Tauler SmartMatic 2.0 Operating instructions

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OPERATING MANUAL FOR THE SHEET PAPER AND

CARDBOARD THERMO PLASTIC LAMINATING

MACHINE

[Technical Documentation]

INTRODUCTION

This manual corresponds to laminating machine number C4011_______, which

should coincide with the number engraved on the identification plate fixed to the

machine.

Prior to start up it is essential that this manual be read carefully.

Machines of the TAULER are modular installations for laminating (paper and

cardboard) with thermal BIOPP polypropylene. The TAULER is comprised of a

laminating unit that is common to the range of products and can be combined with

different alternatives both for paper feeding to the machine and paper exit thus

giving rise to the different machine configurations.

Operation of the TAULER series is based on the placing of different sheets in the

feeder so that this can feed them to the laminating unit where, by means of

temperature and pressure the plastic film is stuck to the paper. Finally, the

separating unit (in the event the machine has one) separates the different sheets.

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SAFETY IN MACHINES

INTENTION OF USE

The machine Smartmatic2.0 is laminator that is designed for applying a plastic film

to sheets of paper or cardboard with a thickness of between 120 and 350g, by

means of a laminating system known as Thermal, consisting of fixing the auto-

adhesive plastic to the sheet by means of heat which is supplied through the

calendar roller of the machine.

Use for any other object that is not strictly that described in the previous paragraph

is totally prohibited and any injury or damages arising from incorrect use of the

machine must be assumed by the operator, under no circumstance by TAULER.

SPECIALISED PERSONNEL

To be understood as specialised personnel shall be any person instructed in such a

way that he/she is capable of using, maintaining and repairing the machine in the

event of necessity.

All Tauler technicians are specialised personnel. As well as the technicians from

distributors who have attended the Basic Technical Course given by Tauler

personnel and attained the corresponding certificate.

GENERAL RULES

1. The machine is designed for working in the manner described under the

heading of Intention of Use. Any manner of working that deviates from this

intention can be dangerous and considered as incorrect use of the machine,

therefore TAULER will not be responsible for any damages caused under

these circumstances.

2. For doing the electrical pre-installation work specialised personnel should be

used who know and comply with current electro technical rules.

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3. The person who will be operating the machine must have been trained for

this by TAULER or by an authorised distributor.

4. At no time should the machine be left alone while in operation.

5. It is totally prohibited to climb on to the machine.

6. Should any handling or revision of the electrical system be required the

machine must be disconnected from the power supply by disconnecting the

main switch located on the side panel of the main electrical switch-board and

always under the supervision of TAULER.

7. Compliance with the rules described here does not restrict compliance of the

current safety rules at the place where the machine is located, but is in

addition to the same.

8. It is the responsibility of the owner of the machine to be aware of and comply

with the current safety regulations for the locality

9. The machine must not be approached with loose clothing (scarves,

handkerchiefs, ties, etc.), neither with jewellery (necklaces, rings, bracelets,

etc.) since these can cause accidents by trapping which could mean serious

injuries.

10. It is the responsibility of the owner of the machine to ensure that the safety

indications supplied with the machine are kept in good order, and if

necessary to substitute the same in case of need.

11. Likewise it is the responsibility of the owner of the machine to guarantee the

existence of a copy of this manual in good condition at the location of the

machine.

12. When placing the film or carrying out cleaning of the calendar take care not

to suffer burns since this portion of the machine is at high temperature.

13. It is total prohibited to divulge the drawings, diagrams or other technical

documents of the machine without the express authorisation of TAULER.

14. It is totally prohibited to make any kind of modification to the machine that is

not authorised and assisted by TAULER. In the event of doing so said

company declines all responsibility arising from damages cause to or by the

machine.

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SIGNS USED IN THE MANUAL AND ON THE MACHINE

The safety signs used on the machine and in the manual of the same are as follows.

Electrical risk. Danger of suffering injuries or even death from

electrical discharge.

Risk of burns by contact with high temperature surface.

Risk of injuries to upper limbs by trapping in rollers.

Risk of injuries to upper limbs from trapping in moving Chaín.

Do not disassemble, cancel or bridge the safety measures installed on

the machine.

SAFETY MEASURES INSTALLED ON THE MACHINE

The installation has systems for isolating danger points, as described below. Said

systems are physical protection means that do not allow for the machine to operate

in the event that these systems are opened. There are also emergency stops for

each one of the modules.

There is also a system controlled by software, which avoids overheating of the

heating elements that provide heat to the calendar.

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DESCRIPTION OF DANGEROUS POINTS FOR THE OPERATOR

Nº

Risk description

1

Risk of cutting with knife.

2

Risk of trapping by moving chain

3

Risk of trapping/crushing between rollers

4

Risk of burns when cleaning calander or feeding film

5

Risk of trapping lower limbs with the wheels

6

Risk of crushing from cutting roller

7

Electrical risk in main electrical panel

8

Risk of being hit by axle when doing maintenance on the rollers

1

8

2

3

4

5

6

7

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START UP AND INFORMATION FOR USE

In order to carry out the start up process, the following steps must be taken:

1. - Unpack machine from the box in which TAULER delivers it.

2. - Lower machine from the box using a fork lift truck capable of lifting 850

kg.

3. - Plug the machine to a three phasic connection 380/400V using the cable

supplied with the machine.

AN INCORRECT CONECTION COULD CAUSE SERIOUS DAMAGE TO

THE ELECTRICAL SYSTEM OF THE MACHINE. IT IS

RECOMMENDED THAT THIS CONECTION PROCESS IS CARRIED

OUT BY SPECIALISED PERSONNEL

4. - Plug the machine to an air supply source (compressor), using the pipe

supplied with the machine.

5. - Switch ON the machine.

6. - Re-arm the safety button.

The machine is now ready for operation.

COMMAND COMPONENTS

1. - Electronic temperature controller.

2. - Emergency reset button.

3. - Emergency stop button.

4. – Pressure regulators.

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- Fig. 1 –

1. - Temperature control: By means of the display we can set the temperature at

which we wish to work. It also indicates the temperature of the calander.

2. - Emergency reset button (Blue). This control must be pressed after any

emergency stoppage of the machine. Before pressing ensure problem causing the

alarm has been solved.

3. - Emergency stop button (Large Red Button). This button instantly

disconnects the exits from the machine when there is a risk situation. This stop

button must only be pressed in the event of an emergency, because in order to

make a normal stop the button described above should be used, as this does not

affect the automatic exits neither any other apparatus and is the normal way to

stop the machine.

- Fig. 2 –

Main control panel. With this the distance of the overlap is set between sheets.

We can also see the number of sheets stored in the counters and the machine

alarms, apart from being able to set and reset the same. It controls as well the

main working functions

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1. - Main Screen.

You use the main screen to adjust sheet size as well as several alarms and the

sheet counter.

Start screen

Merely for information purpouses

Main screen

By pressing the feeder area or the

cutting area in the picture, the user

will go to the adjustments of these

parts.

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Feeder Screen

2 3

4 5

9

1 6 7 8 11

1. - Left arrow key: Let the user to go to control screen.

2. - Run button. By pressing this button, the machine commences its operating

cycle automatically. If the guard is open, the machine will run while the button is

pressed. ONLY FOR CLEANING OPERATION.

3. - Stop button. By pressing this button, the work cycle of the machine is

stopped immediately. To reactivate the only thing that has to be done is to press

the previously mentioned Run button

4. - Manual Up: While this button is pressed, the input table will move up.

5. - Manual Down: While this button is pressed, the input table will move down.

6. - Output blowers: By pressing his button, the output fan battery is activated.

For adjusting the air flow, the potentiometric placed in the electrical cabinet must

be operated.

7. - Feeder on/off: By pressing this key, the feeder will be enabled or disabled.

8. - Pump on /off: By pressing this key the vacuum/blowing pump, will activated

or deactivated.

9. - Automatic rising of input table: Pressing this key the automatic movement

of pile will be activated or deactivated.

When the movement is activated, the input table will move up until the sensor

located on feeder detects the pile of paper.

10. - Thermo key: By pressing this key, the user will go to thermos screen.

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Thermos screen

13

1 2 3

10

4 5 6 11

7 8 9 15

14 12

1. - Run button. By pressing this button, the machine commences its operating

cycle automatically. If the guard is open, the machine will run while the button is

pressed. ONLY FOR CLEANING OPERATION.

2. - Stop button. By pressing this button, the work cycle of the machine is

stopped immediately. To reactivate the only thing that has to be done is to press

the previously mentioned Run button

3. - Photocell selector ON/OFF. This allows us to activate or deactivate the

safety photocell located at the entry point of the feeder module.

IMPORTANT: WHEN THE MACHINE IS IN OPERATION THIS

SELECTOR MUST BE IN THE ON POSITION. IF DEACTIVIATED AND THERE

WERE TO BE A FAILURE ON FEEDING A SHEET, OR THE PILE HAS

FINISHED, THE CALANDER WILL CONTINUE ROTATING AND THE PLASTIC

WILL STICK TO THE PRESSURE ROLLER, SO THAT WORK WOULD HAVE TO

STOP IN ORDER TO CLEAN THIS ROLLER, WHICH CAN BE PARTICULALRLY

DIFFICULT DEPENDING ON THE AMOUNT OF PLASTIC THAT WERE TO HAVE

ADHERED TO IT.

4. - Temperature selector ON/OFF. When this is ON the resistances are also

receiving current, provided the working temperature has not been reached and the

machine is operating.

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When the selector is in the OFF position the resistances are not receiving current

independently of what is indicated by the temperature control.

Take into consideration that as the calendar contains hot oil, the fact of putting the

selector in the OFF position does not mean instant cooling of the calendar

(THERMAL INERTIA)

Machine must be running to heat.

5. - Pressure selector ON/OFF: By means of this selector the pneumatic cylinder

is activated that raises the pressure roller, in such a way that it comes into contact

with the calendar.

If the selector is turned to the OFF position the roller descends and separates from

the calendar.

The pressure roller must not stay in contact with the calendar for prolonged periods

if the machine is not operating because the silicone roller may become deformed.

6. - Maintenance run: By keeping pressed this button, the machine will run. This

is useful for maintenance tasks as cleaning the calendar.

7. - Holding roller selector ON/OFF:

When this is in the ON position, the wheels of the support come into contact with

the roller below them and hold the laminated sheets

8. - Separating roll ON/OFF:

It activates the micro-perforating well and the separating roll.

9. - Pump ON/OFF: By pressing this key the vacuum/blowing pump, wil activated

or deactivated.

10. - Speed Control:

By pressing button “+” it increases the speed

By pressing button “-” it reduces the speed

11. - Sheet size control: By pressing on the format value you can modify the

length of the sheet (in mm).

12. - Feeder key: By pressing this key, the user will go to feeder screen.

13. - Right arrow key: By pressing this key, the user will go to output screen.

14. - Left arrow key: Let the user to go to control screen.

15. – TAULER GoOn

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If any of these controls is activated, a sign ON appears above them.

Output screen

1

2 3 4

5 6

7 8 9

1. - Left arrow key: Let the user to go to thermos screen.

2. - Run button: By pressing this button the machine commences its operating

cycle automatically. If the guard is open, the machine will run while the button is

pressed. ONLY FOR CLEANING OPERATION.

3. - Stop button: By pressing this button the work cycle of the machine is stopped

immediately. To reactivate the only thing that has to be done is to press the

previously mentioned Run button.

4. - Speed Control:

By pressing button “+” it increases the speed.

By pressing button “-” it reduces the speed.

5. - Sheet COUNTER ON/OFF: Star or stop the sequence of the sheet counter (or

re-start in the event of a temporary stoppage) pressing this key.

6. - Sheet Counter: Shows the number of sheets counted during the operation of

the machine. It can be set to 0.

7. - Reset: By pressing this key the counter returns to 0.

8. - Total Counter: Shows the total number of sheets counted during the

operating life of the machine. It cannot be set to 0.

9. - Output display: Shows the output expressed in sheets/hour.

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Screen Settings

1-4

5 6 10-11

7 8 9

12

1-4. - LANGUAGE KEYS: By pressing this keys the user selects the language.

5. - Cutting roller speed: By pressing this key user tries between manual or

automatic cutting roller speed mode.

Automatic mode: The speed of cutting roller is chosen automatically by the

machine. If machine speed Until 10 m/min speed 1 is set, from 10 to 15 m/min

speed 2 is set and from 15 to 20 m/min speed 3 is set.

Manual mode: User can set speed 1, 2 or 3 independently of the speed of the

machine.

6. - Display of the speed of cutting roller speed 1, 2 or 3.

7. - Speed #1: in manual mode set the speed #1, medium speed.

8. - Speed #2: in manual mode set the speed #2, fast speed.

9. - Speed #3: in manual mode set the speed #1, extra fast speed.

Keys 10 and 11 are used for the fine-tuning of the micro-punched and cutting. For

further instructions on these keys see “FINE-TUNNING OF THE MICRO-PUNCHED

AND CUTTING”.

12. - Right arrow key: For technicians only. It goes to special factory screen.

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SPEED REGULATION

The working speed of the machine is totally controllable by the operator.

This parameter depends directly on the size of the sheets as well as the

pressure and temperature at which we are working. It depends as well on

operator’s ability to feed the machine.

To modify the speed, you can use the speed control.

By pressing button “+” it increases the speed.

By pressing button “-” it reduces the speed.

PRESSURE REGULATION

The pressure with which the nip roller (located just below the calendar roller)

presses on the latter is an essential parameter for obtaining a good quality

gloss and adhesion.

As a reference value we can indicate >2 bar <4 bar of pneumatic pressure.

This is the pressure at which most laminating machines operate. ALWAYS

OPERATE AT THE MINIMUM POSSIBLE PRESSURE.

This parameter is controlled by means of the pressure regulator located on the

principal module.

Pressure regulators

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PRESSURE REGULATORS AND INDICATORS

It should also be pointed out that if the machine is stopped for periods of any

length the pressure roller must not be activated, so that it is not in contact

with the calendar, since if this should happen, the neoprene with which this

roller is constructed may become deformed and loose its surface uniformity.

This deformation will cause the plastic not to adhere to the paper in a uniform

manner, therefore causing incorrect lamination.

TEMPERATURE REGULATION

Working temperature for the machine depends on the size of the printed

sheet being laminated and on the speed.

For one and the same sheet format, at greater speed we will require a higher

temperature, for example, for a sheet of a determined format we will require a

higher temperature if the working speed is 15 m/min than if it were only 7

m/min.

This is due to the fact that the exposure time, that is to say, the time the

sheet is in contact with the temperature and pressure rollers is less the higher

the speed, so that in this case we must provide more heat for the final result

to be correct.

In any event practice will in the long run be what defines the correct working

temperature, which will very much depend on the characteristics of the

product being laminated.

It should be pointed out that as we have already explained, in order to heat

the machine before laminating, it is convenient to set the temperature at 40-

50 degrees with calendar in operation. With this what we achieve is that the

initial working temperature is very stable.

We should consider that for practical effects it is preferable to begin working at

80-90ºC and increase this gradually if necessary.

If we do this in the reverse order we run the risk of melting the plastic due to

excessive heat, and we will also suffer a delay due in the first place to the

thermal inertia of the oil, which takes longer to cool off than to heat up; and

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on the other hand to the fact that we may possibly have to stop the machine

in order to clean the calendar roller of plastic fragments that may have

adhered to it.

Temperature is controlled by activating the temperature regulator located on

the control panel of the principal module.

This sensor receives temperature from a temperature sensor (Type J

temperature probe), which measures the actual temperature in the calendar

and forms a part of a PID regulation system in a closed loop, implemented in

the temperature regulator.

The display shows the temperature of the calendar. In order to modify the

working temperature (the temperature we require) only press the ascending

or descending arrow keys in order to increase or decrease the same.

Temperature regulator

SEPARATING UNIT

The separating unit is based on a pulling scissor-movement roll. Previous to

start working, we must place the micro perforating wheel over the edge of the

film as shown in picture below

You must place the sheet over the anti-curling roll and between the green and

black roll, and then activate the Cutting wheels’ selector

To start separating, you must push the Separating roll button.

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The separating process:

1. - The micro-perforating wheel it’s been activate for a while

Micro-perforating wheel

The micro perforating wheel we must be placed over the edge of the film as shown

in picture above.

2. - Afterwards the separating roll separates the sheet.

Separating roll

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In order for the system to operate correctly we must verify the following:

The film micro perforating wheels (rough) must be in contact with the edge of

the plastic film

The cutting roller must be at a suitable height, marked as “A” in the following

figure. If we look from the exit end of the machine, we can see if the roller is too

high or too low. Make sure that when this roller makes the cutting movement it

touches the sheet that is below it. If it were to be too low instead of pulling, it will

nip the sheet and we can even hear a slight noise. If it were to be too high it will

not touch the paper and will not make the cut.

By using this knob, we can raise or lower one end of the cutting cylinder in

order to adjust the cut.

Knob for controlling the cut height

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Tauler SmartMatic 2.0 Operating instructions

Tauler SmartMatic 2.0 Operating instructions

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