension of the fabric winding (detected by the load cells), always remains constant.
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 187 ( 122 )

Version: 1.0
DRAW
When the control mode is set to DRAW, the Winder automatically varies its speed in percentage
relation to the Line speed , according to the following formula.
% DRAW = (WINDER SPEED - LINE SPEED) / (LINE SPEED) * 100

EN
Serial Number: 2014039_40_41_42

Machine: name
7.5.3.2
Sections Title: Use
CHAPTER 7
Pag. 188 ( 122 )

and Functioning
Version: 1.0
LAYOUT OF THE PAGES
UPPER PART
On the top of each page there are some indicators informing the operator about the machine setting
modes, the name of the page, date and time.
Upper part
Tasto/campo Descrizione
1
Display of the instantaneous Line speed.
Display of the instantaneous Winder speed.
Safety status, if activated or not.
Reel length instantaneous display.
It shows the actual reel diameter.

It indicates the actual functioning mode :
Tension
Draw
4
PLC Status
Type of functioning:
M - Manual
S - Semi-automatic
A - Automatic
Furthermore, by touching the icons on the screen, it is possible to enter the corresponding panel
pages.
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 189 ( 122 )

Version: 1.0
Control page
Function page
EN
Diagnostic page
Alarm page
Recipe page
Motor page
Setting and maintenance page
A.Celli Nonwovens s.p.a. reserved page
CENTRAL PART
In the middle of each page, and according to their type, there are all those setting functions reserved
to the operator or the data relating to the instantaneous functioning of the machine.
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 190 ( 122 )

and Functioning
Version: 1.0
Central part
LOWER PART
In the lower part of the page you can find the references to the keys to be used to select the desired
functions, specific to that single page.
Lower part
7.5.3.3
MAIN CONTROL PAGE
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 191 ( 122 )

Version: 1.0
1
S roll section
Main Drum section
Reel relieving section
Bowed roll section
Reel Parameters section
Chucks section
Trim section
Field to set the working pressure of the winding arms (value in bar)
Loading arms section.
10
Type of functioning: Draw or Tension
11
Setting of the low speed
12
Diameter of the winding shaft
13
Button for movement of the unloading truck
14
15
It reset tthe meter value.

Press and hold for 3 seconds to reset.
Table with the memory of the last 10 reels (meters, diameter, date and time).
"S" ROLL SECTION

Function
U.M.
Description
Speed
m/min
Speed setting.
Instantaneous display of the Winder speed.
Draw
Display of instantaneous draw between the Line speed and the Winder
speed.
MAIN DRUM SECTION

Function
U.M.
Description
EN
Serial Number: 2014039_40_41_42

Machine: name
Function
Sections Title: Use
U.M.
CHAPTER 7
Pag. 192 ( 122 )

and Functioning
Version: 1.0
Description
Setting of the draw value between the line speed and the winder speed
Draw
according to the following formula:

% DRAW = (WINDER SPEED - LINE SPEED) / (LINE SPEED) * 100
Indication of the instantaneous draw value between the line speed and the
Winder speed.
Tension
N/m
Setting of the tension of the winding product.

Indication of the instantaneous tension of the winding product.
Setting of the winder speed control type: Tensioning.
Tens pre-cut
Tens post-cut
Setting of the pre-cut tensioning function.

Press the button to activate the function.
Setting of the post-cut tensioning function.
Press the button to activate the function.
RELIEVING ROLL SECTION - SUS

This roller follows the winding of the Master Roll. The Operator sets the motor torque, which can be
constant or variable according to the diameter of the winding Master Roll.
Function
U.M.
Description
Torque
Setting the Torque value.

Indication of the instantaneous torque of the motor, as % of the nominal
value (%).
Button to enable the Torque control function.
Pressure
bar
Setting the pressure of the SUS on the winding reel (bar).

Indication of the instantaneous pressure of the SUS on the winding reel
(bar).
Button to enable the SUS pressure control function.
Serial Number: 2014039_40_41_42

Sections Title: Use
CHAPTER 7
Pag. 193 ( 122 )
and Functioning
Version: 1.0
BOWED ROLL SECTION

Function
U.M.
Description
Setting of the draw value between Line speed and bowed roll speed,
Draw
according to the following formula:

% DRAW = (ROLL SPEED - LINE SPEED) / (LINE SPEED) * 100
EN
MASTER ROLL PARAMETNERS SECTION

Function
U.M.
Description
Length
Setting of the reel length.

Reel length instantaneous display.
Time
hr -
Time to next doff instantaneous display.
min
Time is indicated in hours and minutes.
PRODUCTION DATA SECTION

On the page there is the memory of the last 10 reel changes made (meter - diameter).
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 194 ( 122 )

and Functioning
Version: 1.0
HORIZONTAL CARRIAGES SECTION

These carriages follow the winding of the Master Roll. The Operator sets the pressure of the
pneumatic cylinders, which can be constant or variable according to the diameter of the winding
Master Roll.
Function
U.M.
H.C. Pressure
bar
Description
Setting of the working pressure of the horizontal carriages that press the
winding reel against the main drum.
It is shown the actual working pressure of the horizontal carriages that
press the winding reel against the main drum.
Button to enable the control pressure function
7.5.3.4
FUNCTIONS PAGE
This page shows the summary of the winding functions

- Tension
- SUS Pressure
- SUS Torque
- Horizontal Carriages pressure
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 195 ( 122 )

Version: 1.0
EN
Functions page
Button
Description
Taper control
SUS Torque control
SUS Pressure control
Horizontal carriages pressure control
For each function, it is possible:

- Enable or disable the function
- Indicate if the function is linear or hyperbolic
- Go to settings page
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 196 ( 122 )

and Functioning
Version: 1.0
TAPER FUNCTION
This function allows you to continuously vary the web tension according to the winding reel diameter,
this variation can have a linear or hyperbolic trend.
- Positive trend: the tension of the product increases proportionally to the increase of the
diameter of the winding reel.
- Negative trend: the tension of the product decreases proportionally to the increase of the
diameter of the winding reel.
The operator need only set the two web tension value (Min e Max) and the two reel diameter within
the function must work.
Logically, the diameter values entered must be within the diameter of the core (core) and that of the
maximum reel workable (max).
This function allows to reduce the pressure that the external coils of the reel exert on the internal
ones.
Serial Number: 2014039_40_41_42

Sections Title: Use
and Functioning
CHAPTER 7
Pag. 197 ( 122 )

Version: 1.0
EN
Serial Number: 2014039_40_41_42

Machine: name
Sections Title: Use
CHAPTER 7
Pag. 198 ( 122 )

and Functioning
Version: 1.0
SUS CONTROL FUNCTION - PRESSURE AND TORQUE
This function allows you to continuously vary the SUS PRESSURE according to the winding reel
diameter, this variation can have a linear or hyperbolic trend.
- Positive trend: the pressure increases proportionally to the increase of the diameter of the
winding reel.
- Negative trend: the pressure decreases proportionally to the increase of the diameter of the
winding reel.
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EN
This function allows you to continuously vary the TORQUE according to the winding reel diameter,
this variation can have a linear or hyperbolic trend.
- Positive trend: the torque increases proportionally to the increase of the diameter of the
winding reel.
- Negative trend: the torque decreases proportionally to the increase of the diameter of the
winding reel.
The operator need only set the two web tension value (Min e Max) and the two reel diameter within
the function must work.
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Logically, the diameter values entered must be within the diameter of the core (core) and that of the
maximum reel workable (max).
This function allows to reduce the pressure that the external coils of the reel exert on the internal
ones.
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NIP FUNCTION
Nip, expressed in newton meters (N/m) represents the average linear load between the main drum
and the reel formation, acting along the direction that connects their centers.
EN
To properly manage the Nip need to know that:

- Increasing the strength of the Nip increases the density of the reel.
- The geometry of Nip may be different depending on the design of the winder.
- The Nip influence the characteristics and structure of the ended reel.
- The control of Nip is closely connected to the tension and torque.
NIP APPLIED TO REELS.
On winder the strength that pushes reel against the main drum is realized by a pneumatic cylinder
By varying the pressure of this cylinder is possible to implement a Nip. By means of a wire encoder
integral with the side measuring the diameter of the reel
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DIAGNOSTIC PAGE
On this page, all the actuators of the machine are shown.

Should a control on the panel not correspond to its matching movement, move to this page and press
the key of the relative machine section.
The diagnostic page relating to the selected machine section will appear on the screen.
EN
On every diagnostic page all the necessary conditions for the movement to actually be performed are
listed.
When a condition is satisfied, the indicator is green.
In order for an actuator to move, each indicator must be green.
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ALARM PAGE
This page shows all the alarm messages sent by the machine in chronological order.
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Alarm page
Button
Description
Button to print the page
Button for resetting the PLC alarms
Button for accessing the alarm log
Button for resetting the Drive alarms
Alarm display area
ACKNOWLEDGING AN ALARM
To reset an alarm condition, proceed as follows:
- Display all the alarm messages, if more than one, in the Alarm page.
- Notify authorised and trained personnel who will see to removing the causes.
- Acknowledge the alarm by pressing the ACK button.
- Return to the desired page.
NOTE
ALARMS ARE 2 DIFFERENT TYPES
By pressing the " ACK" , the alarm is acknowledged . With alarm went out and recognized the
corresponding text disappears.
At this point, the alarm is saved and will be visible in the Alarm History page.
In case of alarm or fault on a drive, you have to understand the cause and then reset using the reset
button dedicated.
EN
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Alarm History page
This page lists all the alarms, both the active ones and those that have been resolved.
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RECIPE PAGE
On this page you can create, store and choose the recipes of the functions for the Winder.
EN
Button/range
Description
Select recipe
New Recipe
Data Saving
Erase Data
Write Data of the Recipe in the PLC
Read Data of the Recipe from PLC
Print saved recipes
Print actual recipe
NEW RECIPE
By means of this push button it is possible to create a new recipe and to input the set-up values of the
machine directly in the page.
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It is important to save the recipe before leaving the page, in order not to loose the input data.
Save by means of the following push button.
DATA SAVING
By means of this push button is possible to save the current data that are displayed on the operator
panel.
Data are stored in the actual recipe that is loaded in the page, whose name is displayed on the field:
RECIPE NAME (in practice the data of the actual recipe are replaced).
ERASE DATA
By means of this push button is possible to erase the recipe that is currently displayed on the page.
WRITE DATA OF THE RECIPE IN THE PLC
By means of this push button is possible to write the data of the recipe that is currently displayed on
the PLC.
In practice the machine is set to work with the data of the recipe.
READ DATA OF THE RECIPE FROM PLC
By means of this push button is possible to read the data of the recipe that are set in the PLC and to
display the values on the operator panel.
LOAD A SAVED RECIPE
- Choose from list the desired recipe.
- Load datas by means the button "5" and confirm the choice.
DELETE A SAVED RECIPE
- Choose from list the desired recipe.
- Delete by means the button "X" and confirm the choice.
7.5.3.8
MOTOR PAGE
This page shows the current parameters of motors:

- Speed
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- Torque
- Temperature
EN
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RESERVED PAGE
On this page you can change the machine parameters.
NOTE
THIS PAGE IS USED BY A.CELLI NONWOVENS S.P.A. TECHNICIANS DURING START-UP.
ENCODER CALIBRATION
Button
U.M. Description
Setting of encoder on Horizontal carriages
Setting of encoder on SUS
3
4
ms
Setting of air blowers for cross cut

Button for user management
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U.M. Description
Button to exit the program
CALIBRATION OF LIFTING ARMS ENCODER
NOTE
THIS PAGE IS USED BY SOFTWARE DURING START-UP, TO LOAD THE SET-UP PARAMETERS.
THIS PAGE IS PROTECTED BY PASSWORD.
THE OPERATOR LEVEL IS AUTOMATICALLY RESTORED AFTER 60S AFTER THE INSERTION OF
THE PASSWORD.
EN
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At the pressure on the key, the field appears for

entering the password.
Enter it from the keyboard and confirm with OK.
Press the button again to access the page.
7.5.3.10 USER PAGE
1
Users and password page
Logon
Logout
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WINDING PARAMETERS
The main parameters for the winding of the nonwovens reels are:
(T) Tension
EN
(N) Nip
(C) Torque
A good roll and a perfect finished reel profile can be produced only through the right use of the T.N.T.
variables.
Tension, Nip and Torque are strictly connected in order to get a good reel structure.
Their adjustment and programming cannot be carried out separately, but they have to be carefully
planned and harmonized.
As a general rule, the reel has to be wound tighter at the core and looser at the finish diameter.
7.6.1 TENSION
The tensioning of a material is achieved by having equal and opposite forces pulling on the webs.
7.6.1.1
USEFULNESS OF THE WINDING TENSION
- To produce reels with different densities.

- To ensure a good build-up structure of the reel.
- To spread and slit the web.
- To separate the reels after slitting.
- To guide the web up to the formation of the reel.
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TENSION CONTROL IS THE MOST IMPORTANT PARAMETER FOR

NONWOVENS WEBS.
7.6.1.2
PROBLEMS RELATED TO THE WINDING TENSION
- Any uncontrolled tension variation will disturb and influence the characteristics and structure of
the reel.
- The higher the web tension, the tighter the wind and vice versa. I.e. more tension means more
reels density.
- Too low a tension will make the web to flop around and loose traction on reels.
- Too tight a tension will make the web to neck in or break.
7.6.2 NIP
It is the average linear load between the winding roll and the reel in formation, acting along a line
connecting their centres.
7.6.2.1
FEATURES OF THE NIP IN THE WINDING
- Increasing nip force will increase the density of the reel.

- Nip geometry can be different according to the design of the winder.
- Nip influence the characteristics and the structure of the finished reels.
- Nip control is strictly related to Tension and Torque.
WINDERS
- In case of winders, a pneumatic cylinder applies the force that pushes the reel against the
carrying roll.
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- By changing the cylinder pressure is possible to carry out a NIP control. Using an encoder with
wire, integral with the frame, it is possible to measure the reel diameter.
REWINDER
- It is a pressure control system in the rider roll cylinders and of the chucks, which allows to set
the NIP on the carrying rolls and on the rider roll during the whole rewinding phase. Using a PC
it is possible to set the curves for the desired NIP values.
Ref.
Description
Winding roll
Reel
Carrier drums
Rider roll
EN
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7.6.3 TORQUE
It is the measurement of the action necessary to provoke a rotation which is equal to the force
multiplied by its perpendicular distance between action line of the force and the rotation centre.
7.6.3.1
USEFULNESS OF TORQUE IN THE WINDING
- Torque can increase or decrease the winding tension of the reel, thus influencing the reel
structure and its density.
- Torque is a highly effective tool for the reel structure and can operate on a wider range
compared to Tension or Nip.
- Tension may cause neck in problems whereas Torque does not.
- The higher the winding torque, the higher the reel density.
TORQUE DIFFERENTIAL
THE MOTORIZED ROLLS OF THE REWINDERS CAN BE EQUIPPED WITH
TORQUE CONTROL DIFFERENTIAL.
The concept is to use different torque on the two carrying drums.
Nip force (N) and friction of the web provide the force needed to maintain the rotation of the roll to a
fixed peripheral speed (V).
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EN
Slave drum motor with a higher torque produce a force F on the actual layers of the roll. This force
produces a tension (T) on the inner web layer similarly to the use of the winding torque. Please note
that force F produces a torque on the slave carrying drum, not on the reel!
Winding Torque and Motor torque control are two ways to increase the roll density since in both cases
a tension (T) on the reel layers is produced, helping the maintain the tightness of the growing roll.
A coefficient called LSC (load share) is set. It is the torque percentage of the slave motor referred to
the master actual torque.
LSC is in % and just to give a practical example, if LSC=50%, then T1=T2.
7.6.4 WIT (WOUND IN TENSION)

The action outcome of the three TNT variables is the WOUND IN TENSION, that is the tension
effectively applied to the single turns of the wound reel.
The measurement of such a tension cannot be easily calculated; however, the energy spent in
winding the reel can be given indirectly.
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An empirical method for measuring this variable is that of the crush test, that is the reel is cut
crossways and the slash resulting from the cut is an index of the tension accumulated by the turns
during the winding.
By applying the formula:
A = Ta / Ci
Ta = Cut opening
Ci = Reel circumference
it is possible to work out the web elongation (A).
7.6.5 DRAW
The definition is:
Sc = (Vs - Vm) / Vm
Sc = Draw
Vs = Slave linear speed
Vm = Master linear speed
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THE DRAW CAN BE EITHER POSITIVE OR NEGATIVE.

For example, on the Rewinder. If we want the reel tension output to be less than that of the parent
reel, it should be set a value Vm on the Rewinder greater than that of the Vs on Unwinder.
7.6.6 LOAD CELLS

The direction of the sensitive part, corresponding to the bisector of the web wrapping angle, depends
on the fact that, this way, the effects of the web friction on the roll, together with the inertia effects, can
be minimized.
In this configuration, the sensitive part is loaded by a part of the roll weight as well, therefore, load cell
with a load range higher than the necessary one should be chosen, to be able to read the web
tension.
Should this roll be motorized, the a.m. configuration is not necessary any longer, because of the
motor compensating the friction and the inertia effects.
- P = Reel weight
- T = Web tension
- R = Resultant of the two forces, detected by the load cell
EN
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R = T * COS + T * SIN + P * COS
7.7
TURNING ON THE MACHINE
NOTE
THE READING OF THIS PARAGRAPH REQUIRES THE READING AND LEARNING AS REPORTED
IN THE PREVIOUS SECTIONS OF THIS CHAPTER.
It is forbidden to start the machine without having understood:
- which operations are prohibited

- residual risks present on the machine
- the position of the safety devices
- the location and meaning of the controls of the machine
- PPE to be used during operations
- steps to be taken in case of emergency
- which operators are allowed to work on the machine and their job
BEFORE EVERY START-UP OF THE MACHINE THE OPERATOR MUST ENSURE THAT ALL
SAFETY DEVICES ON THE MACHINE ARE PROPERLY INSTALLED AND IN GOOD CONDITION.
In particular, he must perform the following checks:
- All external protection must be present and properly installed according to the design of reference
- All emergency stop buttons must be in good condition and easily accessible
- The DIP switches in the moveable protections must be installed and functioning properly
- The safety guards must all be installed.
If even one of the controls previously shown fails, the machine can not be used and the operator must
immediately notify the safety manager.
Only after restoring the original conditions of security, it will be possible to proceed with starting the
machine.
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Emergency push button
Sensors
7.7.1 ELECTRIC SYSTEM START-UP

The electrical plant installed to serve the machine has been designed in keeping with the safety
criteria provided for by rule EN 60204-1. The electrical diagram is enclosed to the present instruction
manual.
The interventions on the electrical plant must be carried out exclusively by specially trained personnel.
After having installed the equipment and prior to the first-start up of the plant, it is necessary to carry
out the following tests and checks:
a) verify that the electrical equipment conforms to the technical documentation;

b) in the event of an automatic interruption to protect against indirect contact, the requirements for the
protection must be verified by carrying out the automatic interruption;
c) insulation resistance test;
d) tension tests;
e) protection against residual tension;
f) tests to verify correct functioning.
When such tests are carried out, we recommend they follow the sequence shown above.
For the tests in compliance with b) and c) we recommend using measurement equipment conforming
to the EN 61557 series.
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In the event of a negative outcome of the test it is necessary to proceed to repair the malfunction and
carry out the test again.
CAUTION
ONLY AT THE END OF SAID TESTS, PROCEED TO START-UP THE MACHINE.
7.7.2 STARTING THE HYDRAULIC SYSTEM

When starting the motor-driven pump units, take the following precautions. These are essential in
order to immediately ensure the necessary lubrication of the internal parts.
FILLING
- Make sure that any valves or gates on the intake and delivery side are open.
- Make sure that the pump is free to be turned manually, without encountering excessive
resistance, and that the rotation direction of the motor coincides with that of the pump.
- Fill the pump body with the fluid used in the circuit through the drainage hole or, if this is not
possible, through the delivery conduit.
- Vent the maximum pressure valve located on the delivery conduit. The pumps must normally be
started in a vacuum. In any case, contact the manufacturer to see if different instructions are
given.
- Start the electric jog motor to assist the engaging of the pump, indicated by a pressure gauge
that should be present in delivery and by the change in the noise of the pump, which becomes
quieter when engaged.
NOTE
IF POSSIBLE, IT IS A GOOD RULE TO HAVE THE PUMP RUN FOR A CERTAIN PERIOD OF TIME
AT REDUCED SPEED, TO BREAK IN THE SYSTEM.
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PURGED
- While filling the system, air must be purged, as pressure from air may cause functioning
problems and speed up wear.
- To simplify this operation, special air release valves may be placed on the pump delivery, or
special rapid-lock valves can be placed on stations and special panels.
- Loosening the fittings on the topside of the system may eliminate the air closed within the
pipelines and inserting purge taps; for the cylinders, use the breather screws provided.
- Air release is indicated by the appearance of foam: when a continuous, clear flow comes from
the fitting or breather, the air has been eliminated.
- Once the system has been filled and the air released, check the oil level in the tank and top it up
if necessary, then put the system gradually under pressure. Set and fine-tune the adjustment
valves.
NOTE
THIS STEP MUST BE PERFORMED AT FULL RUNNING TEMPERATURE.
INSPECTION
- The system may now be inspected.
- Make sure that no foam forms in the tank, as this would indicate air infiltration in the pump
intake (as long as the return pipe to the tank remains immersed in oil, as indicated above).
- When particularly viscous oils are used and the environmental temperature is very low,
functioning problems and loud pump noise during start-up could arise. In this case, the oil
should be preheated before start-up (for example, using a heating element) or the pump speed
reduced. In small systems, you can also heat the oil by having the pump run for a certain time in
short circuit under average pressure before running the system.
- After a few hours of operation, clean the filters, check once again the oil level in the tank and
check carefully all fitting seals.
7.7.3 RUN MODES

- automatic mode
EN
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- manual mode
The machine has been designed and built to function both in the automatic and manual mode.
During the threading operation of the product and the first start-up, the machine has been designed
foreseeing the active intervention of the operator involved in the manual operations.
The manual mode is to set the right sequence of operations using commands from the operator
panel of the machine, and it is the basis of the operational sequences, especially at the beginning of
the work.
The automatic mode, optimized during start-up of Machine, facilitates operational sequences and
increases the security conditions in which the operators work. During the automatic cycle, the
operator performs a limited activity, he must check that the sequences are conducted on a regular
basis and if necessary he gives the necessary consent through the controls, located on the various
push buttons around the machine.
Yet, also during these operative automatic stages, without the active intervention of an operator, it is
extremely important not to leave the machine unguarded.
Only a continuous and effective monitoring of all the machine functioning conditions (both drive and
control) can ensure that this remains in the expected safety conditions.
7.7.4 START OF THE MACHINE
DANGER
BEFORE TURNING THE MAIN SWITCH TO "ON" OR "1" CHECK THAT THERE
ARE NO ONGOING MAINTENANCES, THAT THE MACHINE IS CLEAR OF ANY
OBJECTS AND THAT ACCESSES TO SECURITY DEVICES ARE FREE.
THE HANDLING PHASES OF THE MATERIAL TO BE MACHINED MUST BE

PERFORMED BY QUALIFIED PERSONNEL IN THE CONDUCT OF CRANES
AND FORKLIFTS.
PLAN AND ORGANIZE THE SEQUENCE OF OPERATIONS BEFORE STARTING

THE LIFTING OPERATIONS.
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FOR HANDLING THE MASTER ROLLS AND WINDING SHAFTS USE EC

COMPLIANT TOOLS (SLINGS, CRANES, FORKLIFT).
FOR HANDLING THE MASTER ROLLS AND WINDING SHAFTS USE SUITABLE
TOOLS (SLINGS, CRANES, FORKLIFT) REGULARLY MAINTENED AND
SERVICED.
THE LIFTING EQUIPMENTS FOR THE MASTER ROLLS OR FOR THE WINDING
SHAFTS MUST HAVE A CAPACITY GREATER THAN THE WEIGHT OF THE
LOAD.
The machine is fixed and connected to the power supplies.

- The operator must make sure that nothing and nobody is standing in the machine area and then
the Machine power supply interfaces can be activated by push button located on the
Electrical Cabinet.
The operator can transfer many of the working instructions to the machine both in manual and in
automatic mode.
When in manual mode, the correct sequence of operations can be set using the controls on the
machine panel. The manual mode represents the foundation of the working sequences, particularly
when the machine starts working for the first time
The automatic mode, which is optimised during the start up of the machine, makes the operating
sequences easier, increasing as well the safety of the working conditions.
CAUTION
NO ADMITTANCE INSIDE THE MACHINE AREA, WHEN IT WORKS.
EN
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NO-STOP UNWINDER START-UP
Revolver Unwinder has 2 stations:
1-Station for loading and unloading of Master Rolls.

2-station of unwinding.
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Working position
- The Operator turns on the electrical cabinet, open the air supply valve then press the "RESET
EMERGENCY."
- The following conditions must be present :
- The warning lamp is efficient (Test lamp).
- Machine control mode: MANUAL.
- The Operator, with a suitable lifting device, loads one Master Roll on the shuttle.
- The Operator follows the below steps.
- Move the shuttle, bringing the Master Roll in front of the lifting platform.
- Move the Master Roll on the platform towards the chucks.
- Lift the lifting platform, aligning the shaft to the chucks.
- Close the chuck on Operator side and then on Transmission side
- Lower the lifting platform.
- When the Master Roll is clamped between the chucks and the platform is lowered, the Operator
can rotate the revolver bringing the Master Roll in the unwinding position.
NOTE
NOW THE MACHINE IS READY FOR THE THREADING OF THE PRODUCT ALONG THE
UNWINDING PATH, UNTIL IT REACHES THE NEXT MACHINE.
- To perform the operation of threading, use the JOG command placed on control pulpit, so as to
rotate the Master Roll by steps.
EN
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Web thread up
NOTE
THE OPERATION OF THREADING SHOULD BE DONE ONLY WHEN YOU LOAD THE FIRST
MASTER ROLL ON THE UNWINDER; WHEN HE LOADS THE MASTER ROLLS LATER, THE
OPERATOR MUST PREPARE THEM TO PERFORM THE AUTOMATIC DOFFING CYCLE.
The operations so far described refer to the use of the machine during the first running cycle (for
instance, during the line starting phase).
PREARRANGEMENT OF THE MASTER ROLL FOR THE AUTOMATIC CHANGE

In order to perform the automatic doffing cycle must be fulfilled certain conditions.
The full list can be checked in the dedicated diagnostic page.
Green: the condition is satisfied.
Red: the condition is not satisfied.
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Conditions for automatic cycle
During normal operation of the machine, when the Master Roll being unwound has reached the
minimum diameter, the Unwinder automatically perform the bonding of the sheet of the new Master
Roll with the one of the Master Roll being unwound and subsequently cutting.
To perform these automatic operations, however, is necessary to prearrange the Master Rolls that are
loaded on the Unwinder, cutting the tail in a particular way and applying the double-sided tape.
Master roll prearrangement
In addition to the cut edge of the sheet and apply the double-sided tape, the Operator must also take
care to stop the tail with small pieces of tape, very weak. The pieces of tape will prevent the tail to
"flutter" during rotation of the revolver, but will also have to come off or break during the bonding of
the sheet in the doffing process.
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At the end of the doffing, the Operator will have to download the finished Master Roll, which is located
on the loading station.
To do this he will need to lift up the lifting platform, then open the chucks and lower down the platform.
The Operator then removes the Master Roll from the lifting platform using a suitable lifting device.
NOTE
TO DO THIS YOU WILL NEED TO RAISE THE LIFTING PLATFORM SUPPORT UNTIL THE COIL,
THEN OPEN THE TAILSTOCK AND BRING DOWN THE PLATFORM.
7.7.4.2
WINDER START-UP
The operator shall draw winding shaft, preparing it for the threading and the charge in the storage.
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NOTE
To simplify the initial threading of the machine it is recommended the use of double-sided tape, to be
applied on the winding shaft.
EN
- The operator turns on the control panel, open the air supply valve then press the "RESET
EMERGENCY.
- Move pressing arms to "EJECT" position.
- Lower the loader arms (primary forks) and place the winding shaft on the slides against
the main drum.
- Move pressing arms in position "PRESS" against the main drum and returns the loader
arms in a high position.
- Start the procedure of introduction of the product.
- The operator starts the whole production line at the desired threading speed (10 m/min), and
selects the speed control mode DRAW.
WEB THREAD UP
- When the product is in proximity of the Winder, passes it over the first guide roller, around the
cutting roller, in contact with the spreader roller, and then between the drive roller and the
winding shaft.
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Windy 666
Windy Custom 662
- There are air blowers, operated by the button located on the back of the Winder, which serve to
facilitate this operation. Starts the threading blowers and keep them active until the product
reaches the Main drum, by turning off the blow, the sheet passes between the shaft and the
Main drum.
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- Sets the length of product he wants to wand on the shaft and all the other parameters for the
optimization of the functions of the machine.
- Reset the counter.
- The Operator loads the shafts, together with the cores, on the storage.
- Now the machine is running: if necessary, the Operator can adjusts the pressure of the arms
and the product tension, so as to obtain the reel of the desired quality.
- At the end of the web threading cycle the operator will move the loader arms, which had
remained in the low position, to the up position.
NOTE
ANY SLACK OF THE PRODUCT, WHICH COULD HAVE BEEN FORMED BETWEEN THE WINDER
AND THE LINE, CAN BE RECOVERED BY THE OPERATOR BY USING THE COMMAND SLACK.
The operations so far described refer to the use of the machine during the first running cycle (for
instance, during the line starting phase).
Now the Winder is ready to start the production.
- Choose the desired working mode: AUTOMATIC, SEMI-AUTOMATIC, "MANUAL".
- The machine is now winding up: if needed, regulate the winding arms pressure so that the
product is without wrinkles.
- When the reel reaches the planned length, a siren warns the Operator to get ready to start the
reel doffing operations.
7.8
LOADING MATERIAL TO PROCESS
DANGER
FOLLOW THE PROCEDURES DURING THE START-UP "START OF THE
MACHINE A PAG. 220".
EN
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7.9
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STARTING THE WORKING CYCLE
NOTE
DURING OPERATION, THE OPERATOR MUST CHECK THAT THE MACHINE OPERATES ON A
REGULAR BASIS, IN THE EVENT OF A FAULT IMMEDIATELY NOTIFY THE SERVICE.
7.9.1 AUTOMATIC CYCLE

From the Commands page, activate the "AUTO" mode.
On reaching the end of the Master Roll the siren sounds and if all conditions are met, the automatic
doffing cycle starts.
The steps that the Machine performs during the doffing cycle are described in the section "Automatic
sequences a pag. 236".
From the Commands page, activate the "AUTO" mode.
On reaching the meter set the siren sounds and if all conditions are met, the automatic doffing cycle
starts.
The steps that the Machine performs during the cycle are described in the section "Automatic
sequences of Winder a pag. 236".
CAUTION
THE OPERATOR MUST OVERSEE ALL OPERATIONS OF THE MACHINE, EVEN
THOSE TO RUN AUTOMATICALLY.
THE AUTOMATIC DOFFING CYCLE CAN BE COMPLETED IN TWO WAYS :
1) IF IN THE SHAFT WAREHOUSE, THERE IS AT LEAST ONE SHAFT, THE

LOADER WILL AUTOMATICALLY GO TO THE UPPER POSITION WHEN THE
WINDING SHAFT WILL NOT INTERFERE MORE WITH HIS MOVEMENT.
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2) IF THE SHAFT WAREHOUSE IS EMPTY, THE LOADING ARMS REMAIN IN

THE DOWN POSITION. THE OPERATOR WILL MANUALLY RAISE THEM,
AFTER PLACING AT LEAST ONE SHAFT IN THE WAREHOUSE.
7.9.2 SEMI-AUTOMATIC CYCLE

EN
From the Commands page, activate the "SEMI-AUTO" mode.
The semi-automatic cycle always requires Operator intervention to perform the doffing cycle, which
takes place as in the automatic mode, differing only in this:
- The operator, if the conditions are fulfilled, can start the doffing cycle at any time, in example
without waiting for the achievement of set meters.
From the Commands page, activate the "SEMI-AUTO" mode.
The semi-automatic cycle always requires Operator intervention to perform the doffing cycle, which
takes place as in the automatic mode, differing only in this:
- The operator, if the conditions are fulfilled, can start the doffing cycle at any time, in example
without waiting for the achievement of set meters.
7.9.3 MANUAL CYCLE

From the Commands page, activate the "MANUAL" mode.
When "MANUAL" mode is active, the Operator has to use the controls on the panel to run the
machine for the correct sequence of movements in order to run the doffing cycle.
From the Commands page, activate the "MANUAL" mode.
When "MANUAL" mode is active, the Operator has to use the controls on the panel to run the
machine for the correct sequence of movements in order to run the doffing cycle.
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7.9.4 AUTOMATIC SEQUENCES

7.9.4.1
NO-STOP UNWINDER - AUTOMATIC SEQUENCES
The conditions to enable the reel automatic doffing cycle are shown in the diagnostic pages.
- The winding arms are not in ejecting position.
- Supports are closed.
- The cutting group is in low position.
- The cutting group motor overload relay is not tripped.
- The primary forks motor overload relay is not tripped.
- The primary forks are in high position.
- The reel parking is free.
- Drives are Ok.
- The air pressure is OK.
- The emergency is reset.
START CYCLE
Command
Effect
Start rotation of new reel

Start rotation of press roll
Start rotation of revolver
Reel at correct speed
-->
Press roll at correct speed

Revolver in position for raising of cut group
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Command
Version: 1.0
Effect
Raising of the cutting group

-->
Cutting group high
-->
Revolver in splicing position
Revolver rotation
Raising of the press roll
EN
-->
Press roll in high position
-->
Cutting blade forward
Cut
Wound of the tail

Cutting blade backwards
Descent of press roll
Timer of rewind
-->
Blade at rest
Press roll lower
Descent of the cutting group.

Stop of press roll
-->
Cutting group high.

Press roll stopped
Revolver rotation
-->
Revolver in unwind position
END CYCLE
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AUTOMATIC SEQUENCES OF WINDER
Sequences
CAUTION
IF YOU NEED TO STOP THE AUTOMATIC DOFFING CYCLE, SWITCH TO
MANUAL MODE (SWITCH ON THE CONTROL PANEL). THEN, MANUALLY
COMPLETE THE STEPS FOR THE DOFFING CYCLE.
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7.10 STOP
7.10.1 NORMAL STOP
It is possible to stop the Machine in normal stop or fast stop:
- STOP (normal stop): this button operates on the motors controlled by the drives and stops them
slowly in the normal set time.
- FAST STOP: this button operates on the motors controlled by the drives and stops them quickly
in the set time.
7.10.2 EMERGENCY STOP
NOTE
DO NOT USE IMPROPERLY (AS A NORMAL STOP OR FAST STOP)
This button operates on the motors controlled by the drives and stops them slowly in the normal set
time.
The machine has been designed so as to have a double level of movement blocking :
- At software level, all actuators (pneumatic and hydraulic) and all auxiliary electrical circuits are
blocked so that the machine is disconnected.
- At hardware level, the supply for the PLC output cards that operate on the actuators and for the
solenoid valves that manage dangerous parts, is switched off.
The drives, the PLC, the output cards referring to signalling and alarms as well as the input cards are,
on the contrary, not switched off.
EN
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7.10.3 RELEASE AND RESTORING AFTER THE EMERGENCY.

After pressing the emergency button to restore the proper functioning of the machine do the following
:
- Remove the cause of the shutdown or malfunction.
- Turn and pull the emergency stop button.
- Press the Alarm Reset button.
- The machine is ready waiting for commands.
7.11 CHANGE OF SIZE

7.11.1.1 MANUAL MODE
Whenever it is necessary to change the width size of the Master Roll, follow the steps below.
Setting system
The movement of each chuck is performed by acting on the wheel (1), while the position is indicated
on the ruler (2).
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7.12 DIAGNOSTICS AND ALARMS
DANGER
EN

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Sections Title: Maintenance
CHAPTER 8
Pag. 243 ( 58 )
Version: 1.0
EN
CHAPTER 8.
MAINTENANCE
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8.1
CHAPTER 8
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SAFETY WARNINGS
NOTE
PAG. 101".
DANGER
It is forbidden to work on the machine with procedures, or operators or operators
with only qualifications other than those specified in this manual. Access to the
machine and the surrounding areas is allowed only to authorized and qualified
personnel who are fully aware of all the safety measures and techniques of the
machine.
THE MAINTENANCE OPERATIONS MUST BE PERFORMED BY AN EXPERT OR

INFORMED OPERATOR, AUTHORIZED BY THE CUSTOMER.
It is forbidden to carry out the maintenance, cleaning, repair, inspection or

adjustment with the machine switched on or otherwise without first disconnected
and locked the machine. See " Procedure for Lockout and Tagout a pag. 249 ".

EN
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OPERATORS ASSIGNED TO MAINTENANCE FIRST OF ALL MUST LOCK THE

ELECTRICAL, PNEUMATIC AND HYDRAULIC SUPPLY OF THE MACHINE.
FURTHERMORE, THOSE SAFETY GATES, WHICH HAVE TO REMAIN OPEN
FOR MAINTENANCE REASONS, MUST BE LOCKED OPEN IN ORDER TO
PREVENT THEIR ACCIDENTAL CLOSURE.
BEFORE STARTING ANY MAINTENANCE OPERATIONS, THE MAINTENANCE

PERSONNEL MUST MAKE SURE THAT NOBODY IS INSIDE THE MACHINE
AND, IF NECESSARY, TAKE MEASURES SO AS TO AVOID THEIR ACCESS.
ALLOW ANY HOT PARTS TO COOL BEFORE PERFORMING MAINTENANCE

OPERATIONS ON THE MACHINE.
DANGER - ELECTRICAL
OR
THE ELECTRICAL TECHNICIANS SHOULD HAVE THE ELECTRICAL

REQUIREMENTS OF THE LAW IN FORCE IN THE COUNTRY OF
INSTALLATION OF THE MACHINE AND MUST HAVE READ THE WIRING
DIAGRAM AND THIS HANDBOOK.
MAINTENANCE AND ADJUSTMENT OPERATIONS WITH THE ELECTRICAL

PANEL OPEN ARE ALLOWED ONLY TO QUALIFIED ELECTRICAL
PERSONNEL, AFTER IDENTIFYING WITH CERTAINTY THE PARTS UNDER
VOLTAGE.
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DANGER OF ELECTRIC SHOCK. EVEN WITH THE MAIN SWITCH TO "0"

THERE ARE STILL AREAS OF DANGER INSIDE ELECTRICAL PANEL. PAY
ATTENTION TO THE INPUT/OUTPUT TERMINALS THAT CONNECT THE
MACHINE TO THE UTILITIES AND THE INPUT TERMINALS OF CONTACTORS
AND FUSES.
EN
IF THE TYPE OF MAINTENANCE OR ADJUSTMENT DOES NOT ALLOW TO
DISCONNECT THE POWER SUPPLY IT IS RECOMMENDED TO IDENTIFY WITH
CERTAINTY THE ACTIVE PARTS OF THE MAINTENANCE AND ALL THE
POINTS OF POSSIBLE POWER SUPPLY.
REALIZE THE CONDITION OF DOUBLE INSOLATING PROTECTION AGAINST

LIVE PARTS ON WHICH OPERATING.
KEEP STRICTLY THE DISTANCE OF 15 CM BETWEEN THE LIVE PARTS OF

THE INTERVENTION AREA AND PARTS OF THE BODY NOT COVERED BY
INSULATION.
WARNING
THE MAINTENANCE INTERVENTION MUST BE REPORTED AND AUTHORIZED
BY SAFETY PERSONNEL. DURING THE MAINTENANCE OPERATIONS IT IS
NECESSARY TO INDICATE THROUGH THE RELATED SIGN THAT THE
MACHINE MUST NOT BE STARTED, THAT MANOEUVRES MUST NOT BE
CARRIED OUT AND THAT IT IS UNDERGOING MAINTENANCE.
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AVOID CARRYING OUT EMERGENCY OR TEMPORARY REPAIRS.
SUFFICIENT LIGHT MUST BE PROVIDED FOR SAFE OPERATIONS ON THE

MACHINE.
TO ACCESS THE TOP OF THE MACHINE IT IS ABSOLUTELY FORBIDDEN TO

CLIMB ON IT OR USE IMPROPER MEANS; THEREFORE USE A LADDER,
WHOSE CHARACTERISTICS COMPLY WITH THE STANDARDS IN FORCE IN
THE COUNTRY WHERE THE MACHINE IS INSTALLED..
CAUTION
BEFORE RESTARTING THE MACHINE REMOVE THE WORN COMPONENTS,
PACKING MATERIALS AND EQUIPMENT USED IN THE WORK AREA.
THE FREQUENCY OF MAINTENANCE OPERATIONS IS DETERMINED BY THE

OPERATING TIME, BUT MUST NEVER EXCEED THE MAXIMUM TIME
SCHEDULED IN THE MAINTENANCE TABLES.
WITH THE PASSING OF TIME IT IS NECESSARY TO INCREASE THE

FREQUENCY OF PREVENTIVE MAINTENANCE OPERATIONS.
USE ONLY ORIGINAL SPARE PARTS.
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IN CASE OF WEAR OR BREAKAGE OF A COMPONENT IMMEDIATELY

CONTACT THE CUSTOMER SERVICE TO ORDER THE SPARE PART.
SHOULD THESE REPLACEMENTS CREATE ANY PROBLEMS OR BE MORE

FREQUENT THAN EXPECTED, NOTIFY IMMEDIATELY A.CELLI NONWOVENS
S.P.A. CUSTOMER CARE .
8.2
PROCEDURE FOR LOCKOUT AND TAGOUT
NOTE
THE PROCEDURE MUST BE PERFORMED BY MECHANICAL AND ELECTRICAL MAINTENANCE
TECHNICIAN, EACH ON HIS ENERGY SOURCE FIELD.
IT IS NECESSARY TO SIGNAL THAT THE MACHINE IS UNDER MAINTENANCE.
MARK OUT THE MAINTENANCE AREA AND SIGNAL THE INTERVENTION WITH A SPECIAL SIGN
ON THE CONTROL PANEL IN A CLEARLY VISIBLE WAY.
EN
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INDICATE THE ABSOLUTE PROHIBITION TO RESTORE THE POWER SUPPLY VOLTAGE AND TO
PERFORM ANY OTHER OPERATION.
The isolation procedure must be performed before any repair and / or maintenance on the machine, in
any case before dismantling any part thereof, and whenever it is explicitly required by the procedures.
This procedure involves locking, with a padlock, the operating handles of switches and valves in the
safe position to prevent unexpected start up or release of stored energy that may cause injuries.
Safety message on electrical
Example of locking off the main
Example of locking off and tagging
equipment
pneumatic valve
an electrical switch
- Prepare and announce the shutdown.

- Turn off the machine and all equipments.
- Isolate the energy sources.
- Apply Lockout and Tagout devices.
- Release all residual energy.
- Verify isolation.
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8.2.1 TAG, LOCK, CLEAR AND TRY PROCEDURE

The aim is to establish a standard procedure ensuring that any equipment or process shut down or
de-energized for maintenance, cleaning, repairs and/or inspection are properly tagged, locked,
cleared, and tried prior to performing any of these tasks.
EN
8.2.1.1
GUIDELINES
Each individual on the work site is personally responsible for following the Tag-Lock-Clear-Try
procedure.
Locks are intended for individual protection.
Each individual is responsible for making sure that an effective lockout has been carried out prior to
performing work on a piece of equipment or part of a process that has been shut down so as to avoid
sudden and unexpected start-ups.
Tag, Lock, Clear, and Try is a sequential process.
It is the responsibility of each individual to verify that all four steps have been properly completed
before performing any tasks.
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8.2.1.2
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ACCOUNTABILITY
Tagging and Locking of equipment is a relatively straightforward procedure. However, it does involve
each individual being responsible for installing a tag and a lock on each isolation point prior to
beginning work.
In order to safely handle these issues it is very important to use the concept of accountability.
This concept applies to those authorized to operate the equipment as well as to those responsible for
identifying the necessary lockout points.
The following is a general list of managers:
- The manufacturing organizations in charge of production equipment
- The maintenance organizations responsible for shop equipment
- The electrical groups responsible for the power distribution equipment.
If it is unclear who is the person responsible, the decision shall be reached by communication with the
manager responsible for the physical location of the equipment or process and the area safety office
having responsibility for the location.
8.2.1.3
TAGGING
The production and the area manager is responsible for applying "Danger - Do Not Operate" tags to
equipment or processes being shut down or de-energized for cleaning, repairing, inspection, or
maintenance before any of these tasks (cleaning, repairing,) are performed. Tags certify that the
equipment or process has been made safe and is ready for locks to be applied.
TAG APPLICATION
The manager area is responsible for:
- Operating (close, open, vent, etc.) all valves, switches, and controls according to area
procedures;
- Identifying each lockout point with a "Danger-Do-Not-Operate" tag.
Tagging should be performed in the presence of the person who will perform the work or the lead
person of the group who will perform the work. This step will ensure that all lockout points, tagged by
the owner area, will be properly locked by the person(s) performing the work.
Tags must clearly contain the following printed information:
- purpose of the tags
- name of person applying tags
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- date tags are applied
EN
Exemple of Tag
8.2.1.4
LOCKING
The padlock inside the padlock cabinets are the only recognized safety locks on this plant, and shall
not be used for any other purpose.
- Each lock is to be clearly identified with the owner's name.
- When in use, the key to the lock must be kept with the owner's person.
- Only one key will be issued to an individual for assigned locks. Any other duplicate key will be
destroyed. If the issued key is lost, the locks will be cut and destroyed and a new set of locks
issued.
The area owner who issued the locks is also responsible for the destruction of spare keys.
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INDIVIDUAL LOCK OUT

Every time work is performed or personnel enter the equipment their personal lock must be placed on
each lockout point so that the potential hazard has been identified on the equipment in question.
NOTE
NO LOCKS ARE TO BE PLACED ON ANY LOCKOUT POINT UNLESS THE OWNER OF THE
EQUIPMENT HAS PLACED A DANGER - DO NOT OPERATE TAG.
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EN
CLEARING
Once locks have been placed on equipment, the area around the equipment must be cleared before
performing the "Try" step of "Tag, Lock, Clear, and Try" procedure.
To properly clear an area or piece of equipment, all personnel, equipment, tools, or other items that
could interfere with equipment, if start-up occurred, must be removed from operating path.
Guards should be in place or the affected area must be barricaded and all start-up precautions,
according to area procedures, must be taken before performing this operation.
8.2.1.5
TRY
Once equipment has been properly tagged, locked, and cleared, a positive try must be performed to
verify that the equipment is in a safe state prior to beginning work.
Any operation that is performed to satisfy this "Try" step must be preceded by "Tag, Lock and Clear".
The "Try" step shall also include verification that the lock is indeed locked, and that the device on
which the lock is applied cannot be operated.
- After completing tag, lock, and clear steps, a positive action must be taken to verify that the
equipment has been properly locked per area procedures.
- When performing work on equipment that has a start push-button that will positively act to
restart the equipment, it is considered safe to work if the equipment does not start.
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- Whenever a start button is used to try electrically driven equipment, the stop button must be
pushed following the try step. This is necessary to prevent unexpected start-up during the
unlocking of energized circuits.
- When performing work on equipment that utilizes "Try" lights to indicate that the circuit is
energized, it is considered safe to work if the light was observed to be "On" prior to deenergizing and locking the circuit and the light remains "Off".
WARNING
AFTER IT IS POSSIBLE PROCEED WITH MAINTENANCE, CLEANING, REPAIRS
OR INSPECTION.
STORED ENERGY
Stored energy can take on many forms and can be present when you least expect it..
Springs are the most common type of equipment associated with stored energy; some other
examples are:
- pipeline movement after breakage due to it being under tension
- equipment that can be affected by gravity
- lifting devices
All equipment should be reviewed for potential stored energy sources. Where possible, the source of
the stored energy should be removed.
Should this be not feasible, appropriate measures shall be taken to assure that the source of the
stored energy is controlled (e.g. blocking, chucks, other types of physical restraints) so that the
equipment is in a "safe state".
HYDRAULIC COMPONENTS
For the maintenance of hydraulic components (valves, actuators, pipes, hydraulic units,) the
following procedures must be complied with:
- Verify that nobody is inside the maintenance areas and that the safety fences are activated.
- Place the moving parts of the machine in their neutral position and then turn off the electrical,
hydraulic and pneumatic supply.
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- Apply the lockout-tagout procedures on:

- Main power supply on the electrical cabinet;
- Three ways valve on the hydraulic unit.
- Remove any remaining pressure in the hydraulic pipes by pressing the two buttons of the
hydraulic valves using a screw-driver, as shown in the drawing below:
EN
Only when the above mentioned operations have been thoroughly carried out, it is possible to
proceed with the safe dismantling of the hydraulic components.
PNEUMATIC PARTS
For the maintenance of the pneumatic components (valves, actuators, pipes, manifolds,) the
following procedures must be complied with:
- Verify that nobody is inside the maintenance areas and that the safety fences are activated.
- Place the moving parts of the machine in their neutral position and then turn off the electrical,
hydraulic and pneumatic supply.
- Apply the lockout-tagout procedures on:
- Main power supply on the electrical cabinet;
- Main pneumatic valve.
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- Remove any remaining pressure in the actuators by pressing the buttons of the pneumatic
valves using a screw-driver, as shown in the drawing below.
Only when the above mentioned operations have been thoroughly carried out, is it possible to
proceed with safe dismantling of the pneumatic components.
8.3
ORDINARY AND PREVENTIVE MAINTENANCE
8.3.1 PERIODICAL CHECKING

The two main causes of the most common machine failures are :
- The machine is not properly maintained.
- High turnover of operators leads to maintenance neglect.
NOTE
READ THE PARAGRAPH "SAFETY WARNINGS A PAG. 245" IN THIS CHAPTER. USE THE
PERSONAL PROTECTIVE EQUIPMENT INDICATED.
A PROPER MAINTENANCE PROGRAM WILL NOT ELIMINATE ALL PROBLEMS BUT WILL
REDUCE EQUIPMENT DOWNTIME, EXTEND EQUIPMENT LIFE AND REDUCE MAINTENANCE
COSTS.
THE RIGHT PERIOD BETWEEN TWO SUBSEQUENTLY OPERATIONS WILL BE EVALUATED BY

THE CUSTOMER, ONCE THE MACHINE HAS BEEN OPTIMISED AND IN A STEADY STATE,
ACCORDING TO WAY OF USING AND WORKING MODE AND ENVIRONMENTAL AND OPERATIVE
CONDITIONS.
WARNING
DISASSEMBLY AND ASSEMBLY OF MACHINE PARTS MUST BE MADE BY
QUALIFIED PERSONNEL USING APPROPRIATE TOOLS AND WORKING
METHODS.
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THE MACHINE MUST FOLLOW A REGULAR MAINTENANCE PROGRAM.
GENERAL MAINTENANCE CHART

N Maintenance operation
40 160 500 Qualification

h
of personnel
Check the correct positioning

1
of all the safety devices . If

necessary, restore the initial
Dust the Machine with a

suction device.
8h
safety devices. If necessary,
8h
replace the faulty component.

Clean the air filters for
4
ventilation of the motors. If
necessary, replace.
Check the level of lubricating
5
the machine. If necessary, top
up.
Check the oil filters. If you

need to replace.
Drain the water of

7
condensation in the water
operators
turned on
waiting for
commands
Control and efficiency of the

3
Nr. of
Machine is
position.
Machine Status
separator / air.
Cut energy Lockout-Tagout
Machine in
operation
Check anomalous
8
temperatures (E.g.: the oil

temperature of the hydraulic
unit).
EN
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h
of personnel
Check the values of the

9
pneumatic and hydraulic
Machine Status
Cut energy -
Lockout-Tagout
pressures.
Nr. of
operators
Check for air and hydraulic

leakage of the pneumatic and
10 hydraulic cylinders and circuits
Cut energy -
Lockout-Tagout
and change the seals, if
necessary.
Control and efficiency alarms.
11 If necessary, notify your
service representative.
Cleaning the fan filter on the
12 electrical panel. If necessary,
replace.
Control boxes (efficiency
13
control buttons). If necessary,

notify your service
Machine in
operation
Machine is
X
representative.
turned on
waiting for
commands
Check the cleanliness of the

14
outer surface of the electric

motors. If necessary, perform
the cleaning.
Check that the correct
fastening of the fixed guards
15 and bodies of power
transmission. If necessary
tighten the fasteners.

Check the condition of the
16
bearings ( for proper greasing

see the list of lubricants). If
necessary, replace.
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h
of personnel
Check the connections of

17 electrical cables . If necessary,
Cut energy -
Lockout-Tagout
tighten the clamps.
Nr. of
operators
1
EN
Cleaning the inside of electrical

18 cabinets and enclosures of the
Machine Status
machine.
Visual inspection of the status

19
of the contactors and

components in general. If
necessary, replace .
Visual inspection of pipelines
20 furniture . If broken , replace
them.
Check the efficiency of the
21
emergency circuit . If
necessary, replace the
Machine is
X
malfunctioning parts .
turned on
waiting for
commands
Checking the tightening of the

22
bolts of the machine. If

necessary , tighten the
fasteners .
Check the drive belt conditions
23 and replace them, if
necessary.
8.3.2 SAFETY DEVICE CHECK
Machine is running
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- Check that all emergency buttons on the machine are working properly.
- Check that the locking devices positioned on the access doors in the machine's operating area
are working.
- Check that the safety cord - used to stop the machine in an emergency - is working.
- Check that the foot-operated pedals are working and that they allow you to stop the machine in
an emergency.
8.3.3 MAINTENANCE ON COMMERCIAL PARTS
NOTE
FOR THE REPLACEMENT OF SOME OF THE MOST IMPORTANT PARTS, AS WELL AS FOR
THEIR MAINTENANCE OR THEIR POSSIBLE REINSTALLATION, PAY ATTENTION TO THE
INFORMATION OF THE DIFFERENT SUPPLIERS DESCRIBED IN THE ADDITIONAL
DOCUMENTATION AND ENCLOSED IN THIS INSTRUCTION BOOK.
8.3.4 ORDINARY MAINTENANCE FOR ELECTRICAL PLANT

8.3.4.1
PURPOSE
An electrical plant, perfectly installed and accurately assembled and started, ensures a long and
trouble-free working life, with no inconveniences and without requiring any special maintenance.
The overall plant maintenance is essentially made up of several small operations that, in order to be
effective, must be performed on a regular basis. It is therefore very important that such operations,
even if they are very simple, are planned and outlined on the maintenance card of the machine or of
the whole plant itself. On such cards the maintenance operator can register the interventions carried
out and the malfunctions possibly encountered.
The following periodical maintenance operations are therefore extremely important to be performed.
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CLEANING THE PANELS
On a monthly basis, it is necessary to proceed to clean thoroughly all the electrical panels near the
machine to reduce the risks of overheating and fire.
8.3.4.3
VERIFYING THE COMPONENTS
All the electrical components installed to serve the machine (switches, relays, drives, fuses,
transformers, etc.) that are listed in the electrical diagrams, are accompanied by a specific manual
compiled by the manufacturers, which describes the check and maintenance procedures. The user
must carry out the maintenance following the procedures outlined.
8.3.4.4
VERIFYING THE CABLES AND WIRING
On a six-month basis, it is necessary to proceed to verify that the wiring is functioning correctly by
inspecting the panels, the cable raceways, the connections to the appliances (motors, sensors,
valves, etc.). In the event that a component is clearly worn, broken or loose it is necessary to proceed
to repair and/or replace it.
8.3.4.5
VERIFYING CORRECT FUNCTIONING OF DIFFERENTIAL SWITCHES AND

GROUNDING SYSTEM
On a yearly basis, it is necessary to proceed to verify the correct functioning of the differential
switches
and to measure the resistance to ground in compliance with the current regulations
applicable in the country the system is installed.
NOTE
BEFORE CARRYING OUT ANY INSPECTIONS OR MAINTENANCE ACTIVITIES ON THE
ELECTRICAL PLANT, READ CAREFULLY THE FOLLOWING POINTS.
EN
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8.3.5 MAINTENANCE OF PNEUMATIC PLANT

A preventive maintenance keeps the pneumatic plant in the best possible conditions, preventing and
reducing the possibility of unexpected sudden stops of the machinery.
Maintenance operations should be planned according to installation conditions and plant usage.
Maintenance operations must be carried out only by expert and qualified staff. Compressed air can
be dangerous for those who do not know its physical principles.
Every operation must be carried out in complete safety conditions, previously deactivating any
pneumatic, hydraulic and electric energy sources.
When the operation is over and before restoring the energetic sources, ensure that no one is in the
machine area.
To plan a good preventive maintenance under normal environmental working conditions, as far as
temperature, humidity and dust are concerned, in a proper and workmanlike plant with clean and dry
air, keep to the following times.
8.3.5.1
PERIODICALLY
- Empty all filters of the condensate. Clean the polycarbonate cup, using only water and neutral
detergents.
- Check the values set for the pressure gear reducers.
8.3.5.2
MONTHLY
- Check pipes and pipe fitting seals.

- Check the state of filtering elements.
- Operate the valves, at least once every 30 days, in order to avoid any possible malfunctions.
8.3.5.3
SIX-MONTHLY / YEARLY
- Disassemble and clean every component, replace worn parts, reassemble and lubricate gaskets
with the appropriate grease.
- Filter.
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- Pressure reducer.
- Cylinders (max. 500000 m/year).
- Valves (max. 20000000 exchanges)
8.3.5.4
LUBRICATION
Pneumatic components do not require additional lubrications during the working phase, because they
have been greased during the assembling.
In case of need, it is important to use only TURBINE OIL CLASSE 1, ISO VG32 oil (without
additive).
Pay attention to the instrumentation, which must never be lubricated.
CAUTION
ONCE THE COMPONENT HAS BEEN USED WITH LUBRICATED AIR, THIS
MUST BE CONSTANTLY KEPT FOR THE WHOLE WORKING TIME, BECAUSE
THE GREASE INTRODUCED IN THE ASSEMBLY HAS BEEN WASHED AWAY
BY THE LUBRICANT.
8.3.6 ORDINARY MAINTENANCE FOR OIL-HYDRAULIC PLANT

8.3.6.1
PURPOSE
An oil-hydraulic plant, perfectly installed and accurately assembled and started, ensures a long and
trouble-free working life, with no inconveniences and without requiring any special maintenance.
The fundamental principle is to continuously control the quality and the condition of the fluid
transmitting power together with the absence of impurities in the circuit, which is directly related to the
reliability of any oil-hydraulic machine.
EN
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The overall plant maintenance is essentially made up of several small operations that, in order to be
effective, must be performed on a regular base. It is therefore very important that such operations,
even if they are very simple, are planned and outlined on the maintenance card of the machine or of
the whole plant itself. On such cards the maintenance operator can register the interventions carried
out and the malfunctions possibly encountered.
The following periodical maintenance operations are therefore extremely important to be performed
NOTE
BEFORE CARRYING OUT ANY INSPECTIONS OR MAINTENANCE ACTIVITIES ON THE
HYDRAULIC PLANT, READ CAREFULLY THE FOLLOWING POINTS.
8.3.6.2
EXTERNAL CLEANING
A monthly external cleaning permits to detect any possible leaks and take immediate action against
them.
8.3.6.3
AIR FILTER CONTROL
The air filters must be changed on a monthly basis. The control period can vary according to direct
on-site experience and environmental conditions. The air filter is a self standing container in medium
and large size plants. In small plants, it is located in the oil inlet plug.
8.3.6.4
OIL FILTER CONTROL
This operation is extremely important. It must be performed on a weekly basis.
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A - SUCTION FILTERS
a) Immersed filters, which are normally assembled on small units, are not visible from the outside,
therefore every time the hydraulic oil needs substituting, they should be changed as well.
b) The external filters are normally equipped with an electrical obstruction indicator; when the
indicator signals an obstruction, the filtering cartridge must be immediately replaced, following the
below mentioned procedure.
Spin on filter (on line):
Switch off the hydraulic unit.
Unscrew the container using a chain wrench.
Substitute the cartridge with another one alike (code stamped on the container), making sure to
lubricate the sealing with a small quantity of oil before screwing it back to the container.
Switch on the hydraulic unit.
Half-immersed filter:
Unscrew the screws that block the lid against the filter container (located on top).
Take the lid off and extract the contaminated filter cartridge (mind the spring position).
Insert the new cartridge.
Re-assemble the lid and tighten the screws.
Switch the hydraulic unit back on.
B - INLET FILTERS
These filters are located between the pump and the distributing group. They are normally equipped
with an electric visible obstruction indicator. The electrical contact advises the PLC that the filter is
obstructed, while the visible indicator which is normally a green ring enclosed in a transparent
container, progressively turns red because of the obstruction.
Follow this substituting procedure:

Manually discharge the line pressure by means of the first electro-distributor (with in line
accumulators, there is always a manual tap on the discharge itself).
Unscrew the filter using a hex key (on the bottom of the container is a hexagonal end fit for
purpose). Obtain a bowl to collect the oil that comes out from the container.
Extract the filter by pulling it downwards (with vertical filters).
EN
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Clean the bottom of the container from the deposited oil and from any possible contaminants.
Re-assemble a new cartridge.
Tighten the container minding the position of the oil seal.
Close any possible discharge pressure taps.
Switch the hydraulic unit back on.
C - OIL RETURN FILTERS
They are normally located between the distributor and the tank, and can be equipped with electric
visible obstruction indicators they can be divided into:
In- line spin on filters (see above point for their substitution procedure).
Half-immersed filters (see above point for their substitution procedure).
To carry out all the maintenance operations please refer to the oil-hydraulic diagrams, necessary to
identify the components and to locate them on the unit.
8.3.6.5
FLUID TOP UP
The top up must be made when the fluid level drops down to the minimum (the visible level is
mounted on the side of the tank, a transparent window indicating the internal fluid level, a high blue
line indicating its max. level, a low red line indicating its min. level).
Minimum level indicators and pump stop devices contribute to good maintenance and management of
machines running continuum.
The fluid top up must be made with the same fluid used in the first fill-up of the plant which must be
indicated directly on the tank.
The need of a continuous fluid top up proves that there is a leakage somewhere; therefore, we
recommend to check conducts, cylinders, motors, valve groups, etc. on a six month base.
8.3.6.6
FLUID CHANGE
This depends upon the plant application and its degradation.

The substitution is normally needed every 2500/3000 hours of functioning. Frequent controls of the
chemical-physical properties and the contamination grade permit a preventive intervention.
The fluid substitution should follow an accurate cleaning of the tank
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CLEANING OF THE TANK
SWITCH OFF THE HYDRAULIC PLANT

A. Small units
Take out the fluid from the special oil discharge tap, or suck it with a special pump.
In small units the tank cleaning is carried out by taking off the lid of the unit, prior to disconnecting
the pipe fastening to the utilises, and cleaning the tank with solvents or appropriate soaps, to
eliminate, sludge, deposits, water or condense, oil deposit and any other small or big contaminating
particles.
Re-assemble the tank lid and fasten the piping.
Fill up the tank with fluid and re start the plant. Purge any air left behind in the circuit.
B. Medium size and big units

Take out the fluid by means of the discharge plugs or the appropriate pumps.
Disassemble the port light (round cover located on the side of the tank) unscrewing the locking nuts.
Replace any filters immersed in the tank.
Clean the bottom of the tank with solvents or soaps to eliminate, sludge, deposits, water or
condense, oil deposit etc.
Verify that the inside surface of the tank and the area under the lid is clean.
Re-assemble the coverlid and check the gasket.
Fill up the tank with the fluid
Re-start the unit.
USED OIL STOCKING

Used oil and filter cartridges as well as all the instruments and tools used to clean the unit (rugs,
sponges, ) must be stocked in an area marked by a used oil signal. Specialised, certified firms
must dispose of the above mentioned items.
When purchasing any kind of hydraulic fluid, the customer should receive a certificate of origin
specifying its chemical and physical features as well as its usage.
EN
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FLUID TEMPERATURE CHECKS

The wear and tear of the fluid caused by high temperature can severely damage the unit.
Heat can considerably influence the formation of degradation products.
Oxidation speed can be considered as constant up to an oil temperature of 60C; beyond this level,
the speed doubles every 10C.
The usual oil temperature in service plants running continuum can vary between 49c and 58C and
must be checked on a weekly basis.
HEAT EXCHANGER
a) Air/oil exchangers
At the end of each shift carefully remove any dust and particles blocking the radiant mass of the
exchanger. This procedure can be carried out both manually and by means of compressed air
working in the opposite direction of the air moved by the solenoid-valve.
b) Water/oil exchangers
They have to be cleaned every six months approximately. The frequency of this intervention varies
according to the quality of the water.
The daily check of the fluid temperature indicates the deteriorating thermal exchange conditions and
the need to proceed with maintenance works on the exchanger.
8.3.6.8
ACCUMULATOR PRE-CHARGE CHECKS
The pre-charge of the accumulator should be checked every two months by means of appropriate
instruments. Proceed as follows.
- a) Switch the hydraulic unit off and discharge the accumulator pressure by means of its tap.
- b) Remove the upper lid and insert the checking instrument.
- c) Verify the pressure and the result with the data indicated on the hydraulic diagram.
- d) Should the pre-charge pressure be lower than recommended, the accumulator can be
recharged with a nitrogen bottle to be linked to the checking instrument.
- e) When the pressure is 0 and all the pre-charge attempts are unsuccessful, either the
accumulator or the nitrogen container has to be replaced.
- f) Remove the checking instrument, close the tap and re-start the unit.
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SOLENOID-VALVE, VALVE, PUMPS
It is possible to programme a series of checks that can help to determine whether any maintenance or
replacing intervention are needed.
These tests must be carried out on appropriate locations so as to trace any possible leak, wear and
tear. This operation must be carried out every 6/8 months.
Another option (since the cost of stopping the line, starting it up disassembling and reassembling it
are in fact considerable) is that of having a full set of all or at least of the main spare parts, which
needs to be replenished on a regular base.
8.3.6.10 ADVICE RELATIVE TO THE PLANT ASSEMBLY

- Install the oleo dynamic units far away from any heat source (i.e. ovens) or else carefully protect
them. Opt for well-ventilated locations to ease the thermal exchange between the tank surface
and the outside surface.
- Assemble the plant in a clean location adopting all the necessary measures to avoid any
impurities from entering the circuit.
- Check that the new fluid containers are adequately closed and kept in a cool and dry area.
- Raising prices of the hydraulic fluids and safety reasons call for frequent and strict verifications
on any possible leak. Leaks can be dangerous. They cause oil consumption, lower the rhythm
and quality of production and demand a more frequent replacement of spare parts. It has been
proved that in the long run an accurate leak prevention system turns out to be less expensive
than any other work.
- Unfortunately these oil leaks can occur and they are often caused by:
- Loosening of the connections due to bumps or vibrations.
- Water hammers for pipes too long.
- Wear and tear of dynamic seals and of those mechanical parts with which the
corresponding gaskets are in contact, due to excessive loads.
- High temperature together with wear and tear due to too much contaminant in the fluid.
8.3.6.11 OPERATIVE MAINTENANCE
In the following page we enclose a typical table for the operative maintenance of an hydraulic plant.
EN
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FORM FOR A TWO-MONTH OPERATING MAINTENANCE

Nr. .................
YEAR :
.................
TYPE :
.................
PLANT :
.................
LINE :
.................
OPERATOR :
.................
S.N. HYDRAULIC UNIT :
.................
INSTALLED :
.................
OIL CHANGE CARRIED OUT ON :
.................
AT TIME:
.................
FOLLOWING
AT TIME:
.................
FILTERS CHANGE CARRIED OUT ON :
.................
CHANGED:
CONTROL TYPE
FREQUENCY
EXTERNAL CLEANING
MONTHLY
AIR FILTER CONTROL
MONTHLY
SUCTION FILTER
WEEKLY OR
INLET FILTER
WITH INDICATORS
OIL LEVEL CONTROL
WEEKLY
OIL TEMPERATURE CHECK
DAILY
CLEANING AND CHECK OF

THE HEAT EXCHANGER
ACCUMULATORS CHECK
CYLINDERS, VALVES
AND PUMPS CHECK
.................
MONTH 1
MONTH 2
DAILY
EVERY TWO MONTHS
MONTHLY
MAINTENANCE INTERVENTIONS
AND MALFUNCTIONING:
8.3.6.12 MAINTENANCE GUIDE FOR OIL- HYDRAULIC SYSTEMS

1 - PROBLEM : INSUFFICIENT PRESSURE
Or pressure drops with respect to the level expected for the circuit.
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PROBABLE CAUSES
POSSIBLE SOLUTIONS
1) Max. pressure valve partially open
a) Pressure too low

b) Seal housings worn out
c) Impurities beneath the housings
d) Spring broken
2) Pump defective
See problem 2
3) Excessive internal leaks
a) Seals worn in the cylinders or hydraulic motors

b) Valves and distributors worn
c) Oil viscosity too low
4) Excessive load losses
a) Oil viscosity too high

b) Oil passage too small
c) Oil passage partially obstructed
8.3.6.13 2 - PROBLEM : PUMP DEFECTIVE

For little or no capacity with respect to normal valves.
PROBABLE CAUSES
POSSIBLE SOLUTIONS
1) Throttled intake
a) Intake filter too small or clogged

b) Intake hose obstructed
c) Intake hose small or winding
2) Air intakes
a) In the tank inlet

b) In the intake fittings
c) In the seals on the pump shaft
d) Due to oil intake with foam
3) Tank hermetically sealed
Air breather in tank obstructed
4) Defective activation
a) Check coupling
b) Speed too high or too low
5) Oil viscosity too high
See instructions for pump
6) Breakages inside the pump
a) Internal seals broken

b) Blades, plates or pistons stuck
c) Pump head not tight
d) Broken internal parts to be replaced
7) Pump excessively worn
a) Pump to be replaced
EN
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8.3.6.14 3 - PROBLEM : PUMP NOISY

Abnormally (i.e., some gear pumps are always rather noisy)
PROBABLE CAUSES
POSSIBLE SOLUTIONS
1) Cavitation
a) Throttled intake: see problem 2

b) High viscosity: see problem 2
2) Air intakes
See problem 2
3) Internal wear
Excessive slack in supports and plates
4) System vibrations
Defective installation, resonance, etc
8.3.6.15 4 - PROBLEM : OVERHEATING

That is, oil temperature rises above the prudential limit of 50 - 60 C.
PROBABLE CAUSES
POSSIBLE SOLUTIONS
1) Maximum pressure too high
Excessive valve setting
2) Power used needlessly
a) Cut-off valve insufficient

b) End-of-cycle short circuit in-operative
c) Hydraulic circuit to be modified
3) Excessive internal leaks
See problem 2
See problem 1
5) Insufficient oil capacity
Increase the oil tank size
6) Insufficient cooling
a) Add artificial cooling

b) Coolants not efficient
7) Excessive friction
a) Defective internal pump assembly

b) Lack of lubrication where prescribed
c) Oil with little lubricating power
8.3.6.16 5 - PROBLEM : INCORRECT MOVEMENTS

Of the parts hydraulically activated with respect to the established cycle.
PROBABLE CAUSES
CHAPTER 8
POSSIBLE SOLUTIONS
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PROBABLE CAUSES
POSSIBLE SOLUTIONS
1) Air in the circuit
a) Release air bubbles in high points
CHAPTER 8
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b) Eliminate air intake: see problem 2

2) Valves blocked
a) Closing valves blocked by rubber or other

b) Valves partially open due to impurities
3) Cylinders blocked
a) Defective internal cylinder assembly

b) Inadmissible normal axis loads
c) Connecting pins stuck
See problem 1
5) Variable pressure to buffers
a) Insufficient buffer capacity

b) Higher circuit demand due to internal leaks
8.3.6.17 6 - PROBLEM : EXCESSIVE WEAR

Too fast with relation to actual running time.
PROBABLE CAUSES
POSSIBLE SOLUTIONS
1) Oil contains abrasives
a) Oil too old

b) Filters inefficient
2) Insufficient lubrication
a) Poor quality oil

b) Oil too fluid at running temperature
3) High running pressure
With relation to maximum allowed for pump and valves
4) Defective couplings
Abnormal stress on shafts and stems
8.4
LUBRICATION AND GREASING
WARNING
298."
EN
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CAUTION
DO NOT DISPERSE THE LUBRICANT OR GREASE IN THE ENVIRONMENT.
WASH HANDS THOROUGHLY IF THEM COME INTO CONTACT WITH THE

LUBRICANT.
IN CASE OF ACCIDENTAL SQUIRTS IN THE EYES, RINSE THEM WELL WITH

WATER.
IN CASE OF ACCIDENTAL INGESTIONS, DO NOT INDUCE VOMITING BUT

CALL IMMEDIATELY A DOCTOR FOR TREATMENT ADVICE.
NOTE
THE WARNINGS AND RISKS INVOLVED IN USING A MANUAL PUMP TO GREASE ROTATING OR
SLIDING PARTS MUST BE READ CAREFULLY. THE OPERATOR MUST BE FAMILIAR WITH THE
OPERATION OF THE PUMP AND FULLY UNDERSTAND WHAT THE DANGERS ARE. THIS CAN BE
DONE BY CONSULTING THE PUMP MANUFACTURER'S USER MANUAL.
READ THE SAFETY SHEET OF THE LUBRICANT USED. ORGANISE ANY PREVENTATIVE AND/
OR REMEDIAL ACTIONS IN CASE OF ACCIDENTAL CONTACT.
Obligation to wear a mask to protect the face.
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8.4.1 AUTOMATIC LUBRICATION

Not supplied.
8.4.2 MANUAL LUBRICATION

EN
Electrical power disconnected
Pneumatic power disconnected
8.4.2.1
BEARING LUBRICATION
Concerning the bearings with seals on both sides (type 2RS1) these already contain the right quantity
of lithium- based grease and this is why they are lubricated for life. They do not require maintenance
and must never be cleaned.
Concerning the lubrication of bearings without incorporated seals, these must be correctly greased at
regular intervals, to guarantee their functionality.
Grease the bearings of those motor provided with lubricators.
NOTE
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IT IS IMPORTANT TO USE ALWAYS THE SAME GREASE TYPE YOU HAVE PREVIOUSLY
ADOPTED. SOME GREASES, IN FACT, MAY LOSE THEIR LUBRICATING CAPACITY WHEN THEY
MIXED WITH OTHER DIFFERENT GREASE TYPES.
8.4.2.2
LUBRICANT LIST
Bearings:
Lithium- based grease lubrication, with ep features
Gear reducer:
Synthetic-based oil lubrication, ISO 220
- "FINA Giran S"
- "ESSO Glicolube"
- "MOBILGlycole HE"
-
"SHELL Tivela SC"
NOTE
SYNTHETIC OILS ARE NOT COMPATIBLE WITH MINERAL OILS.
The lubricant tanks have to be carefully cleaned before being filled up with synthetic oils. Moreover, it
is necessary that gaskets and rubber components of the equipments are compatible with lubricants
with polyglycole basis.
Hydraulic plant:
Oil ISO 68
- "FINA Hydran TS"
- "ESSO NUTO H"
- "MOBIL DTE"
- "SHELL TELLUS"
If respecting the most elementary safety regulations, these oils, due to their high flash point, do not
have any specific fire risk during their manipulation.
Linear slide guides:
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Linear slide guides are treated with protective oil. Internal lubrication can be made with either oil or
grease.
EN
- Refer to the following table for necessary lubricant quantities.

- When lubricating with oil, the quantity of lubricant must be introduced all at once.
- Introduce the lubricant until it seeps from the seals.
- Re-lubrication intervals depend both on the quantity used in the first lubrication and on
environmental conditions.
Normal values to be employed:
Grease: 20.000 until 200.000 m of stroke
Oil: 10.000 until 50.000 m of stroke.
Size
GREASE: first
lubrication
GREASE: re-lubrication
OIL: first lubrication and

re-lubrication
15
0.5
0.3
0.5
25
2.0
1.2
1.2
30
3,2
1,9
1,6
35
3,3
1,7
45
4,2
3,2
55
14
8,5
5,4
AMOUNT OF GREASE
The table below shows the amount of lubricating oil, grease and hydraulic oil used for the installation
and startup of the Line.
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Machine
Version: 1.0
Lubricating oil (lt)
Hydraulic oil (lt)
Grease (kg)
Axial Jumby
11
300
ACXX
12
320
12
Top Speedy
7,5
435
11,5
Speedster
25
450
15
180 Master Roll rotation
55
1,5
Stock Station (*)
6 (+4)
(+2)
Shaft Handling
10
85
1,5
Corematic
Winders
Slitter Rewinders
Master Roll Handling
Shaft Handling system
(*) The number in parentheses indicates what needs to be provided for each station.
CAUTION!
BEFORE STARTING THE LINE CHECK FOR THE PRESENCE OF LUBRICANT
IN ALL THE COMPONENTS!
8.4.2.3
LUBRICATION POINTS
Local greasers have been foreseen to carry out the periodical lubrication operations.
NOTE
THE GREASING CARTRIDGES MUST BE CLEANED BEFORE USING THE GREASE GUN.
With regards to:
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- lubricating points
- their position on the machine
- number of greasing points
- greasing type
- grease quantity
- lubrication timing
EN
Refer to the drawings :

PL2014040.pdf
PL2014041.pdf
PL2014042.pdf
PL2014039.pdf
8.5
EXTRAORDINARY MAINTENANCE
Extraordinary maintenance of the machine is intended as the set of operations that, with reference to
the strategic safety components, have the following purpose:
- Check that the installation of the components has been carried out correctly, according to the
general recommendations of the suppliers.
NOTE
INSTRUCTION MANUALS FOR COMMERCIAL PARTS ARE ATTACHED TO THIS MANUAL.
- Check that the installation of the components has been carried out correctly, according to the
general recommendations of the suppliers.
- Periodically control the components to verify their working reliability.
- For this purpose, the client must provide programmed inspection
and maintenance cards
including:
- Checks and functional tests to be carried out on the various components.
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- Time intervals over which these checks and tests must be performed.
- Responsibility for organisation and management of the tests.
- Provide the results of the tests and verifications.
- Carry out proper operations of the system calibration and regulation each time these tests and
verifications highlight any faults due to any malfunctioning of the safety components or of any
other part of the machine connected to them.
The same operation of calibration and regulation must be executed after any replacements or
interventions (modification, replacement and repair) on parts of the machine that could impair
functioning.
Such measures must always be reported to the constructor, who evaluates their functionality and
authorises their execution.
For the safety circuit inspection as for the general inspection of all electrical devices, remember that
all connections have been identified (CEI EN 60204-1 regulations) with the following colours:
- BLACK: AC and DC power supply circuits
- LIGHT BLUE: Neutral Conductor
- RED: Command Circuits AC
- BLUE: Command Circuits DC
- YELLOW/GREEN: Protection conductors
- WHITE: External Supplies
Each end of all wires has an identifier on the electrical plans: this applies to the terminal boards and
for every electromechanical or electronic parts.
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8.5.1 ELECTRICAL CUBICLES

All the verifications and inspections regarding the electrical cubicle must bring evidence of the
reliability and correct functioning of its components.
8.5.2 CONTROLS PANEL

8.5.2.1
PLC DIGITAL OUTPUTS
The PLC programming specification includes some digital outputs to control the pneumatic and
hydraulic actuators and general outputs described in the electrical diagrams.
8.5.2.2
PLC DIGITAL INPUTS
The PLC programming specification includes some digital inputs to control commands, sensors and
alarms as described in the electrical diagrams.
8.5.2.3
INTEGRITY TEST OF THE BUFFER BATTERY
Every three months check the LED BAFT state:

- LED off = buffer battery charged
- LED on = buffer battery flat. In this case, change the battery without cutting off the power supply
of the PLC.
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8.5.3 SAFETY UNITS

A safety unit controls all the locking devices (door-lock). Each locking device is controlled by a button
locking or unlocking the corresponding fence.
Each button is provided with a warning light, which switches on when the fence is locked.
The fence cannot be opened when the machine is working. Vice versa, if the fence is not closed and
locked, the machine cannot start.
A dedicated safety unit manages the emergency stop buttons. Each emergency stop button is
provided with a warning lamp, which is controlled at a hardware level by the button itself, indicating
the intervention.
By activating the emergency stop button, all auxiliaries are deactivated, except the PLC power supply,
the converters and the PLC output cards supply.
The emergency reset intervenes at a hardware level directly on the control unit.
NOTE
THE CUSTOMER IS ASKED TO SUPPLY A "NORMALLY CLOSED" CONTACT COMING FROM THE
PRODUCTION LINE, UPSTREAM OF THE MACHINE, WHICH OPENS IN CASE OF AN
EMERGENCY STOP.
8.5.4 SAFETY LIMIT SWITCHES

8.5.4.1
CORRECT USE ACCORDING TO ITS UTILIZATION
Safety switches are electromagnetic interlock devices with guard locking device. They interlock
movable protective guards so that :
- Dangerous operations on the machines can only be carried out if the guard is closed and
locked;
- The guard cannot be opened when the machine is running.
- Starting commands, which may cause dangerous conditions, can be initiated only when the
guard is in its protective position and the guard-locking device is locked.
The guard-locking device must be released only when the dangerous conditions have been
neutralized.
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Limit switch
8.5.4.2
SAFETY PRECAUTIONS
The safety switch performs a personal protection function. Incorrect installation or tampering can lead
to severe injuries to personnel.
Safety switch must not be bypassed (bridging of contacts), turned away, removed or otherwise made
ineffective.
Switchover operation can only be triggered by actuators specially provided for this purpose, which are
permanently connected to the protective guard.
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FUNCTIONING
Safety switches permit position monitoring and locking of the movable protective guard by a positiveaction locking device. The same switchover element is used for position monitoring of the guard and
interlock monitoring.
8.5.4.4
SERVICE AND INSPECTION
If damage or wear is found, the complete switch and actuator assembly must be replaced.
NOTE
REPLACEMENT OF INDIVIDUAL PARTS OR ASSEMBLIES IS NOT PERMISSIBLE!
No service work is required, but regular inspection of the following is necessary to ensure trouble-free,
lasting operation:
- Correct switching function.
- Secure mounting of components.
- Debris and wear.
- Sealing of cable entry.
- Loosing of cable terminals or plug connectors.
The complete safety switch assembly must be replaced :
- After 1 million switching operations with straight or angled actuators
- After 100 000 switching operations with hinged actuators.
8.5.5 DISMOUNTING OF COUNTER-KNIVES

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To remove the counter-knives bands proceed as follows:

- Deflate the roller from the compressed air.
- Loosen the screws of the flange.
- Before removing the flange, with suitable equipment, keep the roller to prevent the roller
cantilever can damage other parts of the machine.
- Remove the flange.
- Pull the bands of counter-knives.
To replace the bands, proceed in reverse order.
NOTE
PAY ATTENTION TO THE ASSEMBLY OF THE INTERNAL BEARING.
Unmounting sequence video

663_Smont.c_lame.avi
8.5.6 REPLACEMENT OF KNIVES

EN
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To replace the knifes, proceed as follows:

- Use a screwdriver to loosen the screw on the pressure nut of the Belleville springs,
- Push the blade rotation locking device with your finger so that you are able to undo the nut with
a prong spanner.
- Remove the Belleville springs (remembering the arrangement in which they are assembled) and
remove the blade.
- To assemble the knife, reverse this sequence. Secure the pressure nut by tightening it until the
quota "X" = 0 is reached.
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- After replacing a knife or counter-knife blade, check that the distance between the blade of the
knife holder and the counter-knife is approximately 1.5mm. This must be done with the
retractable pin inserted in the seat of centre.
- If the distance is incorrect, act on the seat, which should catch the centring pin.
- Adjust the blade overlap of the knife holder to the counter-knife blade. Sharpening changes the
diameter of the blade. To maintain the same cutting point the blade of the knife holder must be
moved towards the counter-knife.
Using an 8mm Allen key:

- loosen to increase the overlap
- tighten to reduce the overlap
The overlap value depends on the type of product being cut and the working conditions. Therefore,
you must adjust this value according to your experience. Approximate overlap values can be deduced
from the table below.
product
mm
Tissue
0.4 - 0.8
Light-heavy papers
0.4 - 1
Light cardboard-cores
0.5 - 1
Tnt
0.4 - 1.5
Side load: all cutting units must be loaded in the same way to ensure that they have an identical
degree of wear. In the Slitto system the blades are loaded against the respective counter-knives at a
pressure of 5 bar. Increasing side loading would not improve operation. Rather, it would increase the
wear of the system.
Toe-in angle: the cutting angle is set by the technical personnel of A.Celli Nonwovens s.p.a. during
assembly of the knife holder. The figure shows a left knife.
EN
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8.5.7 SHARPENING OF KNIVES AND COUNTER-KNIVES

CAUTION
SHARPENING CANNOT BE CARRIED OUT WITH THE BLADES IN THE
OPERATING POSITION. KNIFE HOLDERS MUST NOT BE USED AS SUPPORTS
FOR SHARPENING BLADES. DO NOT ALLOW DUST BUILT UP BY THE
GRINDER TO PENETRATE THE BEARINGS OF THE SYSTEM.
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- To sharpen the knives, dismantle the blades following the instructions given in the previous
paragraph.
- Only use the knife grinder on the side of the blade that is slanted by 30 degrees
EN
NOTE
WE RECOMMEND THAT YOU DO NOT RESHARPEN BLADES WITH A DIAMETER OF LESS THAN
142 MM.
- Counter-knives must be dismantled prior to sharpening, following the instructions given in the
previous paragraphs.
INDEPENDENT COUNTER-KNIVES
- Only use the knife grinder on the side of the blade that is slanted by 5 degrees
- Finish sharpening the blades manually with the grinding stone to remove very slight
unevenness that may remain.
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The counterknives must be sharp on cutting edge which and on the support surface both.
Remove on both surfaces of the same amount of material.
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EN
Sectional view of the counterknife
Ref.
Description
Counterknife
Clamping flange
Detail of surfaces to be machined
NOTE
THE SURFACES MUST BE BOTH MACHINED OTHERWISE YOU WILL LOSE THE POSITION OF
THE CUTTING EDGE.
IN CASE OF PROBLEMS, THE PROCEDURE MUST BE PERFORMED IS FOR THE OFFSET

CALIBRATION.
COUNTER-KNIVES BAND
- Only use the knife grinder on the side of the blade that is slanted by 5 degrees.
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- Finish sharpening the blades manually with the grinding stone to remove very slight
unevenness that may remain.
Counter-knife band
8.6
CLEANING
The operator responsible for running the machine must visually check the cleanliness of the machine,
with particular reference to:
- The presence of dust inside the unwinding area;

- The presence of waste inside the machine;
- The presence of dust in the transmission area;
- The presence of dust on the sensors;
- The presence of waste on the rolling guides.
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WARNING
THE OPERATOR MUST BE SUITABLY PROTECTED DURING ROUTINE

CLEANING OF THE MACHINE. WE RECOMMEND THE USE OF NORMAL
PERSONAL PROTECTIVE EQUIPMENT SUCH AS DISPOSABLE COVERALLS,
MASKS, GLOVES AND GOGGLES.
Danger of hot surfaces.

Before performing cleaning operations, wait for all parts of the machine to reach
room temperature.
FOR CLEANING OPERATIONS, DO NOT USE FLAMMABLE SOLVENTS

AND/OR WHICH MAY CREATE EXPLOSIVE MIXTURES. FOR CLEANING
OPERATIONS ALSO ACIDS AND/OR AGGRESSIVE SOLVENTS ARE NOT
RECOMMENDED. TO AVOID FIRE, USE NEUTRAL CLEANING MATERIAL
WATER BASED.
During cleaning operations, smoking and using naked flames or hot surfaces is
strictly forbidden.
CAUTION
RISK OF DAMAGE TO THE MACHINE. DO NOT USE STEEL SPATULAS TO
REMOVE EXCESS DUST. RISK OF DAMAGE TO REELS AND OTHER PARTS.
EN
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NOTE
WHEN THE CLEANING IS OVER, THE OPERATORS CHANGE AND WASH THEMSELVES, TO
ELIMINATE ANY DUST RESIDUALS FROM THEIR BODIES.
IN CASE THERE WERE SOME PROBLEMS DURING THE DIFFERENT CLEANING PHASES, TURN
TO THE PERSON RESPONSIBLE OF THE MACHINE.
Obligation to wear a mask to protect the face.
8.6.1 REMOVAL OF WASTE AND DUST
NOTE
THE CUSTOMER, ACCORDING TO THE TYPE OF MACHINED/WORKED PRODUCT, WILL HAVE
TO CONSIDER THE NEED OF AN EFFECTIVE LOCAL DUST- AND WASTE-EXHAUSTING
SYSTEM.
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THE DESIGN OF THE PLANT MUST BE CARRIED OUT FOLLOWING THE TECHNICAL
REGULATIONS AND, IF NECESSARY, ALSO THROUGH AN ENVIRONMENTAL INVESTIGATION
ON DUSTS.
The customer will have to periodically clean the machine and the working areas with a frequency that
may differ according to the greater or smaller dust emission and waste production and that will be
carried out according to a special procedure.
The cleaning of the machines must be carried out avoiding any dust lifting in the environment. Dust
can deposit even in areas hardly accessible during ordinary cleaning interventions.
Suction tubes/pipes, rather than brooms, should be used.
In some hardly accessible areas, it is possible to use compressed air jets, following the instructions :
- The operation must be carried out by two operators at the same time: one blows the dust and
the other sucks it with the vacuum cleaner;
- The two operators must be wearing masks to protect their breathing organs against dusts,
glasses, caps for the hair, protective disposable overalls to prevent any dust from entering the
clothing and the body; gloves.
- The whole staff must be kept away from the cleaning area and the air pressure must be
regulated at 2 bar, so as not to cause air blasts too strong.
- The operator with the air gun places himself near the area to be cleaned, starting slowly to
direct the air in order to eliminate any dust residuals; at the same time the other operator places
the suction tube near the dust discharge, trying to capture the greatest quantity of dust as
possible. The operator holding the vacuum cleaner must not to be directly exposed to the dust:
no more than 90 with respect to the compressed air blast.
- These operations should last as little as possible.
8.6.2 REMOVAL OF WASTE FORMED

All waste formed during production must be removed from the machine, specifically:
- Non-woven fabric;
- Pressed dust waste.
Non-woven fabric must be removed manually without pulling or tearing but by gently removing the
materials from the area where it is stuck.
EN
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8.6.3 REMOVAL OF OILS AND LUBRICANTS

Leakage of oil or grease can contaminate the product or soil sensors and devices. Therefore, in areas
where accidental leakage has occurred, thorough cleaning must be performed using degreasing and
detergent products and cloths made from cotton or a non-abrasive, synthetic material. As a general
rule, the following products may be used:
- Cleaning of transparent surfaces (alcohol)
- Cleaning of varnished surfaces (degreaser)
- Cleaning of stainless steel surfaces (protective product such a WD40)
- Cleaning to guarantee hygiene (alcohol)
8.7
ARRANGEMENTS FOR STOPPING THE MACHINE FOR LONG

PERIODS AND THEN RESTARTING.
NOTE
FOR LONGER PERIODS OF STORAGE OR INACTIVITY, YOU WILL HAVE TO CONTACT THE
MANUFACTURER TO DETERMINE APPROPRIATE MEASURES TO GOOD AND SAFE STORAGE
OF THE SYSTEM.
Should the machine be inactive for a long time (3 months and more), it is very important to protect it
by following the below-mentioned precautions:
- Storing temperature should be 0 40 C; with peaks not higher than 10 C above and below.
- Every month rotate the spools/shafts (a few revolutions are sufficient) of the main drive, to
prevent damage to bearings and seals.
- Should the products be sitting on stock for more than two months, mating surfaces like flanges,
shafts and couplings must be protected by an adequate rust inhibitor (eg. "MOBILARMA" 248 or
equivalent).
- All elements with externally machined surfaces must be greased to prevent oxidation.
- Should the machine remain inactive for more than six months, reducers must be emptied from
the lubricant.
- Before putting it back into use, check that each tank has been filled with the proper type and
quantity of oil (See lubricant list)
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- All machine parts must be in rest position. If a component is leant against another one, wood
slates must be placed between the two parts, to avoid surface indentation.
- Loosen the belts provided with a belt tightener. Pre-tensioned belts should be loosened as well.
- Check that all parts are protected against condensation and humidity.
- After a long time of inactivity, the machine re-start-up can only be performed with no load (by
threading speed). This is to allow the adjustment of all moving or rotating parts.
- The new start-up of the machinery must be carried out by trained personnel using suitable tools
and working methods.
EN
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Sections Title: Troubleshooting
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EN
CHAPTER 9.
TROUBLESHOOTING
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9.1
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SAFETY WARNINGS
NOTE
PAG. 101".
DANGER
9.2
WINDING DEFECTS AND SOLUTIONS
The quality of a finished reel can be measured in terms of :

- Geometry
- Width
- Diameter / Length
- Core type & Size
- Slit Quality
- Clean cut
- Good separation of the web
EN
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- Geometry Tolerance
- Dishing/Telescoping
- Roundness
- Core stick-out
- Core eccentricity
- Exterior analysis
- Cleanness
- Smooth edges
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9.2.1 TELESCOPIC EFFECT

The outer layers produce a pressure on the inner ones. If the web width is smaller than the
compression force, we will have a combined bending and compressive stress that causes the
deflection of the reel.
EN
POSSIBLE SOLUTIONS
- Apply the negative taper effect, by decreasing the winding tension according to the increasing of
the diameter of the reel which is being rewound.
- Make sure the roll draw values of the unwinder have been correctly set.
- Apply a relieving curve, so as to reduce the rider roll Nip as the reel diameter increases.
- Apply a variable load share, proportional to the reel diameter, to the slave carrying roll, so as to
reduce its torque as the winding reel diameter increases.
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9.2.2 RAMPS
Accelerations and decelerations can change the reel profile in its initial and final part.
POSSIBLE SOLUTIONS
- Extend the acceleration and deceleration ramps.
- Increase the S-ramp coefficient: that is, insert a time-variable acceleration.
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9.2.3 INTERFERENCE RINGS

Defects occurring at regular longitudinal intervals produce some interference lines on the reel profiles.
EN
POSSIBLE SOLUTIONS
- All along the process, it is necessary to track down any periodical defects which may alter the
physical-chemical structure of the web.
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9.2.4 J-LINE
If the turns on the core are not tight enough, a slipping effect will occur, especially on the master rolls,
because shafts are heavier and the reel diameters are bigger.
POSSIBLE SOLUTIONS
- Try and get a tighter winding on the first turns while generating the master roll. This can be
accomplished by applying a higher starting torque and the taper effect on the tension, thus
reducing the diameter of the parent reels.
- Use the axial helper on the unwinders.
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9.2.5 STARS BY THE CORE

This effect occurs if the first layers have not been wound tight enough. It usually occurs when using
rigid materials and when winding with low initial torque values.
EN
POSSIBLE SOLUTIONS
- It is necessary to increase the winding torque.
- Increase the working tension.
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9.2.6 SIDE-SKID OF THE WEB

In some cases, one or several sheets can side-skid. This often occurs when slippery products are
used.
POSSIBLE SOLUTIONS
- Increase the LSC value (load share).
- Decrease the initial pressure of the rider roll.
- Increase tension.
- Check that the unwinding belt pressure has a correct value. In case of oval-reels, it could be
necessary to increase this value.
- Check that the chuck relieving pressure has a correct value.
9.2.7 TROUBLESHOOTING FOR THE LONGITUDINAL CUTTING SYSTEM

9.2.7.1
INTRODUCTION
The basic elements to shear slitting that guarantee optimal slit conditions and function are as follows :
- Blades sharpness.
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- Blade run out.

- Vibration.
- Cant angle.
- Side load.
- Blades overlap.
9.2.7.2
EN
BLADE SHARPNESS
A sharp blade produces a clean slit. However, it is very important to determine when a blade is sharp
or dull and needs changing. You should not wait to change a blade only and when the quality control
department notices a poorly slit edge. By that time, a huge amount of poorly slit rolls have been
produced.
Machine operators can be trained to spot dull blades simply by looking at the blade itself, generally a
shiny, polished edge will form on the counter-knife and a rough, jagged edge will form on the front
slitter blade.
Typical wear band of blade
The polished edge is the result of blade interaction between the counter-knife and the front slitter
blade. As the blade wears, it becomes thicker and dull. Blades are typically changed when the cutting
edge approaches a width of approximately 0.5mm (0.020 in).
Though each application is unique, the polished edge width may vary from the suggested 0.5mm.
Factors such as cant angle, side load pressure and blade overlap will influence the edge width and
determine how quickly you reach the minimum wear width.
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A maximum tolerable edge width should be established early on, and used as a basis for regular
blade sharpening.
HOW MUCH CAN BE GROUND OFF A BLADE?
A blade can be reground until it no longer reaches the counter-knife. This is not advised though, as
the more the blade is ground the smaller the diameter. This in turn causes excessive blade thickness,
a common problem with double bevel blade set-up.
With slitting systems using multiple blade set-ups, it is necessary that all blades be ground to the
same diameter. The usual practice is to grind in sets, so that the overlap be identical for all slits
across the machine width.
NOTE
DO NOT GRIND BLADES, WHOSE DIAMETER IS SMALLER THAN 93% OF THE ORIGINAL
DIAMETER.
Example:
Blade 150 mm
Max. Grinding 139,5 mm
double bevel blade angles
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The correct grinding procedure is outlined below.

Operation
Rough Grind
Remarks
Remove wear ring band and
chips. Restore roundness
Wet/Dry
Wet
Grind edge
Re-establish grind angle.
Wet
Finish grind edge
Do not overheat
Wet
Deburr
Hand operation
Dry
Stone Type
40/60 grit Medium
soft
100 grit Medium
180 grit
Medium/hard
Oilstone or hone
This operation cannot be carried out in place. To avoid dust build up by the grinding stone, which can
penetrate into the bearings of the rotating assembly, the counter-knife blades must not be used as a
support during the grinding procedure. During regrinding heat build-up must be avoided or edge
hardness will be lost. It is especially important that the edge burr (feathered edge) be honed off before
returning the blade to service. One of the major problems associated with not following this part of the
finishing procedure is the loss of microscopic particles of metal from the blade edge. The end result
being rapid blade dulling.
The finished grind edge should be as smooth as possible. Blade life is greatly extended when said
edges are super finished, with the added benefit of less dust formation caused by web rubbing
against the reground edges.
EN
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BLADE RUN-OUT AND VIBRATION
WHAT IS BLADE RUN OUT?
Blade run out is the unwanted movement of knife blades that causes rapid blade and counter-knife
wear and/or poor slit edges due to equipment variables beyond optimum settings. Run out occurs in
the axial or radial plane of movement.
Axial run out is a lateral movement of the blade, which creates distinctive wear patterns on blades and
produces slit edge variables on the material being slit.
Radial run out is a vertical movement of the blade. The vertical loping will show unusual blade wear
patterns and slit edge characteristics.
HOW ARE BLADES AFFECTED BY RUN OUT?
Any axial run out of either blade directly influences blade side load and can have a drastic influence
on the blade life. The A.Celli Nonwovens s.p.a. design takes this factor into account; counter-knives
mount rotating assemblies with adjustable collars. These adjustable collars remove the natural play
found in the bearings, therefore eliminating any axial run out and blade stress that can exceed the
yield strength of the steel, usually resulting in chipped edges.
Furthermore the A.Celli Nonwovens s.p.a. front slitter design is equipped with flexible springs to
compensate for variable side load forces that can result in severe high frequency impact forces that
rapidly destroy blade sharpness.
Radial run out of either blade causes unnecessary vertical scrubbing movement between blade
contact surfaces, resulting in rapid development of the wear band around the blade parameters.
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As this wear band develops, the cut point shifts from the proper nip point between blades, resulting in
poorer and poorer slits.
EN
Abrasion from radial misalignment
A 30 X magnification of the front slitter blade reveals abrasion from severe radial run out (aka loping).
Axial run out (aka wobble) exceeded the yield strength of the blades steel edge causing the edge to
chip.
Abrasion from side load
A 20 X magnification of the counter-knife blade shows severe edge erosion caused by excessive side
load. Vibration greatly increases the effects of run out, often chipping away enough metal to scoop out
the edges.
WHAT IS THE MAXIMUM ALLOWABLE RUN OUT?
The maximum allowable run out depends on specific applications, product requirements and
customer specifications.
The maximum allowable run out can be quantified by the following example: if a customer specifies a
slit width tolerance of 0.50 mm (0.020 in.), the maximum allowable axial run out of the blade cannot
exceed 0.50 mm.
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The influence of the front slitter knife axial run out is more complex because much depends on the
ability of the front slitter knife to respond to run out without creating high side loading forces. Machine
speed impacts the destructive force of run out.
WHAT ARE THE CAUSES OF RUN OUT?
Small inaccuracies can increase into large run out.
Run out (axial wobble) can be caused by any of the following conditions:
- Blade edges not ground true to central bore.
- Debris under slitter-knife/counter-knife blade or blade mount.
- Worn blade hub assembly bearings.
- Bent or worn knife holder axle.
- Inaccurately ground blades (Slitter blades or Counter-knife blades).
- Warped blades.
- Front knife slitter blade notch not properly aligned with holding pin. (SAVAL-DELSAR).
- Lockdown collar nut not properly tightened.
- Belleville springs caught in thread of rotating assembly, correct collar nut lockdown not possible.
Radial loping can be caused by one of the following conditions:
- Bent slitter shaft or inaccurately ground hub assembly surfaces.
- Critical problem with counter-knife drive shaft.
- Slitter blade or counter-knife blade inner diameter too large.
- Slitter blade or counter-knife blade inner bore not concentric with outer dimension.
- Debris under slitter-knife/counter-knife blade mount.
- Slitter-knife or counter-knife hub inner dimension too large (loose fit on rotating assembly)
- Blade hub bearings worn.
To illustrate how critical it is to have a clean accurately fit blade, consider that a particle or a metal
burr of 0.001 in. on a 2 in. diameter hub will cause an axial wobble of 0.004 in. at the perimeter of an
8 in. diameter blade.
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MEASURING RUN OUT

Measuring run out accurately is simple, the most useful instrument for determining the amount and
type of run out is a dial indicator mounted on a magnetic base. Typical dial indicators have a
resolution of 0.001 in. This resolution is sufficiently accurate. The instrument should be equipped with
an articulated support necessary for the proper alignment/set-up of the instrument to measure axial
and radial run out.
When taking measurements, it is important to identify blade run out and equipment run out as two
separate elements of the total run out condition. A.Celli Nonwovens s.p.a. recommends you
determine equipment run out first.
FRONT SLITTER-KNIFE
Check the front slitter-knife rotating assembly for straightness and roundness and confirm that the
bearings are running true before checking the blades. Blade mounting hubs and axles are more
difficult to check, because of their short length and inaccessibility. Because front slitter-knives are
more susceptible to damage during the slitting process (material jam up and bearing wear), they
require more than the usual attention when checking run out. After that equipment run out is
determined, blade run out can be checked. This is usually a verification that the blades are accurate
and that the assembled blades are running true.
COUNTER - KNIFE
Blade mounting hubs should be checked in a lathe or similar accurate holding device (A.Celli
Nonwovens s.p.a. Set-up Bench) that allows rotation of the hub while taking dial indicated readings.
Performing this reading on the rewinder introduces too many external variables to provide and
accurate reading. Hubs should be checked for roundness of bore and accuracy of blade mounting
relative to bore axial wobble of the blade mounting surface.
The screws that bolt the counter-knife blade to the mounting hub should be tightened using a torque
wrench set at 28 Nm (21 Ft-lbs).
After an initial nip check the blades with the dial indicator for run out. If there is no indication of run
tightening the bolts until the torque wrench reaches its release point.
Check the blade one last time and verify if there is any run out.
The total run out should fall within the maximum allowable run out tolerance determined by the
individual application requirements.
EN
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HOW IS SLIT QUALITY AFFECTED BY RUN OUT?

The position of the counter-knives determines the location of the slit line and therefore, any axial run
out will be the causes of an out of tolerance or a wavy slit line; depending on the amount of
eccentricity.
The wavy edge causes the characteristic annular rings called slitter bands on the face of the roll.
The number and placement of the rings corresponds to the geometric relationship between the slit
edge caused by the wobble in the blade and the circumference of the wound roll.
Radial run out of the counter-knife in a tangential slitting system raises the slitting surface under the
web.
This increases web tension across the counter-knife blade and promotes a splitting tendency of the
slit point.
This will scuff and mark the underside of the sensitive webs.
Alternatively, if the counter-knife blade falls below the web, it will cause a burst slit by the top blade.
Slits made in this manner will display alternately clean and then ragged edges corresponding the
circumference of the counter-knife blade.
Radial run out causes blade rims and cut points to shift from their ideal locations, producing ragged,
dusty, stretched slit edges.
9.2.7.4
CANT ANGLE
Cant angle settings on tangential shear slitters can be the most misused adjustment and is the cause
for poor slitting and reduced blade life. The need for cant angle adjustment capability in shear slitters
is a required feature, unfortunately not all operators are aware of the optimum angle for their
application. Attempting the adjustment of the cant angle is not easy and requires a precise setting.
There are several factors important to cant angle.
In this section we will attempt to understand cant angle and its effects on the slitting process.
WHAT IS CANT ANGLE?

Cant angle, (aka toe-in) is the angular relationship between the counter-knife blade and the front
slitter blade.
It is the angle at which the nip point between slitter blades is chosen to perform a clean slit.
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WHY IS CANT ANGLE REQUIRED?

Cant angle is necessary to ensure positive cut point contact and compensates for any slitter
misalignment.
When the edges of the blades are in contact, the cant angle is positive. When the trailing edges of the
blades in contact the cant angle is negative.
A negative cant angle will not slit causing the web to bunch up with the possibility of damaging the
blade.
Front slitterknife holders need to be checked regularly for looseness and misalignment as this has the
potential for allowing the front slitter blade to angle away (move away) from the cut point, causing
material tears at the slit point rather than a clean slit.
HOW MUCH CANT ANGLE IS REQUIRED?

Certain materials are sensitive to cant angle while others slit well without any concern with toe-in.
Elongation, elasticity and fiber orientation are important factors when determining the correct cant
angle.
Generally a low elongation factor will require less cant angle and a higher elongation factor will
require a higher cant angle.
Low elongation material would include :
- Cellulose and paper products
- Low stretch plastic sheets such as polyester and resin bonded products
Cant angles for these products should not be more 1.
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PROBLEMS CAUSED BY EXCESSIVE CANT ANGLES

High cant angles create problems in two areas :
- Shortened blade life.
- Increased web damage in the slit line (fuzz)
When two overlapping blades are inclined towards each other, the cant angle (toe-in) reduces the
area of contact to an extremely small load-bearing surface. In these conditions it is very easy to
exceed the yield strength on the steel in the blade. This will result in chipped blade edges. Higher cant
angles also means more wear to the counter-knife blade.
WHAT ARE THE SYMPTOMS OF INCORRECT CANT ANGLE?

Inadequate cant angle is usually recognized better when slitting stretchy material. The problem is
more evident if front slitter blades are flat because of misalignment, which can induce negative angle
to the blade, causing the slit point to open.
To compensate for this, A.Celli Nonwovens s.p.a. front slitter blades are dished and are factory
adjusted. Angles can be changed based on different slitting requirements in increments of 0.5
Generally the factory setting done in A.Celli Nonwovens s.p.a. facility is sufficient to guarantee an
optimal working condition for all nonwovens materials.
9.2.7.5
UNDERSTANDING SIDE LOAD
It is important to understand side load and how it affects the life of the slitters. In shear slitting two
metal blades are in contact, both rotating at high speeds. The wear of the blades is influenced by the
accuracy in the side loading mechanism.
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Dished Blade
Pos.
Description
Dished Blade
Dished measure
Dished blades are required for systems that have blades that tilt or shift away when sided loaded.
The force between the two blades must be controllable and should be precisely adjusted to maintain
the slitting function. The lateral force holding the front slitter blade to the counter-knife blade is
referred to as side load between blades. The front slitter is the side loaded element, while the counterknife is in a fixed position.
The side load is the force of the front slitter (moveble) against the counter-knife (fixed position.)
Proper side load control involves uniform and controllable lateral force. This force is guaranteed by
the specially designed Belleville cup springs.
The Belleville cup springs compensate for lateral run out by keeping the front slitter blade in contact
with the counter-knife blade. The centrifugal force generated by the rotating speed of the slitters is
such that in induces blade shift away from each other.
The springs have one problem though, If they are not correctly adjusted or as in many cases abused
(over tightening) they have a tendency of twisting and popping, the result being a loss in side load
control. The A.Celli Nonwovens s.p.a. slitter system is also equipped with a lateral adjustment block
known as a centring block for the purpose of setting up the correct side load.
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This system guarantees a staring point and can with practice guarantee that all slitters are set-up the
same through the width of the machine. This set-up will reduce the risk of front slitter blade over riding
and therefore hitting the face of the counter-knife blade.
Dished Blade
With properly adjusted slitters the side load force required to keep the blades in contact is minimal.
Stretchy materials with high elongation are sensitive to proper blade sharpness and nip point integrity.
If any of these requirements are compromised, operators have a tendency of increasing the side load.
9.2.7.6
BLADES OVERLAPPING
Correct positioning of the front knife holder is essential to obtain the correct blade overlap for optimum
slitting quality. Tangential shear slitters have different requirements. The rub area of the front slitter
blade is the part that penetrates into the web.
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Blades overlapped
For most materials the edge of the front slitter blade should not overlap for more than half the
thickness of the counter-knife cutting edge. When the blade is adjusted to the correct overlap, the
cutting edge aligns perfectly with the counter-knife providing optimum slitting quality.
Excessive overlap will place the cut point ahead of the tangent point and create ragged slit edges.
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Sections Title: Dismantling
and disposal
CHAPTER 10
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EN
CHAPTER 10. DISMANTLING AND DISPOSAL
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and disposal
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and disposal
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10.1 SAFETY WARNINGS
NOTE
PAG. 101".
BEFORE ANY DISASSEMBLY OPERATION PLACE THE MAIN SWITCH TO

"OFF" OR "0" POSITION. DISCONNECT THE POWER SUPPLY. DISCONNECT
THE PNEUMATIC SUPPLY. ALLOW ANY HOT PARTS TO COOL BEFORE
DISASSEMBLING THE MACHINE.
DISPOSAL OF THE BUFFER BATTERY OF EXHAUST LUBRICANTS, OF USED

OIL FILTERS, AND OF THE MATERIALS THAT MAKE UP THE MACHINE MUST
BE IN COMPLIANCE WITH THE REGULATIONS IN THE COUNTRY OF
INSTALLATION OF THE MACHINE. USE PERSONAL PROTECTIVE EQUIPMENT
DURING THE DISASSEMBLY AND HANDLING OF THE MACHINE
COMPONENTS.
EN
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10.2 DISASSEMBLY AND DISPOSAL PROCEDURE

- Disconnect the machine from the electric power supply line. Act on the main switch positioned
upstream of the machine power supply line.
- Check with the tools that there is no voltage on the electrical cabinet.
- Disassemble the machine components.
The disposal of components shall occur in accordance with the laws of the country of installation of
the machine.
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parts
CHAPTER 11
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CHAPTER 11. SPARE PARTS
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11.1 HOW TO ORDER SPARE PARTS

11.1.1 TYPE OF SPARE PARTS
The list of the machine spare parts are divided into:
Pneumatic, electric and hydraulic spare parts
These spare parts lists are not separated according to the single machines but concern the whole
plant.
Mechanical spare parts

Separated according to the single machines.
As for the kind and quantity of the spare parts recommended to be kept in store and to be purchased
together with the machine, refer to the list of the recommended spare parts filled out by A.Celli
Nonwovens s.p.a. Customer Care and sent to the customer before the shipping of the machine.
The data shown in this chapter concerning the quantity of recommended spare parts are approximate;
on the contrary, the list filled out by A.Celli Nonwovens s.p.a. Customer Care is the result of a more
accurate research and analysis.
The main purpose of the lists and the drawings contained in this chapter is to support the customer in
finding the code of every component installed on the machine.
CAUTION
USE ONLY ORIGINAL SPARE PARTS.
NOTE
EVERY OPERATION MADE WITH NOT ORIGINAL MATERIAL AND/OR PERFORMED BY
PERSONNEL NOT EXPRESSLY AUTHORIZED BY THE MANUFACTURER WILL PREJUDICE THE
WARRANTY PERIOD COVERAGE AND RELIEVES THE MANUFACTURER FROM ANY LIABILITY
FOR ANY DAMAGE CAUSED TO PEOPLE, ANIMALS OR PROPERTY.
EN
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11.1.2 SPARE PARTS ORDERING INSTRUCTIONS

All components assembled in A.Celli Nonwovens s.p.a. machines undergo the most severe quality
control and reliability tests, their functioning performances being therefore guaranteed.
To maintain the machine in perfect functioning conditions, it is necessary to follow the ordinary and
extraordinary maintenance procedures indicated in this instruction book and to use only original spare
parts, as the ones suggested by sub-suppliers.
This specific chapter contains the suggested list of spare parts (with reference to the machine groups
and related to mechanical components).
The list includes the suggested spare parts together with their priority.
P = Priority.
Priority nr 1
A.Celli Nonwovens s.p.a. recommends that customers keep these components always in stock;
should they get damaged, in fact, they could not be immediately available in the market. The perfect
working of the machine is strictly dependent on the good functioning of these components.
Priority nr 2
A.Celli Nonwovens s.p.a. recommends that customers keep these components always in stock.
These are not easily available, either. Their chance of getting damaged, however, is minor to those
belonging to Priority 1. The perfect working of the machine is strictly dependent on the good
functioning of these components.
Priority not indicated
A.Celli Nonwovens s.p.a. believes that these components can be easily found on the market, in a
relatively short time. There is minor chance of unexpected failures of these components compared to
components with priority 1 and 2.
Further indications concerning our spare parts lists:

POS.
Indicates the position number related to the number of the reference drawing.
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Q.I.
Installed quantity, referred to the machine groups.
To order spare parts it is necessary to report all the identification data of the machine and of the spare
part. This information makes it easier to search and delivery the spare parts, this also avoids
unpleasant misunderstandings.
EN
Please include the following information:
- order number of the Customer
- serial number
- model of the machine
- number in the spare parts table
- part code number
- part description
- quantity
- exact address and name, completed with contact details for the goods delivery.
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Sections Title: REEL
HANDLING
CHAPTER 12
Pag. 335 ( 30 )
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EN
CHAPTER 12. REEL HANDLING
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Pag. 337 ( 30 )
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12.1 INFORMATION
The symbols included with the information in this manual are as follows:
ROUND For forbidden or obligatory procedure.
EN
TRIANGULAR For danger warnings.

RECTANGULAR For information.
SAFETY RULES
- Carefully read the labels on the machine, not cover them and replace them immediately if damaged.
- The machine should be used only by authorized and specially trained personnel.
- During the machine operation pay attention to the other people present.
- Use eventual Personal Protective Equipment at the various stages (cleaning, maintenance, etc.).
Types of PPE
Signal
Shoes
Gloves
- In the case of parts replacement, request original spare parts.

- Before any maintenance is indispensable disconnect the electrical power supply of the machine.
- Before using the machine, check that all the doors and the fixed covers are positioned as
indicated in the manual of use and maintenance and that all the safety light curtains (photocells) are
engaged and running.
- Dispose the consumable materials in strict accordance with current rules.
- When the machine is not in use, arrange disposal of the materials that it contains, especially oils,
batteries and electronic components.
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- All adjustment settings must be carried out by a single person, and while this work is underway,
unauthorized personnel must not approach the machine.
- After any adjustments settings, all protection systems must be replaced in the original positions as
soon as possible.
- When an intervention is to be made because of a fault or
breakdown, observe all safety
precautions described in this manual to protect all persons or animals from injury, and to prevent
damages to other objects.
- Before beginning any work on the machine pay close attention to the work in hand; the operator
must concentrate on his work and be able to act rapidly when necessary. The operator should
always be rested and in good health to be able to carry out his functions correctly.
Where an operator is not in perfect health and presents a danger risk while running the machine or
any of its accessories, inform the foreman.
- The operator working on the machine must not be under the influence of alcohol, drugs, or
psycho-pharmaceutical medicines.
- The operator must be dressed appropriately for working on the machine, avoiding any type of
clothing or long hair which can be trapped in moving parts.
- Belts, chains, rings and bracelets must not be worn while working on the machine.
- Long hair must be tied back and contained with a hair net.
- Always cleans all machine parts, command buttons and panels, with a soft dry cloth.
PROHIBITED PROCEDURE
Incorrect use of the machine, that is reasonably planned, imposes the obligation to comply with the
following prohibitions:
- It is prohibited to cross the transport conveyors.
- It is prohibited to block or eliminate the safety protections.
- It is prohibited to remove the protections that require the use of tools to be removed.
- It is prohibited to carry out control checks while the machine is running.
- It is prohibited to sit on the protection systems provided.
- It is prohibited to lean on the machine while running.
- It is prohibited to sit on machine components.
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- It is prohibited to use the machine, or any of its components, in any way other than the function
described in the manual.
- It is prohibited to change or modify any machine parts.
- It is prohibited mount any additional components on the machine.
- It is prohibited to use any kind of solvent, alcohol, fuel or diluents when cleaning the machine
surfaces.
- It is prohibited for repairs or maintenance to be carried our by non qualified personnel.
- Never for any reason place hands, arms or other parts of the body near any moving machine
parts.
- Disable persons must not work on this machine.
- Personnel under the age of 18 must not work on this machine.
ATTENTION! The company will not be held responsible for any malfunction or damage
caused by neglecting to follow the instructions included in this manual.
EN
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12.2 GENERAL INFORMATION
This manual has been drawn up in compliance with the following standards regulations:
- 2006/42/CE Machinery Instructions and following modifications.
- UNI EN 415-1: 2014
Safety of packaging machines.
Terminology and classification of packaging machines and associated equipment.
- UNI EN 415-6: 2013
Pallet wrapping machines.
- UNI EN 415-9: 2010
Noise measurement methods for packaging machines, packaging lines and associated
equipment, grade of accuracy 2 and 3.
- UNI EN 415-10: 2014
General requirements.
- CEI EN 60204-1
Electrical equipment for industrial machinery.
- UNI EN ISO 12100:2010
Safety of machinery.
General principles for design.
Risk assessment and risk reduction.
- 2004/108/EC Instructions concerning electro-magnetic compatibility.
- Established laws covering protection systems and safety precautions.
This manual is considered as an integral part of the machine.

For the whole period of the machine's working life, the manual must be kept carefully in a
handy place for consulting at any time.
It must be read carefully before any operations are to be carried out on the machine.
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All important information concerning their particular work on the machine must be
communicated to operators and other personnel.
All instruction concerning safety precautions for personnel are written in heavy script.
EUROPEAN STANDARDS APPLIED TO WORKING AREAS AND IMPORTANT POSITIONS
Only authorised staff, who knows the function and safety measures of the machine, can enter to the
working area.
The structural perimeter of the machine is made in accordance with the European standards:
UNI EN ISO 12100:2010

General principles for design.
Risk assessment and reduction.
UNI EN ISO 13857:2008

Safety distances to be prevent hazard zones being reached by upper and lower limbs.
UNI EN 349: 2008

Safety of the machinery.
Minimum gaps to prevent any parts of the body from being crushed
UNI EN 953: 2009

Safety of the machinery
Guards General requirements for the design and the construction of fixed and moving
guards.
EN
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12.3 SYSTEM COMPONENTS
ZONE A
Gr. SHA
- Shuttle
SHUTTLE Gr. SHA

This shuttle receives the stacks from rolling device, it moves them, pulls out the rod, recovers the
tails and finally unloading them onto the shuttle packaging.
TECHNICAL DATA
- Min. stack diameter
mm 150
- Max. stack diameter
mm 1500
- Min. stack size
mm 1000
- Max. stack size
mm 2200
- Max. stack weight (shaft 3")
Kg 1000
- Max. stack number
17
- Min. single stack size
mm 100
- Max. single stack size
mm 2200
- Max. transportable size
mm 2200
ZONE B
Gr. PLB
- Platform
- Lifting platform
Gr. PLB - A
- Platform
Gr. PLB - B
- Platform
Gr. PLB - C
- Lifting belt
Gr. PLB - D
- Parapet
Gr. PAR - B
LIFTING PLATFORM Gr. PLB - A

The functions of the lifting platform are: provide to the unwinder the PE reels, remove the shafts and
unload the faulty stack to the platform.
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PLATFORM Gr. PLB - B

The functions of this platform are: provide to the unwinder the PE reels, remove the shafts and / or
the faulty stack.
LIFTING BELT Gr. PLB - D
EN
The functions of the lifting platform are: provide to the unwinder the PE reels and unload the faulty
stack to the platform.
TECHNICAL DATA
mm 95
mm 1200
- Min. stack size
mm 1000
- Max. stack size
mm 2200
Kg 1000
Kg 2300
ZONE C
Gr. SHC
- Shuttle
SHUTTLE Gr. SHC

This shuttle provide to the unwinder the NW stacks and remove the exhausted stack.
TECHNICAL DATA
mm 95
mm 1500
- Min. stack size
mm 1000
- Max. stack size
mm 2200
Kg 800
Kg 900
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GENERAL SECTION
ELECTRICAL SYSTEM
- Power supply voltage
400V AC- 50 Hz
- Total power installed
W 8200
- Current consumption at 400 V AC
A 14,9
12.4 GENERAL SAFETY PLAN

WORKING AREAS AND IMPORTANT POSITIONS
OPERATOR POSITIONS:
Reference Drawing: GR 001
The machine has been designed and built to be used by several operators.
The working range of the machine is delimited by its structural perimeter and this includes the
following areas:
ZONE A
The area next to the shuttle tracks.

ZONE B
The area next to the control desk and the control panels.
ZONE C
The area next to the control desk and the control panels.
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NOTE: It is possible to enter the guarded areas only under certain specific conditions of the
machine status.
EN
12.5 PACKING INFORMATION

Before delivery to the customer, this machine is disassembled and the various parts are filmed with
plastic film and strapped.
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All packed machine parts are strapped or bound so that they are blocked against movement
during transport and handling which could cause damage or injury to the personnel.
12.6 TRANSPORT
The machine can be transported as follows:
- delivered to the customer by the manufacturer;
- delivered to the customer through a transport company;
- transport by the customer using his own means.
PRECAUTIONS TO BE USED DURING TRANSPORT
The following precautions must be observed when transporting the machine:

- never place other material on the machine load in order to prevent machine damage or
upsetting load balance;
- never cut the straps which prevent the load from shifting or falling;
- all delicate machine parts that may be exposed to damage from accidental contact during
transport, must be visibly marked on wrapping film with red paint.
All these instructions are printed on a special card attached to the various packed parts.
The handling equipment must be adequate for the weight and size of the load to be raised.
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12.7 HANDLING
All machine, or machine component handling must be carried out by expert personnel (crane and
fork lift drivers). Slinging and handling means must be adequate for the volume and weight of the
crate as marked on the identification plate and/or the machine data sheet.
EN
Shuttles Gr. SHA & Gr. SHC
Where the crate is raised using cables, check the cable strength and make sure the cables are
securely attached to the guide pulleys or to the machine chassis.
Take care that the forks do not interfere/damage parts of the conveyor (motor, cylinders, guides
etc..).
If the operators view is blocked during transport and handling because of size or volume, place a
second person to clear the transit areas and give instructions.
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Platform
The platform is divided in several parts, to be moved better.
Where the machine is to be handled using a fork lift, take care that the forks do not interfere /
damage parts of the platform (motor, cylinders, guides etc..).
Where the crate is raised using cables, check the cable strength and make sure the cables are
securely attached to the guide pulleys or to the machine chassis
If the operators view is blocked during transport and handling because of a crate size or volume,
place a second person to clear the transit areas and give instructions.
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12.8 SAFETY MEASURES

The machine is equipped with two types of safety protections:
Working safety protection
designed to eliminate possibility of injury to the operators:
EN
Safety light curtain (see chapter 8).
Sensible bumper for shuttle.
Red emergency button: it is strongly recommended to keep the area near the emergency button
free for immediate access.
Nets protections with system of safety limit switch and a special access door.
Warning signal lights to show when machine is on line.
Red flashing lamp for emergency signalling.
Functional protections
designed to avoid damage to machine structure and installation:
Limit switches and mechanical stops.

Protective thermal switches on motor and fuses inside electrical board.
All the area around the machine control panel must be left free of any material or objects
and the flooring marked out with red paint to show free area.
It is severely prohibited to limit, or tamper with any safety device or sensor on the machine,
or to use them for any function other than those for which they were designed. All safety
protections should be regularly checked and maintained in efficient condition.
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12.9 MACHINE INSTALLATION

- Check that the packing on the machine is free from damage and breakage; if the packing has
been damaged check the contents carefully and where necessary advise the manufacturer
immediately.
- Place all machine parts for easy and safe access for the operator during handling operations.
Before machine installation, check that the area destined for machine installation is large
enough to consent easy access and movement around the machine.
- Clean the machine carefully, removing all dust, dirt and grease, and check that all parts are in
correct condition (e.g. photocells and control panel).
- Place the machine on a perfectly level floor.
- Fixed the lateral protections wired.
- Place the safety light curtain (see Figure).
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Warn the operators of all danger of trapping or crushing upper and lower limbs in machine
parts, plus risks for machine damage. Before connecting the machine to the main supply
line, check that the machine voltage is the same as that of the main line: V400 Hz50 3ph +
PE.
Before starting up the machine, check that the earth wire has been correctly connected.
Lack or incorrect connection can cause risk of electrical shock and irreparable damage to
the electrical components.
- Wire the cables to the electrical items on the machine and to the terminal blocks in the control
cabinet.
- Check that the motors are turning in the correct direction, in case of fault disconnect from the main
line and invert any two of the 3 phase wires between them.
EN
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12.10MACHINE START UP
Before connecting the wrapping machine to the electrical net, check that the electrical
tension is: V400 Hz50 3 phase + PE.
- Wire the cables to the electrical items on the machine and to the terminal blocks in the control
cabinet.
- Connect the machine to the plant of the compressed air.
- Check that EMERGENCY push-button is not pressed.
- Check that the line is in manual run.
- Check that safety photocells are not obscured.
12.11AUTOMATIC FUNCTION
Check that the work area is completely free and that no danger risks are present for the
operator (trapping or crushing of members).
Shuttle Gr. SHA

a) The arrival of the stack on the shuttle will activate the sensor of presence stack.
b) The two reel keepers shuttle close automatically. When the reel keepers are closed, the
extractor moves to the upstroke position of the clamp.
A photocell detects the rod slowing the ascent.
Reached the contact position between the clamp and the rod, the ascent is stopped and the rod is
locked.
Now the rod is deflated until the pressure switch will signal the completion of this operation.
c) Now the extractor automatically performs the extraction of rod from the stack.
d) Extracted the rod, the operator moves the shuttle from pos. "P1" to pos. "P2 - out of line."
e) After reaching the position "P2 - out of line" the stack is unloaded on the packaging shuttle.
f) After unloading the stack, the operator rotates the stack plane supporting in the receiving position
and stack presence not engaged
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g) The bridge crane brings the rods with cores in the warehouse, the extractor is at rest and the
operator has the conditions to bring the shuttle in position.
Platform Gr. PLB

a) The operator, using a forklift with the pole, brings a new reel PE in the loading area of the lifting
belt "Gr.PLB-D" and deposits it on the supporting plane "V" of the same.
b) The operator drives up the lifting belt to align it with the belts mounted inside the line and opens
the door to the parapet "Gr.PAR-B" (operation only possible if the gate of access is closed and
interlocked).
c) With the door open the external belts move the stack until it is in contact with the adjustable side
rail. This adjustment serves to center the stack over the unwinder (activating the position sensor).
d) The operator, using the appropriate pushbutton box, moves the stack from the platform "Gr.PLBB" to the lift platform "Gr.PLB-A".
e) The arrival of the stack on the lift platform "Gr.PLB-A" will activate the sensor of presence stack.
f) The operator raises the lift platform of the stacks as necessary to align the shaft with the
unwinder chucks.
g) Once closed the chucks, the operator lowers the lift platform of the stacks until to enable the
position sensor.
Shuttle Gr. SHC

a) The operator, using a forklift with the pole, load the TNT stack on the rolls of the shuttle.
b) The arrival of the stack on the shuttle will activate the sensor of presence stack.
c) The operator commands the opening of the access door to the unwinder zone.
d) The operator controls the movement of the shuttle from pos. "P10" to pos. "P11" by activating the
mechanical sensor.
e) The operator commands the lifting of the stack transport plane until to align the cardboard core
with the tailstocks of the unwinder.
f) Once closed the tailstocks, the transport plane of the stacks is lowered to close the platform,
activating the position sensor.
g) Only with active position sensor you can close the gateway to the unwinder.
EN
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HANDLING
12.12TROUBLE SHOOTING
When there is a fault, the emergency light is flashing and the siren sounds.
Shuttle Gr. SHA
THE SHUTTLE DO NOT MOVE
1) The access door to unwinder zone is closed.
2) Check the function of the presence sensor.
TRANSPORT PLAN DOES NOT INCREASE
1) The stack is not centered.
TRANSPORT PLAN DOES NOT DECREASE
1) The chucks are not closed.
Platform Gr. PLB

THE LIFT PLATFORM DOES NOT INCREASE
THE LIFT PLATFORM DOES NOT DECREASE
1) The chucks are not closed.
Shuttle Gr. SHC

THE SHUTTLE DO NOT MOVE
2) Check the unloading arms position.
3) Check the shaft position.
4) Check the vice position.
5) Check the status of the inflation cylinder.
6) Check the overhead crane position.
THE SHUTTLE IS NOT ALIGNED
1) Check the function of the sensor.
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12.13MAINTENANCE
To ensure correct technical, product and safe machine conditions
and long working life, the
machine must be checked regularly and maintained correctly.

This machine has been designed with all protective systems to prevent all injury to the operator if
the machine is used correctly.
EN
All repairs and maintenance must be carried out by skilled and experienced personnel.
Do not wear loose clothing which can be caught up in moving machine parts.
It is advisable to wear a closefitting overall.
Never remove or change any protective systems without the written consent of the
manufacturer.
In cases where is not possible to disconnect the machine, take great care when carrying out
maintenance operations, and inform the operator of all danger risks during these operation
(electrical shock, trapping or crushing in moving parts).
If work need to be carried out with the machine connected, a second person must assist the
maintenance personnel in case of accident near the electrical panel.
Never leave tools or other objects on or around
the machine when carrying out
maintenance operations.
REGULAR MAINTENANCE OPERATIONS

It is advisable to adopt a precautionary maintenance program, controlling the following points,
according to a regular time table.
When compressed air is needed for cleaning operations, take care that no foreign matter is blown
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into the moving parts.

- Never lubricate any points which are not deliberately mentioned in this manual.
- Check the chain tension regularly controlling the tensioners.
- After any setting operation, tighten the lock screws carefully.
Daily checks:
- clean photocells thoroughly.
Every 200 hours:
- lubricate all bearings and rollers using the appropriate tools;
- lubricate chains, guides and wheels;
- check that all bolts are tightened correctly.
GEAR UNITS
The gear units are supplied by the factory, or by authorized dealers, already filled with synthetic oil.
In the absence of contamination, the synthetic lubricant supplied by the factory, does not require
periodical changes throughout the lifetime of the gear unit.
Operation of gear units is permitted at ambient temperatures between -20C and +40C.
However, for temperatures between -20C and -10C unit may only start up after it has been
progressively and evenly pre-heated, or otherwise initially operated unloaded.
Load may then connected to the output shaft when the gear unit has reached the temperature of 10C or higher.
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12.14SETTING AND REPLACEMENT OF WORN OR BROKEN

COMPONENTS
EN
All repairs and maintenance must be carried out by skilled and experienced personnel.
Do not wear loose clothing which can be caught up in moving machine parts.
It is advisable to wear a close-fitting overall.
PRECAUTIONS: before carrying out any type of repairs or maintenance, switch off
the
machine by turning the switch to 0 position, and where possible disconnect the machine
from the main supply.
Also disconnect the compressed air supply by closing the main supply tap, and empty all air
from the circuit through the condensation drain.
SETTING
- To center photocells, proceed as follows:
1) Loosen the fixing screws and turn the photocell so that the reflector is centered correctly. If the
centering is correct, the photocell LED will light up. If not, repeat the operation.
- To set the magnetic sensors, proceed as follows:

1) Loosen the fixing screw of the magnetic sensor and set it in the cylinder limit switch position.
2) Tighten the screw without damaging the thread, and the machine is ready for use.
-To set the magnetic sensors, proceed as follows:

1) Loosen the fixing screw of the magnetic sensor and set it in the cylinder end-of-run position.
2) Tighten the screw without damaging the thread, and the machine is ready for use.
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REPLACEMENT OF WORN OR BROKEN COMPONENTS
MOTOR REDUCERS
- First of all, read the instructions in the paragraph PRECAUTIONS.
- Now loosen the fixing screws of the motors reducer.
- Use a fork lift and straps to bind the motor reducer, both on the motor side and shaft side to avoid
damage or injury. Raise and transport to workshop for replacement of the worn or broken part.
- Take the replacement part from stock and replace it on the machine, screwing in on to the special
attachment plate, then follow all instructions provided in the paragraph concerning setting
operations.
CYLINDERS
- First of all, read the instructions provided in the paragraph PRECAUTIONS.
- Using a spanner, press down on the connection joint to free the supply and/or discharge hosing.
- Loosen the cylinder attachment pin and the fork pin.
- Check the damage, then send to the manufacturer for repairs.
- Once it has been repaired, proceed with replacement operations by fixing the 2 pins of the
cylinder, insert the 2 compressed air supply hoses, then regulate the magnetic sensor as described
previously in the paragraph: setting operations.
ROLLERS
- First of all, read the instructions provided in the paragraph PRECAUTIONS.
- Now loosen the fixing bolts of the worn or damaged roller from the roller frame.
- Raise the roller upwards, remove it from the chain taking care not to break the roller pinion.
- Replace the roller, inserting it in the chain, taking care not to break the roller pinion.
- Tighten the bolts carefully.
IDLE/NEUTRAL ROLLER
- Loosen the two fixing screws and remove the roller to be changed. Take the new roller and attach
it in place correctly with its screws.
PHOTOCELLS
- As always, refer to and fallow the instruction in PRECAUTIONS.
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- Disconnect the wiring connected to the photocell (remember to respect the same connection order
when mounting the new photocell).
- Loosen the fixing screws and replace the photocell with the replacement.
- Tighten the screws correctly connect the wiring to the relative terminals in the previous order. To
center the photocell, refer to the paragraph describing setting operations
EN
LIMIT SWITCHES
- Refer to and follow the instructions in PRECAUTIONS.
- Disconnect the connection wiring to the limit switch (remember to respect the same order when
replacing the new limit switch).
- Loosen the fixing screws.
- Place the new limit switch in position and connect the wiring in the previous order.
SENSOR OF PROXIMITY SWITCHES
- Loosen the 2 fixing screws attached to the bracket.
- Disconnect the connection wiring from the branching box taking care to respect the pole order.
- Replace the sensor of proximity switch with a new switch, tightening the nuts correctly but without
damaging the sensor of proximity threading. For setting see paragraph setting.
VALVES
- Using a spanner, press down on the connection joint to free the supply and/or discharge hosing.
- Disconnect the connections from the coil (remember to respect the same order when mounting
the new coil).
- Loosen the fixing screws, replace the valve with the new replacement if this is a complete
electrovalve; if it were only the coil to replace, loosen the fixing nut attached to the electrovalve
body, remove and replace in the same way it was removed.
- Take care to connect it in the previous connection.
- Attach in the previous position with the fixing screws, connect the air hosing and supply the circuit
with compressed air.
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12.15MACHINE DISMANTLING
When the machine is not in use, take all the precautions described in the handling chapter after
having carried out the following procedure:
- Disconnect the machine supply wiring and compressed air hosing;
- transport with a fork lift or crane to a secluded area where it does not hinder normal working
conditions (stocking area).
- Cover the machine completely with polyethylene film if the machine has not been destined for
dismantling.
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12.16ELECTRICAL INSTALLATION
All material used in the electrical installation on board this machine comply with CEI EN 60204 - 1
EN 418 standards and regulations.
All materials have an IP 54 protection rating.
The machine is complete with electrical scheme and electrical component information included in
this manual (see additional documents).
In any EMERGENCY situation, press the red emergency hand button to arrest all machine
action instantly.
ZONE C +ECT CONTROL PANEL
EN
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1) POWER ON white pilot LED

When the machine is on line this light is on.
2) EMERGENCY STOP red hand button
In the case of any danger or malfunction of the machine, press this button completely
inwards, it will stop and cut out the whole machine.
The danger signal is shown by a flashing light located above the electrical cabinet.
To release this emergency push button, turn it in the direction shown by the arrow.
3) MAIN SWITCH
To place the machine on line, turn the on the electrical cabinet from 0 rest position to position 1.
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ZONE C CB1 PUSH BUTTONS BOX
EN
1) SHUTTLE PLANE UPSTROKE black hand button

Pressed simultaneously with the button "SHUTTLE 2nd HAND" permits the upstroke of the shuttle
plane.
2) SHUTTLE SIDE MOVE BWD/FWD black selector
Permits the side move of the shuttle.
3) SHUTTLE BUMPERS RESET blue light push button
When pushed, it brings electrical power to auxiliary circuits of the bumpers of the shuttle: the blue
lamp inside the push button will be illuminated.
4) SHUTTLE PLANE DOWNSTROKE black hand button
Pressed simultaneously with the button "SHUTTLE 2nd HAND" permits the downstroke of the
shuttle plane.
5) EMERGENCY red hand button
In the case of any danger or malfunction of the machine, press this button completely
inwards, it will stop and cut out the whole machine.
The danger signal is shown by a flashing light located above the electrical cabinet.
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To release this emergency push button, turn it in the direction shown by the arrow.
- SHUTTLE PLANE 2nd HAND black button
Pressed simultaneously with the hand button "SHUTTLE PLANE UPSTROKE" (item 1) or
"SHUTTLE PLANE DOWNSTROKE" (item 4), permits the vertical movement of the shuttle plane.
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CHAPTER 12
Pag. 365 ( 1 )
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EN
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CHAPTER 12
Machine: name
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HANDLING
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A.CELLI NONWOVENS S.p.A.

Via Romana Ovest, 252
55016 PORCARI
LUCCA - ITALY

Linea - Rev 1.0 2014039-40-41-42 LIDERSAN - EN

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INSTRUCTION MANUAL

- Unwinders and Winder Customer :

LIDERSAN SAGLIK VE GIDA

Italian : original instructions

Instruction Manual complies with:

Serial Number: 2014039_40_41_42

Customer Lidersan Saglik

Machine: Unwinders and Winder

Sections Title: Chapter_Name

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Customer Lidersan Saglik

Serial Number: 2014039_40_41_42

Machine: Unwinders and Winder

Sections Title: Introduction

IDENTIFICATION OF THE MACHINE AND INFORMATION TO THE CUSTOMER .............17

MANUFACTURER'S IDENTIFICATION DATA .................................................................................................19

DESCRIPTION OF THE MACHINE .........................................................................................29

SAFETY WARNINGS ................................................................................................................................53

HANDLING AND TRANSPORT ..............................................................................................51

SAFETY WARNINGS ................................................................................................................................65

Customer Lidersan Saglik

Serial Number: 2014039_40_41_42

Sections Title: Introduction

GENERAL SAFETY WARNINGS ............................................................................................................... 101

USE AND FUNCTIONING ..................................................................................................... 121

SAFETY WARNINGS.............................................................................................................................. 123

Customer Lidersan Saglik

Machine: Unwinders and Winder

Sections Title: Introduction

Start of the Machine .....................................................................................................................................224

Serial Number: 2014039_40_41_42

SAFETY WARNINGS ..............................................................................................................................245

DISMANTLING AND DISPOSAL ..........................................................................................325

Customer Lidersan Saglik

Serial Number: 2014039_40_41_42

Sections Title: Introduction

SAFETY WARNINGS.............................................................................................................................. 327

SPARE PARTS ..................................................................................................................... 329

REEL HANDLING ................................................................................................................. 335

Serial Number: 2014039_40_41_42

Customer Lidersan Saglik

Machine: Unwinders and Winder

Sections Title: Introduction

Serial Number: 2014039_40_41_42

Customer Lidersan Saglik

Sections Title: Introduction

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Serial Number: 2014039_40_41_42

Customer Lidersan Saglik

Machine: Unwinders and Winder

Sections Title: Introduction

This instruction book provides also:

Serial Number: 2014039_40_41_42

Sections Title: Introduction

THIS INSTRUCTION BOOK HAS BEEN WRITTEN FOR THESE USERS.

THIS INSTRUCTION MANUAL SHOULD BE RETAINED FOR FUTURE REFERENCE. STORE IN A

HOW TO READ THE INSTRUCTION MANUAL

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Sections Title: Introduction

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Sections Title: Introduction

PICTOGRAMS USED IN THE MANUAL

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