AspiraUser Manual

ASPIRA
Operation manual
spol. s r.o.
Dvořákova 1001
563 01 Lanškroun
No.: Česká republika
ASPIRA/ ASPIRA Comfy 1
CONTENTS
1. BASIC INFORMATION ....................................................................................................................................3
1.1 Description of machine use and function .......................................................................................................3

1.2 Schematic drawing .........................................................................................................................................4
1.3 Diagram of machine process ..........................................................................................................................5
2. TECHNICAL PARAMETERS..........................................................................................................................6
2.1 Output.............................................................................................................................................................6
2.2 Input and output material ...............................................................................................................................6
2.3 Feeding...........................................................................................................................................................6
2.4 Control logic...................................................................................................................................................6
2.5 Conditions of machine operation....................................................................................................................7
2.6 Working mode.................................................................................................................................................7
3. SAFETY RULES.................................................................................................................................................8
3.1 Machine installation .......................................................................................................................................8

3.2 Starting operation...........................................................................................................................................8
3.3 Manipulation and transport............................................................................................................................8
3.4 General...........................................................................................................................................................9
3.5 Different groups and subgroups ...................................................................................................................10
3.6 Electrical ......................................................................................................................................................16
3.7 Maintenance and adjustment........................................................................................................................17
3.8 Disassembly and disposal.............................................................................................................................18
4. TECHNICAL DESCRIPTION ........................................................................................................................19
4.1 Machine function ..........................................................................................................................................19

4.2 Description of different groups and subgroups ............................................................................................22
4.3 Adjustment of different groups......................................................................................................................26
5. MAINTENANCE ..............................................................................................................................................37
5.1 Individual groups..........................................................................................................................................37

5.2 Regular maintenance of electrical equipment ..............................................................................................39
5.3 Lubrication chart..........................................................................................................................................40
6. DESCRIPTION OF CONTROL......................................................................................................................42
6.1 Description of buttons in the control panel and their functions ...................................................................42
6.2 Machine start-up ..........................................................................................................................................50
7. ERROR MESSAGES........................................................................................................................................52
8. MACHINE TRANSPORT................................................................................................................................53
9. WARRANTY TERMS......................................................................................................................................53
10. LIST OF SERVICE CENTERS.....................................................................................................................54
Appendices:
1. BASIC INFORMATION
1.1 Description of machine use and function
The machine is used for laminating sheets of paper.
1.2 Schematic drawing
levelling guiding pulling unw inding up per low er

roll roll c rolls d isk snapp ing roll snapping roll
laminating
ro ll
u nloading ta ble
14 60
conveyer
pressure
roll
decu rling
bar
2355
MAIN PLACE OF SEC ONDARY PLACE OF

OPERATION OPERATION
1250
1190
1.3 Diagram of machine process
AUTOMATICAL
C HECKIN G OF
PA PER OVERLAP
PAPER
LAMINATING SNAPPING UNLOADING
FEEDING
MANUAL
TAKING OUT
OF WASTE
2. TECHNICAL PARAMETERS
2.1 Output
Minimum laminating speed 3 m/min
Maximum laminating speed 15 m/min
Tipping speed 2 m/min
2.2 Input and output material
- Specification of paper
Maximum paper format 520 x 700mm
Minimum paper format 200 x 200mm
Basic weight - minimum 115 g/m2
- maximum 600 g/m2
- Specification of film
Sort polypropylene, polyester, nylon
Thickness 24 - 40 micron
Outer diameter of reel 350 mm
Inner diameter of reel 57÷77 mm
Film length per reel 3000 m
Specification of swing stops

- overlap 2 ± 1 mm
- square weight 115 g/m2 until 600 g/m2
- type of the paper two-sided art paper
- speed 6 until 15 m/min
2.3 Feeding
2.3.1 Electrical
Supply voltage 1 x NPE 230V 50Hz
Control voltage 24V DC
Rated current 13 A
Input 2900 VA
Recommended value of protection 16 A characteristics C
Coverage IP 21
2.3.2 Adjustment of laminating temperature

Temperature range of laminating roll 0-135°C
Laminating temperature 105-135°C
2.4 Control logic

Programmable automatic unit MISUBISHI - FX1s
2.5 Conditions of machine operation

Ambient temperature Max. +35°C
Relative humidity of air Max. 95%
2.6 Working mode

Continuous
Operator Instructed person (EN 60204-1 Art. 3.30)
3. SAFETY RULES
3.1 Machine installation
!
1. The machine can be connected to the power source by a responsible person, trained by a
service technician of KOMFI spol. s.r.o. only.
2. During the machine installation in the workplace the working height of the loading
conveyor must be observed, see chap1.2
3. The machine must be located in such a manner when the horizontal position of the loading
conveyor is ensured.
3.2 Starting operation
!
1. Before starting operation, check if all the machine parts are complete and undamaged!
2. When the machine is put in operation by the qualified worker, it must be ensured so as
nobody else would intervene in the machine.
3. When the machine is put in operation, all safety rules regarding safe operation of the
machine must be observed.
4. The operator must cautious when he operates the machine and he must not touch the
machine movable parts by any part of his body.
5. The machine can be adjusted for the respective sort of sheets of laminated paper and the
covers of the machine movable parts can be taken off by the machine fitter only.
6. Nobody else but the fitter can approach the machine during the adjustment.
7. The machine must be switched off for all repairs on the mechanical part.
3.3 Manipulation and transport
!
Length x width x height 850 x 1190 x 1460 mm
Transport dimensions with pallet 1150 x 1500 x 1460 mm
Weigth 395kg
Observe the general safety rules for the manipulation with a load during the transport of the
machine and manipulation with it.
3.4 General
!
1. The machine may be operated by a qualified person only and person who is older than 18
years!
2. The operator can use the machine solely for laminating sheets of paper, having
the parameters specified in chap. 2.2 Input and output material. The machine must not be
used for any other work.
3. The sort of film and paper must comply with the conditions, specified in chap. 2.2 Input
and output material.
4. There are necessary control elements on the machine that ensure the machine function. It
is not allowed to adjust them or to modify their position otherwise than as provided by the
manufacturer.
5. It is not allowed to operate, to adjust, to maintain or to repair the machine under the
influence of alcohol, drugs or certain medicaments.
6. In case the operator gets suddenly tired or sick while working on the machine, he must
interrupt his work immediately and the machine must be stopped.
7. It is not allowed to touch the machine movable parts by fingers or other parts of the body
during the machine work cycle, whether controlled automatically or manually.
8. It is not allowed to do any activity on the machine (cleaning, opening covers, etc.) while
the machine is in operation.
9. Never adjust any mechanisms while the machine is in operation. The machine must be
stopped, adjusted and then restarted.
10. Any repair or exchange of a machine part must always be done after the machine is
stopped. The main switch must be secured by a padlock to prevent its incidental start
during the repair or exchange of a machine part or its maintenance.
11. Never put any objects on the top surface of the machine covers or other machine parts.
12. Never open the protective covers while the machine is in operation.
13. Check before starting the machine operation if all covers are installed and secured against
opening. If not, the operator must put them in their places and secure against their
removal.
14. Check before starting the machine working cycle if nobody is standing near the machine.
15. Always repair or change the machine parts in the laminating section after the laminating
roll cools down to the ambient temperature.
16. Never clean any of the rolls – laminating roll, pressing roll, drawing rolls, snapping roll or
others - while the machine is in operation. If necessary, turn the rolls slightly and use
button "SLOW REV" for cleaning or for control.
17. Proceed as follows to use button "SLOW REV":
− Press button "SLOW REV".
− Wait after depressing button "SLOW REV" till the machine stops.
− When the machine is stopped, you can start to clean the rolls or any other operation
on the machine.
18. Every day check the safety sensor of the laminating roll cover and button of the
emergency stop on the control panel if they work correctly.
19. Be cautious at manipulation with paper and during any activities near the tightened web of
paper with film – risk of cutting on the edge of paper.
20. Lighting of regular intensity, suitable for the machine and the respective sort of work,
should be arranged by the user.
3.5 Different groups and subgroups
!
3.5.1 Frame
1. After the machine is started, neither the operator nor anyone else may intervene in its run
or touch or exceed the ground plan of the machine with any part of the body or clothes
outside the operator’s workplace.
2. The user is obliged to ensure the location of the machine in such a manner, so as it would
not move during its operation in consequence of the machine strokes and vibrations.
!
3.5.2 Laminating section
3.5.2.1 Laminating and pressure mechanism
The working temperature of the laminating roll is 105-135 °C. In order to assure the
machine functionality, it is not possible to cover fully the area near the laminating roll and
pressing roll, which is very dangerous due to the high temperature and possibility to access the
area where both rolls are under pressure. Therefore the following safety rules must be strictly
observed:
1. Never touch the hot laminating roll.
2. Never get close with your fingers or any part of the body near the contact surface of the
laminating roll and pressing roll, which is under pressure.
3. Use button "SLOW REV" for cleaning. Never clean the surface of both rolls while the
machine is running.
4. Have tight clothes when films are inserted or at any manipulation near the laminating roll
and pressing roll, because loose clothes might get caught by the moving rolls.
5. Never use any objects for cleaning the rolls or for removing the film residues while the
machine is running.
6. The plexiglass cover above the laminating roll must be always closed during the machine
operation. The cover may not be removed or modified otherwise than as provided by the
manufacturer.
7. Never put any objects on the top of the plexiglass cover, which could deform it or could
cover the ventilation holes.
8. To load the first sheet of paper with the film, proceed as follows:
− Insert paper with the film between the laminating roll and pressing roll
− Pull the sheet behind the laminating roll so as the distance between your fingers and the
laminating roll is minimum 20 cm
− Press button "B“ to press the pressing roll and pressurize the hydraulic circuit to the
requested pressure by the lever of the manual hydraulic pump, the indicator, which
signals pressing of the pressing roll, illuminates
− set the mechanical thrust of the pressure roll on the laminating roll with the lever or by
the motor (E-make)
9. At cleaning, observe the Safety rules – Cleaning, specified in chapter 3.4.
10. When the movement of the pressing roll up and down is checked, it is not allowed to
approach or to touch the guideway of the pressing roll in the area of hydraulic cylinders.
11. When the plexiglass cover of the laminating roll is opened, it must be opened to full so as
the cover can get secured at the limit position.
12. Before every maintenance or adjustment it is necessary to wail till the temperature on the
roll surface gets down below 50 °C. The roll temperature must be checked on the display
of the temperature regulator when the machine is switched on. The temperature can also
be checked by an external contact temperature meter. Or wait 60 min. after the roll
heating was provably switched off.
VIEW OF THE LAMINATING ROLL AND PRESSING ROLL FROM THE SEPARATOR
DANGERO US PLACE DANGEROUS AREA

DO NOT GET CLOSE HIGH TEMPERATURE OF
WIT H YOUR FINGERS! ROL L SURFACE!
Laminating
roll
Pressure
roll
DANGERO US PLACE
DO NOT GET CLOSE
WIT H YOUR FINGERS!
3.5.2.2 Adjustment of the position of straightening strip

During laminating there is inner stress between the paper and the laminated film. The
straightening strip helps straighten the sheets so as they were straight after laminating.
Observe the following safety rules for the adjustment of the straightening strip:
1. Loosen the locking lever of the straightening strip carefully. If it is loosened swiftly, the
locking screw can hit the edge of the groove on the regulating wheel.
2. Be careful when changing the position of the control lever. If the control lever is changed
sharply it can hit the securing lever of the straightening strip or the surrounding parts of
the machine.
3. When changing the position of the straightening strip, do not put your fingers near the
groove on the regulating wheel.
3.5.2.3 Drawing rolls

Due to the machine functionality it is not possible to cover fully the zone around the drawing
roll. Therefore observe strictly the following safety rules:
1. During the machine operation the plexiglass cover over the drawing roll must be closed
and secured by a lock.
2. Never put your fingers or other part of your body near the contact surface between the
upper and lower drawing rolls.
3. Be cautious at tipping the lever to change the position of the upper drawing roll. Prevent
the lever from hitting the machine cover.
4. At tipping the lever to change the position of the upper drawing roll, it is not allowed to
touch the control and pressing mechanism. There is a risk of injury by squeezing or
crushing.
5. When the cover of the drawing mechanism is opened, it must be opened to the limit
position where it is supported by a bar.
6. Do not put any objects on the top of the plexiglass cover, which might deform the cover.
7. The plexiglass cover may not be removed or modified otherwise than as provided by the
manufacturer.
!
3.5.3 Film unwinding
This group is located between the machine sides. Due to the machine functionality it is not
possible to cover fully the area between the laminating roll, pressing roll and the roll on the
film lead. It is a very dangerous place exposed to a high temperature with the access to the
place where both rolls are under pressure. Therefore observe strictly the following safety rules:
1. When a roll of the laminating film is changed, the arm with the perforating wheel must be
tipped in the parking position.
2. Be cautious at changing a roll of the laminating film. There is a risk of injury by the teeth
of the perforating wheel.
3. The film in the machine must be changed and it must adjusted on the shaft by two
operators. The machine must be switched off.
4. Be cautious at introducing a film in the machine over the guide roll to the laminating roll.
There is a risk of injury by burning on the laminating roll.
5. Have tight clothes at loading films and during any manipulation near the laminating roll
and pressing roll. Loose parts of your clothes might be caught by the moving rolls.
6. Do not use any objects for cleaning the rolls or removing the film residues if the machine
is running.
!
3.5.4 Conveyor
The conveyor is used for manual loading of the different sheets of paper in the machine. Due
to the machine functionality it is not possible to cover fully the area between the laminating
roll, pressing roll and conveyor. It is a very risky place exposed to a high temperature with the
access to the place where both rolls are under pressure. Therefore observe strictly the
following safety rules:
1. The operator must be cautious at work - the rotating parts can cause injury.
2. Be cautious at manipulation with paper – risk of cutting on the edge of paper.
3. Be cautious at loading paper on the belt conveyor. There is a risk of burning by the
laminating roll.
4. Have tight clothes at loading sheets of paper. Loose clothes might be caught by the
moving belts.
5. Do not use any objects for cleaning the belts if the machine is running.
6. Use button "SLOW FWD" or "SLOW REV" for cleaning. Never clean the surface of both
rolls and belts while the machine is in operation.
7. Never put your hands or other part of your body near the contacting surface of the
8. Never adjust the position of the guide ruler while the machine is in operation.
3.5.4.1 Swing stops

Swing stops serves in automatical regime for guarding of paper overlaps. This space is not
covered, from the reason of function and adjusting of swing stops, adjuting of bridge and
holder of brushes. Here is a danger of high temperature from the laminating roll and danger of
pressing from the laminating roll and pressure roll. It is necessary to keep safety rules:
1. The operator must be cautious at work - the rotating parts can cause injury.
2. Be cautious at manipulation with paper – risk of cutting on the edge of paper.
3. Be cautious at loading paper on the belt conveyor. There is a risk of burning by the
laminating roll.
4. Have tight clothes at loading sheets of paper. Loose clothes might be caught by the moving
belts.
5. Do not use any objects for cleaning the belts if the machine is running.
6. Use button "SLOW FWD" or "SLOW REV" for cleaning. Never clean the surface of both
rolls and belts while the machine is in operation.
7. Never put your hands or other part of your body near the contacting surface of the
8. Never adjust the position of the guide ruler while the machine is in operation.
9. It is necessary to make adjusting of bridges, swing stops, wiping of brushes when the
machine stops.
10. Be careful about layed aside tolls and another things on the conveyer. It is necessary to
avoid geting of these things in the space of laminating and pressure roll.
!
3.5.5 Separator
3.5.5.1 Frame + conveyor
The conveyor is used for carrying the separate sheets of paper between the snapping rolls
and carrying the laminated sheets out of the machine. Due to the machine functionality it is not
possible to cover fully the area between the conveyor belt and the frame sides. There is a risk
of injury by pulling between the conveyor belt and rolls or between the snapping rolls.
Therefore observe strictly the following safety rules:
1. The operator must be cautious at work. There is a risk of injury by the rotating parts and
of winding.
2. Be cautious at manipulation with laminated paper – risk of cutting on the edge of paper.
3. Wear tight clothes to avoid catching the loose parts of the clothes by the moving machine
parts.
4. Do not use any objects for cleaning the belts while the machine is in operation.
5. Use button "SLOW REV" for cleaning. Never clean the surface of the belt while the
machine is running.
6. It is not allowed to manipulate the balancing rollers while the machine is in operation.
7. Do not put your fingers or other part of the body near the roller mechanism while the
machine is in operation.
8. It is possible to put in and take out the weights if the machine is stopped only.
9. The position of the guide strip between the belt and form rollers can be adjusted if the
machine is stopped only.
10. The form rollers can be adjusted only after the machine is stopped.
3.5.5.2 Snapping unit

Due to the machine functionality it is not possible to cover fully the zone around the snapping
roll. There is a risk of injury by pulling between the snapping rolls. Therefore observe strictly
the following safety rules:
1. Never adjust the pressing force of the snapping roll while the machine is running.
2. Never put your fingers or other part of your body near the contact surface between the
upper and lower snapping rolls.
3. Do not put any objects on the top of the plexiglass cover, which might deform the cover.
4. The plexiglass cover and covers of the bearing boxes may not be dismantled or modified
in any manner otherwise than as provided by the manufacturer.
5. Be cautious at turning the pulley, which forms a wave on the snapped web of laminated
paper, to avoid injury of fingers between snap rolls.
6. Always move and tip the pulley arm while the machine is stopped.
7. Be cautious at tipping the lever to change the position of the upper snapping roll. Prevent
the lever from hitting the stops in the limit positions.
3.5.5.3 Drive of separator

The snap rolls and camshaft are driven by the main motor chain. Its motor is located on the
other side from the operator and it is covered with a solid protective cover. To ensure safe
work, the following safety measures must be followed:
1. Any manipulation with the drive mechanism may be done only by a qualified and
responsible worker.
2. Regarding the drive maintenance, it is allowed to lubricate the chain and to tighten the
chain or belt. All other activities must be done by a professional serviceman.
3. Before tightening the belt or chain, the machine must be switched off by the main switch.
!
3.5.6 Drive
The motor drives the loading conveyor, laminating roll and drawing roll. It is located on the
other side of the operator and it is covered with a solid protective cover. In order to secure
safety work, observe the following safety rules:
1. Any manipulation with the main drive mechanism may be done by qualified and
responsible worker only.
2. Regarding the drive maintenance, it is allowed to lubricate the chain and to tighten the
chain or belt. All other activities must be done by a professional serviceman.
3. Before tightening the belt or chain, the machine must be switched off by the main switch.
!
3.6 Electrical
After switching the machine off by the main switch, the circuit for acoustic signalling of
the pressure roll pressing to the laminating roll remains live. If the machine is to be
shutdown for a long time, the machine must be disconnected from the line by unplugging
the supply cable or in another suitable way!!!
1. If any defect is detected in the electro-installation, switch the machine off immediately
and lock it.
2. The electrical installation complies with standard EN 60204-1:2000. In compliance with
this standard art. 3.28, the machine may be operated only by an electrically instructed
person, i.e. a person adequately instructed by electrically skilled workers (for example
production and maintenance workers), so that any danger that may be caused by
electricity would be avoided.
3. The work on the electrical equipment, such as repairs, adjustment and cleaning, may be
executed according to EN 60204-1 art. 3.52 by an electrically skilled person, i.e. a person
with technical experience enabling him to avoid risks that may be caused by electricity.
After finishing work, all covers (including the ones in switchboard) must be returned to
their original places.
4. Before switching the machine on, it must always be checked whether all safety covers are
fully functional and in the proper state.
5. It is not allowed to disconnect any devices on the machine (predominantly the cover
safety switch, limit position switches, etc.) or to modify the connection of the devices that
might lead to changing their functions. Before switching the machine on, it must always
be checked whether all safety covers are fully functional and in the proper state.
6. The plug of the machine flexible supply cable may be connected only to a socket of a
fixed electrical distribution, regularly inspected according to standards applicable in the
user's country. Before putting the machine into operation, the initial inspection of
electrical equipment according to IEC 3646-61 must be executed, including the fixed
supply lead if the machine is not connected by a flexible cable. The machine may be put
into operation only provided that all requirements of applicable regulations and standards,
valid in the user's country for putting single-purpose machines into operation, are met.
7. During the machine use the user must ensure regular inspections of electrical equipment
in intervals according to relevant regulations and standards, applicable in the user's
country.
According to standard EN 60204-1 art.12.4, for work on electrical equipment, the machine
user must always ensure free space in front of the switchboard, minimum 1.0m wide.
!
3.7 Maintenance and adjustment
1. The machine maintenance or adjustment may be done by a specially trained and qualified
worker only.
2. Be cautious at any maintenance or adjustment.
3. For every maintenance or adjustment the machine must be switched off and the main
switch must be secured.
4. The only exception is the adjustment of the optical sensors on conveyors, which must be
connected to the power supply when adjusted. The adjustment may be done by a specially
trained worker only.
5. Be cautious at any maintenance and adjustment.
6. The machine may be adjusted by a specially trained and qualified worker.
7. Never adjust any mechanism while the machine is running. The machine must be stopped,
adjusted and then restarted.
8. It is not allowed to take the covers off while the machine is running.
9. It is not allowed to switch the machine on with removed covers.
10. It is not allowed to adjust and to test the groups without the local covers on the rotating
parts of the machine.
11. It is not allowed to adjust and to test the groups without the local covers on the heated
parts of the machine.
12. The machine may not be maintained if the temperature on the surface of the laminating
roll exceeds 50°C.
Check the temperature of the laminating roll as follows:
- read the values on the temperature regulator on the control panel
- use an external temperature meter
13. If it is not possible to ensure the temperature on the surface of the laminating roll as per
Point 4, the maintenance or adjustment may be done 60 min. after the roll heater was
provably switched off.
14. The worker, adjusting the machine, must wear tight clothes.
15. Use proper tools for the machine adjustment or maintenance. (Risk of injury if improper
tools are used.)
16. Wear a protective shield for setting springs.
17. It is not allowed to clean the machine while it is running.
18. If it is necessary to turn the rolls to another position before cleaning, use buttons "SLOW
FWD" or "SLOW REV".
Proceed as follows:
− Press button "SLOW FWD" or "SLOW REV".
− Wait after depressing button "SLOW FWD" or "SLOW REV" till the machine stops.
− After the machine stops, you can star cleaning the rolls or any other operation on the
machine.
19. Be cautious at cleaning the laminating roll, because the surface temperature of the roll
reaches 105-135 °C. Always use rubber gloves for cleaning the laminating roll.
20. Do not use aggressive solvents for cleaning the rubber rolls, which can injure or damage
the rubber-coated surface. Use non-aggressive solvents only.
21. At cleaning the pressing roll or the machine, when the operator's hands are close to the
pressing roll, it is not allowed to press button "B" and to pump with the lever of the
manual pump.
3.8 Disassembly and disposal

The disassembly and disposal of the machine should be done in compliance with the
applicable law on the waste disposal.
4. TECHNICAL DESCRIPTION
4.1 Machine function
The machine is used for laminating sheets of paper.
The individual groups and subgroups of the machine:

• Machine frame JU-01-000B/a
• Laminating section JU-06-000
• Film unwinding JU-12-000
• Paper loading JU-01-300
• Swing stops JU-06-000
• Separator, unloading table JU-24-000, JU-31-000
• Drive JU-01-600
• Stickers JU-43-200
• Electrical JU-06-000
• Covers JU-42-100 to JU-42-720
4.1.1 Frame
The frame is screwed of two supporting side plates, on which other supporting components of
the frame are mounted. The sides, which are connected with bars, together with other
components of the frame support all other groups, including the hydraulic unit and electrical
box with the control panel.

The laminating section consists of the laminating and pressure mechanism, straightening strip
and drawing rolls.
4.1.2.1 Laminating and pressure mechanism

The laminating roll is used for heating and guiding the film applied on sheets. One side of the
film is coated with glue. The pressure roll located under the laminating roll is used for correct
pressing of the glue and film on the surface of sheets. The pressure is controlled manually by a
lever through a shoulder-lever mechanism – 3 positions. In Comford-make it is controlled by
the motor, using the setting on the control panel.
Position 1/3 5,3 k/N
Position 2/3 10,6 k/N
Position 1 16 k/N
In ASPIRA Comfy -make it is controlled by the motor, using the setting on the control panel.
4.1.2.2 Straightening strip

It is used for straightening deflections of paper after the film is laminated on paper by the
laminating roll. The strip position should be adjusted according to the paper thickness.

The drawing rolls are used for deriving the pull of paper between the laminating section and
the drawing rolls so as the paper would get straightened on the straightening strip.

The film unwinding consists of the roll belting, unwinding and film perforation.
4.1.3.1 Guide roll

It is used for guiding the film from the reel and its belting around the laminating roll so as the
film would heat even at the highest working speed of the machine.
4.1.3.2 Unwinding
It is used for even unwinding of the film from the reel. The tightening force at unwinding and
thus the unwinding evenness are regulated by a friction brake on the unwinding shaft. During
laminating, the center of the reel should be set symmetrically in the center of the machine.
4.1.3.3 Perforation
It is used for perforating (cutting) the film edge in order to facilitate snapping of the laminated
paper web into the different laminated sheets of paper.
4.1.4 Conveyor
4.1.4.1 Belt conveyor

The conveyor is a facility for manual loading of individual sheets which should overlap
mutually. The sheets loaded in such a manner are transported by the conveyor to the
laminating section. Before entering the laminating section, there is a sensor, checking the sheet
overlap and ensuring that the film will not stuck on the supporting roll. On the side the loading
position is determined by a bar which may be adjusted according to the sheet size and position
of the film reel.
4.1.4.2 Automatical guarding of paper sheets overlaps

It checks automatically whether the sheet edges overlap. It is turned on by the "OVERLAP
CONTROL" button. There is a sensor before the entry to the laminating section, checking the
overlap automatically.
4.1.5 Snap roll

It snaps individual sheets coming from drawing rolls and separates them from the laminated
web. The separated sheets are carried out of the machine onto the unloading table where they
are stacked. At the outlet from snap rolls there is a sensor for counting the laminated sheets.
4.1.5.1 Snap rolls

The snap rolls of the separator are driven by the gear from the main motor at speed that is
higher than the speed of the belt. When the upper snap roll drops on the lower roll, the
laminated paper snaps from the side with the perforated edge across as a result of the speed
difference and the formed wave. The perforated edge of the web is tightened and the other
edge is braked by the turned follower. The follower turning and its position affect the
formation of the wave and impacts or the continuity of the laminated web cutting.
4.1.5.2 Cover of snap rolls

They are fixed to the machine frame and they protect the operator against injury.
4.1.5.3 Unloading table

The unloading table is used for stacking the laminated sheets. The position and angle of the
table inclination may be modified according to the format size and paper thickness.
4.1.5.4 Drive
It drives the belt of conveyor and outgoing pulleys at the end of the separator. The motor
speed as well as the laminating section drive are regulated by one inverter and they are
controlled by the operator from the control panel.
4.1.5.4 Separator covers

They are mounted to the frame of conveyor and they are used for the operator's protection
against injury by the machine parts.

The unloading table is used for stacking the laminated sheets of paper. The position and
inclination angle can changed according to the format and thickness of paper.
4.1.6 Drive 4HG-6000

4.1.6.1 Laminator drive
It drives entire laminating section and belt conveyor. The motor speed as well as the
separator drive are regulated by the same inverter and they are controlled the operator from the
control panel.
4.1.7 Covers 4HG-9000
4.1.7.1 Cover of laminating roll

It is used for the protection of the operator against burning and pulling into laminating section.
4.1.7.2 Cover of drawing rolls

It is used for the protection of the operator against pulling between drawing rolls.
4.1.7.3 Peripheral covers of laminating section

In the upper part of the sides of the laminating machine the drive mechanisms are located,
which are covered. Thus the operator is protected against injury. The cover also includes a
switchboard with a control panel.
4.2 Description of different groups and subgroups
4.2.1 Frame
The frame is riveted of bent steel plates, fitted with boards in functional parts on which other
mechanical machine elements are fastened. The sides are connected with bars and all the
frame carries all other groups, including the electric box with the control panel.

The laminating section consists of the laminating and pressure mechanism, a straightening
strip and drawing rolls.
4.2.2.1 Laminating and pressure

The laminating section consists of a laminating roll with inner heating and a pressure roll
guided vertically. Both rolls are placed on bearings and they are connected with supporting
boards carrying the pressure between them so that the machine frame would not be stressed.
The laminating roll is driven by a chain wheel. The upper position of the pressure roll is
scanned by a sensor.
4.2.2.2 Straightening bar

The straightening bar with a guide roll is located between the laminating roll and drawing rolls
between the machine sides. On the operator's side on the inner part of the side there is a
control lever changing the position of the roll of the straightening mechanism against the
straightening bar according to the thickness of laminated paper. The position of the
straightening bar is secured with a brake.

The drawing roll is made of metal, it is driven, coated with rubber and pressed by springs by
means of lever mechanism. The lever controlling the pressure has two positions: closed - open.

The film unwinding consists of a belting roll, unwinding and film perforation.
4.2.3.1 Belting roll

It is located between the machine sides. The position of the roll shaft is determined at the
assembly and7 should not be adjusted. The roll is mounted onto the shaft on bearings and it
turns freely with the unwinding film.
4.2.3.2 Unwinding
The unwinding shaft is placed on the reel sides and it may be taken out freely. The shaft is
placed in the machine in such a manner that a friction brake is on the operators side, which
may be adjusted by the nut for spring tightening. On the operator's side and on the side of the
drive there are rings bearing on the reel side and they are secured against turning the screw
heads, oriented upwards.
The film reel is set on clamping cones. One of the cones is fixed on the shaft closer to the
operator. The second one is placed on the shaft and pressed to the film reel through a nut and
sleeve.
4.2.3.3 Perforation
The perforating mechanism is located between reel sides. A guide rod, mounted between the
sides, carries arm with perforating wheel and weights.
The perforating wheel turns freely according to turning of the unwinding reel. The position of
the weight and the perforating wheel on the lever is adjustable in grooves. The arm can be
pushed and turned on the rod. The position of the arm against the reel can be secured by a
screw, while the arm can turn freely round the rod.
4.2.4 Conveyor
4.2.4.1 Belt conveyor
The belt conveyor is separate and it can be taken out of the machine after loosening two
screws. After the conveyor is put back in the machine, it is possible to adjust its inclination by
eccentric screws, which carry blocks.
The conveyor has two belts, driven over the driving roll from the chain wheel. The driven roll
is clamped in the blocks of the tightening mechanism. The tightening screws are accessible
from the conveyor front.
There is a rod located between the conveyor sides, onto which a ruler is mounted (it can be
pushed and turned) for guiding the sheets of paper to the laminating section. The ruler is
secured against pushing and turning by two screws on both sides.
4.2.4.2 Automatical guarding of paper sheets overlaps (swing stops)

The swing stop is placed on bearings on sides of machine. Lifting of swing stop is made be
electromagnet, which is placed on drive side. The bar on which are fixed brushes and charging
pulleys, is placed between sides. The holder of brushed have not to bend or strike to the swing
stop.
4.2.5 Separator
4.2.5.1 Conveyor
The conveyor consists of a frame on legs and a belt conveyor. The conveyor drive is mounted
to the machine frame by covers and sensor BQ2 for counting the number of the laminated
sheets of paper. A shaft of outgoing pulleys is put behind the driving roll between the sides,
driven by the belt wheel. On the output side, outside the conveyor outline, there are two
holders for the unloading table.
The conveyor belt is tightened by two forcing-off screws at the driving roll. The driving roll is
driven by a chain wheel.
4.2.5.2 Snap rolls

The shaft of the lower snap roll is fixed between the machine sides. The shaft of the upper
snap roll is located between swing arms, anchored in the sides. Its swing enables removing and
lowering to the lower snap roll. The swing of the upper roll is derived from excenters on the
revolving shaft through a clutch and brake. Both snap rolls (lower and upper) are driven. The
impulse for switching the upper snap roll is given by the control unit depending on the length
of the processed format.
4.2.5.3 Drive
It is used for driving conveyor. It consists of a motor with a gearbox, chain wheels with a
chain and pulleys with an indented belt. The chain should be tightened by pushing the motor in
the groves on the holder. The belt should be tightened by pushing holder with shaft
and outgoing pulleys.
4.2.5.4 Covers of separator

They are used for preventing the access to the machine and for protection of people against
injury or accident. They are mounted to the frame and other machine parts. The covers are
solid.
Peripheral covers are mounted to the machine frame by screws. There are two covers on
separator mounted on boxes. The plexiglass cover of the pressure roll is suspended on them.

The unloading table is used for stacking the laminated sheets of paper. The position and
inclination angle of the table can be changed according to the paper format and thickness.
The inclination angle can be changed by adjusting the length of the adjustable legs and on the
front mounting of the table. By adjusting the height of the front mounting of the table, the
height of the stack of the sheets can be adjusted either. It is possible to adjust the front and side
plates according to the format of the paper sheets. The laminated sheets fall on the plates and
they are stacked there.
4.2.6 Drive
It drives entire laminating section and belt conveyor. The motor speed as well as the
separator drive are regulated by the same inverter and they are controlled by the operator from
the control panel. The drive is located under a solid protective cover on the side opposite the
operator. The cover can be taken off and the mechanism can be manipulated by a qualified
worker only.
4.2.6.1 Drive of laminator

The drive of the laminating section consists of a motor with a gearbox, double-row chain
wheels with chains and tightening pulleys. The drive of the belt conveyor is derived from the
same motor with a gearbox as the drive of chain gears. It consists of indented belt wheels with
a two-sided indented belt and of a tightening pulley.
4.2.7 Covers
4.2.7.1 Cover of laminating roll

The cover is made of clear polycarbonate. There is a row of ventilation holes in the upper part,
preventing the cover from overheating. It is mounted to a pin on the drive side, which allows
to tip it in the direction from the operator. The open position of the cover is arrested. The
cover may never be in the interposition, it must be always in one of the limit positions. The
"closed" position is secured by safety sensor SB1 of the cover.
4.2.7.2 Cover of drawing rolls

The cover is made of clear polycarbonate and it is pivoted on pins. It is secured against
opening by a lock with a key. The limit positions are given by stops.
4.2.7.3 Peripheral covers of the laminator

They are fastened to the machine frame. There is a switchboard with a control panel on the
operator's side.
4.3 Adjustment of different groups

4.3.1 Frame
The machine frame does not require adjusting. There is sensor BQ1 (transmitter-receiver) on
the frame for sensing the sheet bending. The sensor beam goes through the belt conveyor. The
sensor position is adjusted by the manufacturer.
- The receiver is located under the belt conveyor on bar. If it is necessary to change the
pressing roll, take the sensor with holder out. The correct position for the assembly is ensured
by pins.
- The transmitter is located on rod with holder. The direction of the sensor beam should be
adjusted as follows:
1) Loosen the locking screw on sleeve.
2) Turn, or push, the sensor-transmitter with the holder against the receiver.
3) Tighten the locking screw on sleeve.

The laminating section does not require adjustment for different formats of sheets. Before
starting laminating, clean the laminating roll and pressing roll. Change the pressing roll if
necessary due to its wear.
The position of the pressing roll is sensed by sensor SB2, which signals the pressing roll
movement into the work position. The time of the sensor switching can be adjusted by
changing the position of the sensor on the groves.
Before starting laminating, it is necessary:
1. To set the laminating temperature on the temperature regulator, which is controlled from
the operator's panel.
2. To introduce the film from unwinding to the laminating section.
3. To adjust the straightening strip.
4. To introduce the web of the laminated sheets between the drawing rolls.
4.3.2.1 Adjustment of the required regulation temperature

Set the required temperature of the laminating roll by means of buttons " + " and " - " on the
operator's panel.
Number of laminated sheets
Machine speed
Roll temperature
SHEET: XXXXXX
m/min: XXXXXX
Required roll PV XXXXXX
temperature
SV XXXXXX
Wait till the real temperature of the roll reaches the required temperature.
4.3.2.2 Introduction of the film in the laminating section

The film reel is centered and a sheet of paper is stuck at the end of the film, see chapter 4.2.3.
Continue introducing the film in the laminating section as follows:
1. Follow plan "Polly-out" or "Polly-in" and introduce the film round the guide roll through
the laminating roll. Put a sheet through the gap between the laminating roll and the
pressing roll so as the paper is min. 200 mm behind the contact surface of the rolls.
ATTENTION! Follow the safety rules for the zone of the laminating and pressing roll,
chapter 3.5.2.
2. Close the protective cover, adjust the minimum speed of the feed on the potentiometer and
prepare a separate sheet of paper for its loading in the machine.
3. Turn the lever controlling the position of drawing rolls to adjust the rolls to the "open"
position with a gap between them.
4. Press the pressure roll to the laminating roll by turning the lever of the shoulder-lever
mechanism (or setting on the control panel on ASPIRA Comfy) to one of the three work
positions.
5. Turn the machine on by the START button.
6. Let 2-3 sheets of paper go through the laminating section at the minimum machine speed.
Lead the web of laminated sheets according to the plan over the straightening strip
between the drawing rolls and onto the separator belt.
7. By turning the lever for control of the position of the drawing rolls, adjust the rolls to the
"closed" position. The rolls bear on each other.
8. Let other 2-3 sheets of paper go through the laminating section at the minimum machine
speed. Lead the web of the laminated sheets to the separator, see chapter 4.2.5.
le velling guiding pullin g unwinding upper lower

roll ro llc rolls disk snapping roll snap ping ro ll
laminating
ro ll
unloadi ng table
1460
conveyer
pressure
roll
decu rling
bar
23 55
4.3.2.3 Adjustment of straightening strip

The position of the straightening strip is controlled by a lever and it is arrested after tightening
the brake. Turn the straightening strip according to the thickness of laminated paper in the
following range:
- Lowest basic weights - the web is led to the strip over the roll so as it will bend by 90°
- Lower basic weights - the web is straightened over the edge of the straightening strip with
radius "R1"
- Higher basic weights - it is possible to turn the strip after loosening the screws and to
straighten by radius "R2"
- Highest basic weights - the web moves freely without bending between the roll and the
straightening strip
LAMINATING LEVELL IING PULLI NG LAMINATING LEVELLING PULLING

ROLL ROLL ROLL S ROLL ROLL R OLLS
PRESSURE DECURLING PR ESSURE DECURLING

ROLL BAR ROLL BAR
4.3.2.4 Disassembly (assembly) of the pressing roll

If the pressing roll is worn-out, it must be changed. Proceed as follows:
1. Dismantle the lever controlling the shoulder-lever mechanism
2. Remove side covers on both sides of the drive from the machine
3. Take the inlet belt conveyor out of the machine
4. Loosen the screws on the holder of sensor BQ1, take the holder with the sensor out and
put them in a safe place to prevent the sensor and cable from damaging
5. Dismantle the side screw of the pressure roll with a washer
6. Dismantle the clamping sleeves on both sides of the roll
7. Unscrew the screws of guide bars between the sides on the operator's and drive side
8. Take the released roll out of the machine
9. To assemble the pressing roll, proceed in the reverse order.
10. The described operation must be done by two workers.
4.3.2.5 Disassembly (assembly) of the laminating roll

If the laminating roll, heating or temperature sensor are damaged, the roll must be changed.
The assembly and disassembly may be done by a service technician only. Please contact the
supplier.

Foil unwinding consists of the belting roll, unwinding shaft and foil perforation.
Before using a new reel, proceed as follows:
1) Adjust the position of the film reel on the unwinding shaft.
2) Adjust the position of the perforating arm to the reel edge closer to the operator.
3) Introduce the film from the reel to the guide roll.
4.3.3.1 Procedure for adjustment of the position of the film reel on the unwinding shaft
When a new film reel is loaded, which has a different width than the previous one, proceed as
follows:
1. Take the unwinding shaft with the original film reel out of the machine (two people) and
put it aside. Protect the film reel from damage.
2. Return the tightening nut on the taper sleeve of the drive side to its original position, i.e.
as close to the clamping bolt of sleeve as possible.
3. Loosen screw M6 on sleeve and take it together with nut and taper off unwinding shaft.
4. Pull the film reel off the unwinding shaft.
5. Check if the coated film side on the new reel is on the outer or inner side of the film.
Depending on the manner of the film application - "POLLY IN" or "POLLY OUT", put
the film reel on the unwinding shaft as per the picture - "PLAN OF FILM
INTRODUCTION".
6. Loosen screw M6 on taper sleeve, push it together with the reel approximately to the
center and tighten slightly.
7. Put on taper and the sleeve with the nut on the unwinding shaft.
8. Put the unwinding shaft with a new film reel in the machine (two people), the screw heads
in sleeves are oriented so as they would lean against the grove on the side and prevent the
sleeves from turning over.
9. Set the reel position into the center between the machine sides.
10. Tighten screws M8 on the sleeves.
11. Tighten the nut, which pushes into the taper sleeve on the drive side. The reel should not
slip on the tapers when the brake is regulated.
4.3.3.2 Adjustment of the position of the perforating arm to the reel edge closer to the operator
The perforating wheel bears on the film reel edge on the operator's side as a result of its own
weight. To adjust the position, proceed as follows:
1. After setting the reel position, loosen locking screw pos. 3328
2. Lift and push the arm. The teeth of the perforating wheel should be 2mm from the edge of
the film reel.
3. Tighten locking screw pos. 3328
4.3.3.3 Introducing the film from the reel to the guide roll
Proceed as follows:
1. Check the coated side of the film
One side of the film is coated with glue.
It can be checked:
- visually - the coated side is matte
- by placing the film on the edge of the laminating roll - the film with glue up does
not stick on according to the color stripe on a new film (red or blue)
2. "POLLY-OUT" or "POLLY IN"
Depending on the coated side of film, put the reel with the film on the unwinding shaft.
If the coating is on:
- inner side - it is marked "Polly-in" - red stripe
- outer side - it is marked "Polly-out" - blue stripe
3. Position of the reel with the film on the unwinding shaft
Tighten the reel by means of the taper sleeves so as the reel center is in the middle
between the sides, see chapter 4.2.3.1 Procedure for adjustment of the film reel
position on the unwinding shaft (measure with a meter from the side).
4. Sticking a sheet of paper to the beginning of the film
In order to make the film introducing easier, stick a sheet of the same width as is the
width of other sheets, prepared for laminating, to the beginning of the film.
POLLY - IN POLLY - OUT
FIL M FIL M
UNWIND UNWIND
LAMINATING LAMINATING
ROLL ROLL
PRESSURE PRESSURE
R OLL R OLL
4.3.4 Conveyor
The belt conveyor is driven from the main drive by two-side toothed chain with tightening.
When the conveyor is to be taken out of the machine, dismantle only the machine cover on the
drive side.
To tighten the belts of the conveyor, the length of the ruler must be adjusted either.
Before introducing a film in the laminating section, the position of the ruler must be adjusted
according to the film reel, set on the unwinding shaft. The ruler should guide a sheet of paper
to the reel edge on the drive side so as the film would cover the required position and would
not exceed the edge of the laminated sheets.
4.3.4.1 Procedure for the adjustment of the position of the ruler on the belt conveyor:
1. Loosen the locking screws on both ends of the ruler.
2. Turn the ruler by approximately 10°, push it on the guide rod and put it back to the
horizontal position.
3. Tighten the locking screws on both ends of the ruler.
4.3.4.2 Procedure for tightening the conveyor belt:

1. Loosen the screws on the blocks of the tightening mechanism.
2. Loosen connection bolts pos. 4144 on the ruler between components 4HG-4119 and 4HG-
4107.
3. Tighten the conveyor belt evenly on both sides by turning the connection bolts.
4. Tighten the screws on the blocks of the tightening mechanism.
5. Tighten connection bolts pos. 4144 on the ruler between components 4HG-4119 and
4HG-4107.
4.3.4.3 Aujusting of automatical guarding of paper sheets overlaps
After pressing of button “OVERLAP CONTROL”, the machine works in automatical regime
of overlaps guarding. If the button is lighting, the regime is set in motion. When the button
“OVERLAP CONTROL” is swiched on, the machine during minimal speed run automaticaly
accelerates for speed necessary for function of automatical regime of stops. Next increasing of
speed is made by potenciometer marked “SPEED”.
The mechanism for automatical quarding of overlaps is adjusted from production for square
weight 115 till 250 and 5 ± 3 mm overlap. It is not recommended to dislocate or readjust the
mechanism, when the key is necessary.
By producer allowable possibilities for adjusting

The operaton can adjust scraping brushes by loosening of control elements. In the case that the
paper is lifting on the edges of swig stop, brushes scrap the paper in direction of swing stop
and by this way is paper loosening from the swing stop and has free way to the lamination roll.
When brushes are wrongly adjusted, it can happen to the situation, that the paper is braked
(brushes are pressed on the conveyer belt) or do not scrap from the swing stop – are fare for
the swing stop or high above conveyer belt. Some kinds of paper is possible to laminate in
automatical cycle without brushes. The holder of brush could touch the swing stop in any case
(or restric the swing stom in movement).
The weight, which is in accesssories, is used for reaching of overlaps accuracy. The weight is
fit on the pins of weight. The size of weight and its use is influenced by: square weight of
paper, length of paper, and therefore is necessary to gain sufficient number of experiences in
its using, the same is valid by usind of brushes.
Electromagnet
of tilting stops
Mechanism
for adjustment
of tilting stops
Wiping
brush
Charging
pulleys
Tightening
screw
4.3.5 Separator
The position of the separator against the laminator is secured by setting the machine on table.
If the customer does not demand the table, offered by KOMFI spol. s.r.o., the separator must
be linked to the laminator by components and two screws to prevent the separator from pulling
to the laminator. Furthermore the user must ensure the machine setting in such a manner so as
the machine would not move during the operation in consequence of the machine strokes and
vibrations.
The separator consists of a conveyor, separator, drive, covers and unloading table.
4.3.5.1 Conveyor
The belt conveyor has its own drive through a chain to the driven conveyor roll. The shaft of
outgoing pulleys is driven from the driving roll through an indented belt.
The conveyor belt is to be tightened by the forcing-off screws at the driven roll.
Procedure for tightening the conveyor belt:

1. Remove the front cover of the loading conveyor from the machine
2. Loosen the screws on the blocks of the driven roll.
3. Tighten both sides of the conveyor belt evenly by the forcing-off screws.
4. Tighten the screws on the blocks of the driven roll.
5. Mount the side covers on the operator's and drive side on the machine.
4.3.5.2 Separator
The grip force of the snapping rolls in the separator is adjusted by the manufacturer. It derives
from the pre-stressed springs. If necessary, the force can be adjusted by changing the pre-
stress of the springs with the nuts on the guide rods. The machine must be stopped and
disconnected from the power supply for the at adjustment of the grip force.
Procedure for the adjustment of the grip force on the snapping rolls:
1. Loosen the screws on the covers on the separator sides and take the covers off.
2. Set the force of the grip of the rolls by turning all four nuts by the same number of
revolutions.
3. Put the covers back and tighten the screws.
4. Test the set force, repeat the procedure if necessary.
The position of the separator on the conveyor should be adjusted at every change of the length
of the laminated sheets of paper. The position should be adjusted when the machine is stopped,
or an experienced operator can adjust it when the machine is running at the lowest speed.
Procedure for changing the position of the separator against the conveyor:
1. Loosen the locking screws on the separator guideway.
2. Turn the lever on the operator's side and lift the upper snapping roll of the separator over
the eccentrically located shaft.
3. Push it on the guideway by pressing evenly on the separator edges.
4. The distance of the center of the snapping rolls from the middle of the drawing rolls must
be bigger than the length of one sheet and smaller than the length of two sheets.
5. Introduce the web of the laminated sheets between the snapping rolls.
6. Tighten the locking screws on the separator guideway.
7. Turn the lever on the operator's side. Put the rolls back and grip the web of the laminated
sheets of paper.
At introducing the web of the laminated sheets of paper, it is necessary to adjust the position
of the pulley, which brakes the web on the side without perforation and forms a wave on the
web. Adjust the position of the pulley and its turn roughly while the machine is stopped. Then
it should be fine-adjusted as necessary while the machine is running. Push the guide plates
according to the position and width of the web. Both the pulley and the web are located on
guide rod.
Procedure for the adjustment of the position of the pulley and guide plates:
1. Loosen locking screws.
2. Push the arm with the pulley and guide plates on guide rod according to the position of the
sheets of paper.
3. Tighten locking screws.
Procedure for the adjustment of the pulley turn:
1. Loosen the locking screw on the pulley arm.
2. Take control wheel by hand and turn pulley.
3. Tighten the locking screw on the pulley arm.
4. Test the function while the machine is running and repeat the procedure if necessary.
4.3.5.3 Drive
The separator drive is mounted on conveyor frame. There is a chain gear that connects the
motor to the conveyor roll. The shaft of the outgoing pulleys is driven from the driving roll
through an indented belt.
The chain should be tightened by pushing the motor in the groves on the holder.
The belt should be tightened by pushing holder with shaft and outgoing pulleys.

The unloading table is used for stacking laminated sheets. The angle of the table inclination
may be set in two positions.
− The front clamping of the table should be adjusted with the table unstressed. Loosen the
screws and set the table to a new position so that locking screws could be put through the
holes in counter-pieces.
- The front and side plates, on which the laminated sheets fall and where they are stacked,
should be adjusted after loosening the locking screws in the grooves on the holder.
4.3.6 Drive
The cover can be taken off and the mechanism can be manipulated by a qualified worker only.
4.3.6.1 Laminator drive

Every three months or if necessary the qualified worker should take off the drive cover and he
should check tightening of the belts and chains. If necessary, they should be tightened by
tightening wheels or by pushing the gearbox in the grooves on the holder.
5. MAINTENANCE
5.1 Individual groups
5.1.1 Frame
If the paint is damaged, repaint the damaged place.
Before starting laminating, always test the function of the sensor, located on the machine
frame over the input conveyor.

Clean the surface of the rolls and straightening strip daily or if necessary. ATTENTION!
During cleaning follow the safety rules for the zone of the laminating and pressing roll,
chapter 3.5.
The pressing roll may be assembled or disassembled and the springs of the drawing rolls may
changed by a qualified worker only.

Clean the surface of the guide roll daily or if necessary.
In the case of any problems or if the machine is too noisy at snapping the sheets in
the separator, check if the teeth of the perforating wheel are sharp enough and if they cut the
film edge sufficiently. If the teeth of the perforating wheel are blunt, change the tool.
5.1.4 Conveyor
The belt conveyor in the machine may be assembled or disassembled by a qualified worker
only.
The operator should clean the surface of the conveyor belts whenever necessary to preserve its
properties.
The processed material, see chapter 2.2 Input and output material, may be put on the conveyor
belts only.
5.1.4.1 Automatical guarding of paper sheets overlaps

Adjusting of overlaps can make only trained person. During automatical operation of overlaps
guarding can be the worked material see chap. 2.2
5.1.5 Separator
5.1.5.1 Conveyor
The operator should clean the surface of the conveyor belts whenever necessary to preserve its
properties.
The processed material, see chapter 2.2 Input and output material, may be put on the conveyor
belts only.
5.1.5.2 Separator
Clean the surface of the rolls daily or whenever necessary.
If roller is worn out, it should be changed by a qualified worker.
The springs of the snapping rolls may be changed by a qualified worker only.
5.1.6 Drive
Drive of Shaft of Drive of the excenter Clutch and

laminating lower of upper snap roll brake of
roll drawing switching with snapping
roll tightening control
Motor and main Main drive Tightening of Tightening of

drive gearbox tightening lower snap roll upper snap roll
drive drive
The maintenance workers may change or tighten the roller chains and indented belts only. If a
belt is damaged, it must be changed. The respective type of the belt is specified in the list of
parts and it is also printed on the top of the belt. To change the belt, it is necessary to loosen
the tightening wheels.
At the maintenance proceed as follows:

- Dismantle the solid protective cover.
- Check the chains and belts.
- Tighten the chain or indented belt.
- Put back the solid protective cover.
At the replacement of a chain (due to damage or excessive length in the links) proceed as
follows:
- Loosen the tightener.
- Search visually the chain link.
- Take out the pin and link.
- Take the chain out of the machine.
- Put a new chain in the machine. Both free ends should be accessible on the chain
wheel.
- Put back the pin and secure it.
- Tighten the chain by the tightener.
To change a belt, proceed as follows:

- Loosen the tightener.
- Take the belt out of the machine.
- Put a new belt in the machine.
- Tighten the belt by the tightener.
5.2 Regular maintenance of electrical equipment

The machine is put into operation by a worker of KOMFI spol. s.r.o. who knows the space
requirements for the machine work and maintenance. The maintenance of electrical equipment
may be done by an electrically skilled person (according to EN 60201 - 1 art. 3.52). Regular
maintenance of electrical equipment consists of checking and cleaning the machine electrical
elements. Clean all optic sensors min. every 7 days.
We recommend to execute regular maintenance always after a certain period of operation,
according to the instruction of a worker of KOMFI spol. s r.o.
We always recommend to keep records on executed maintenance and service, because they
may be a useful aid for further maintenance and repairs
Before starting work on electrical equipment, the machine must be disconnected from the lines
by unplugging the supply cable or in another suitable way. After switching the machine off
by the main switch, the circuit for acoustic signalling of the pressure roll pressing to the
laminating roll remains live!!!!!
Check of electrical equipment

Check visually fastening of all devices and tightening of series terminal connectors and
terminal connectors on devices. Tighten all loosen connections. A special attention should be
paid to tightening of the relay terminal connectors and contactors. The insulation resistance
between conductors of power circuits and the protective circuit measured at 500 VDC must
not be lower than 1 MΩ (see EN 60204-1:2000 art. 19.3.).
Check of the protective circuit
Check tightening of all connections of protective conductors. Tighten all loosen connections.
The continuity of the protective circuit should be verified by supplying current of at least 10 A
at 50 Hz from the PELV source for minimum 10 s. The test should be done between the PE
terminal and various points that are included in the protective circuit (see EN 60204-1: 2000
art. 19.2).
The voltage measured between the PE terminal and testing points must not exceed the
following values:
U = 3.3 V for S = 1.0 mm2
U = 2.6 V for S = 1.5.mm2
U = 1.9 V for S = 2.5.mm2
where U ... biggest measured voltage drop
S ... smallest efficient section of a protective conductor of the tested branch of the
protective circuit.
The frequency of measurements of the protective circuit continuity is determined by the

requirements of relevant regulations and standards, applicable in the user's country.
5.3 Lubrication chart

Lubricate and check the machine different parts regularly in order to prolong the machine
service life and correct function.
DAILY:
- Visual control for completeness
- Control if all covers and screws are installed
- Control of continuity of the electrical installation
- Control of hydraulic liquid for leakage
- Control of cleanness of perfect state of the laminating roll
- Control of cleanness of other machine rolls
- Control of cleanness of the pressing pulleys on the separator
- Control of the correct function
- of optic sensors
- of the cover safety sensor
- of sensor of the pressing roll position
- of emergency stop button
MONTHLY:
- Tighten and lubricate all roller chains with grease

- Tighten all indented belts
Drive gear boxes:
Running-in - 300 hours - oil PP 90 H

Regular operation - 400 hours - oil PP 90 H
Oil in hydraulic circuit:
Hydraulic oil HM 46
6. DESCRIPTION OF CONTROL
6.1 Description of buttons in the control panel and their functions
6.1.1 Description of the operator's panel
Screen 1 - ASPIRA Comfy version
Displayed only when the machine is stopped
Counter of laminated
Display of actual
sheets
temperature of
laminating roll
Display of
set format
Display of actual
temperature of
laminating roll Access to
screen 2
Display of pressing
force of pressure roll
to laminating roll Display of overlap
length in millimetres

Displayed only when the machine is switched on
Display of actual Counter of laminated

temperature of sheets
laminating roll
Display of
Display of actual laminating
temperature of speed
laminating roll
Access to
screen 2
Display of pressing
force of pressure roll
to laminating roll
Display of overlap
length in millimetres
Screen 1 - ASPIRA version

Displayed only when the machine is stopped
Display of actual sheets
temperature of
laminating roll
Display of
Display of actual set format
temperature of
laminating roll
Access to
screen 2
Display of
laminating time for
set batch

Displayed only when the machine is switched on
Display of actual sheets
temperature of
laminating roll
Display of
Display of actual laminating
temperature of speed
laminating roll
Access to
screen 2
Display of
laminating time for
set batch
Screen 2 – identical in both ASPIRA / ASPIRA Comfy versions
Access to
Button for return
screen 3
to screen 1
Adjustment of
Adjustment of
overlap in mm
sheet format
Button permitting or barring

tilting stop function
Choice of counter type

(counting upwardly / in
descending order
Access to
Button for return screen 5
to screen 2
Setting of batch of Access to

sheets screen 4
Display of
laminating time for
set batch
Choice of counter type

(counting upwardly / in
descending order
Access to
to screen 2
Setting of batch of
sheets
Display of
laminating time for
set batch
Button for return

to screen 3
8x buttons - pre-
selection determining
pressing force of
pressure roll to
laminating roll in kN
Control of
Button for return IRC function Access to
to screen 3 screen 6
Total number
of laminated
sheets x 100
Number of hours of
machine run
Button for choice of

language on panel
Access to
to screen 5
Button calling display of last arisen

error
Access to
Button for return screen 9 Access to
to screen 5 screen 8
Data for
service
purposes

The screen determined for production service only.
Display of
used SW
version for
operator's
panel
Display of used SW version

for PLC
Screen 10 - for display of errors – identical in both ASPIRA / ASPIRA Comfy versions
Button for error reset
Return to
screen 1
Text describing error

Screen active when a gap is detected between sheets on control sensor BQ1 – identical in
both ASPIRA / ASPIRA Comfy versions
6.1.2 Description of control buttons – identical in both ASPIRA / ASPIRA Comfy

versions
• MAIN SWITCH: Switches the machine on/off, may be used as emergency stop.
• START: Starts the machine. The cover of the laminating roll must be closed.
• STOP: Stops the machine.
• REVERSE: Tipping button for running at low speed backwards. It is active only when
the machine is stopped. The cover of the laminating roll may be open.
• SPEED potentiometer: Regulates the laminating speed.
• OVERLAP: Switches on/off the automatic mode in which sheets are led under the
laminating roll automatically with the pre-set overlap.
• SNAPPING: Switches on/off the snapper and determines the exact snapping point.
• ACOUSTIC SIGNALLING: If the operator does not release the laminating roll and
pressure roll by the main switch before switching the machine off, it is be signalled till
the rolls are released.
Description of control buttons 4 - ASPIRA Comfy version
• PRESSURE: By pressing the button, you start the motor that presses pressure roll to
the laminating roll with pre-set force. If the operator forgets release the rolls after the
machine stops, the rolls release automatically after 50s, but provided that the machine
was not switched off by the main switch.
• RELEASE: By pressing the button, the laminating roll and pressure roll release.
6.2 Machine start-up

6.2.1 Machine start-up without paper
• Switch the main switch on and check the desired temperature of the laminating roll on
• Set: 1- sheet format
2- desired overlap
3- desired pressure of the pressure roll to the laminating roll
(ASPIRA "E" version).
• As soon as the desired temperature is reached, the operator should introduce the foil,
paper under the laminating roll and close the cover.
• If no error messages are displayed on the operator's panel, the operator may start the
machine by the START button and execute the following activities:
ASPIRA version: Set the pressure necessary for pressing the pressure roll to the
laminating roll by the lever .
ASPIRA version: Press the PRESSURE button to start the motor that will press the
pressure roll to the laminating roll with the pre-set force.
• The machine is ready for loading sheets with overlap.
6.2.2 Machine start-up after short-time shutdown
• Before starting the machine, check the temperature of the laminating roll and check
whether the foil and paper are introduced properly and the cover is closed.
• Depending on the machine type, execute pressing of the pressure roll to the laminating
roll.
6.2.3 Machine start-up with manual control of overlap

• Switch the main switch on and check the desired temperature of the laminating roll on
Set the desired pressure of the pressure roll to the laminating roll.
(version ASPIRA Comfy ).
• As soon as the desired temperature is reached, the operator should introduce the foil,
paper under the laminating roll and close the cover.
• Switch off the function of tilting stops in screen 2.
• Lift the tilting stop by the OVERLAP CONTROL button.

• If no error messages are displayed on the operator's panel, the operator may start the
machine by the START button and execute the following activities:
ASPIRA version: Set the pressure necessary for pressing the pressure roll to the
laminating roll by the lever .
ASPIRA version: Press the PRESSURE button to start the motor that will press the
pressure roll to the laminating roll with the pre-set force.
6.2.4 Machine stop
• Stop the machine by the STOP button.

• Release the laminating roll and pressure roll.
6.2.5 Machine switch-off
• Stop the machine by the STOP button.

• Release the laminating roll and pressure roll.
• Switch the machine off by the main switch.
After switching the machine off by the main switch, the circuit for acoustic signalling
of the pressure roll pressing to the laminating roll remains live. If the machine should
be shutdown for a long time, it must be disconnected from the line by unplugging the
supply cable or in another suitable way!!!
7. ERROR MESSAGES
Machine faults are displayed on the operator's panel.

Errors displayed on the panel in English
Error Possible Cause Procedure

(message)
Reset the error by turning the
Snapping 1. Defective sensor BQ3
snapper shaft manually in the sense
mechanism is not at 2. The snapper is jammed of snapping. Thus sensor BQ3
the start position
3. The "SIMPLEBLOCK" clutch approaches the diaphragm of the
scanning the snapper is not snapper start position and the
working snapper is braked in that position.
Reset the error by turning the
Bad IRC encoder or 1. Defective sensor BQ2
IRC is disconnected incremental sensor snapper shaft manually in the sense
of snapping. Thus sensor BQ3
or main drive is not 2. Defective or overheated motor approaches the diaphragm of the
moving
3. The snapper is jammed snapper start position and the
snapper is braked in that position.
After removing the error, press the
Snapping 1. Defective sensor BQ3
RESET button in screen 10, or the
mechanism did not 2. The snapper is jammed START button. Thus the error is
leave the sensor
3. The "SIMPLEBLOCK" clutch reset.
after activating
scanning the snapper is not
working
Laminating roll is 1. Defective or incorrectly focused
overheated. temperature sensor BQ4
START button. Thus the error is
Check heating 2. Defective power solid state relay reset.
circuit A2
Short circuit or 1. Defective temperature sensor
disconnecting of the BQ4
START button. Thus the error is
temperature sensor 2. Defective or disconnected lead of reset.
temperature sensor BQ4
A return thermostat is put on the heating roll, whose function is to disconnect feeding of the infra-
red radiator if software protection against overheating fails. The thermostat equipment is not
indicated on the operator's panel. As soon as the overheated roll cools down, the thermostat switches
on automatically.
8. MACHINE TRANSPORT
The machine must be transported in the work position, screwed to a wooden transport frame.
It is allowed to transport the machine with the table on a transport frame by means of a
forklift or pallet truck only.
To take the machine with the table off the transport frame, proceed as follows:
- Unscrew the fastening bolts.
- Put the for of the forklift between the pallet and the machine table.
9. WARRANTY TERMS
12 months after the date of shipment.

10. LIST OF SERVICE CENTERS
If an error or defect is detected, which you are not able to correct, please contact us:
Head Office:
KOMFI spol. s r.o., Dvořákova 1001, 563 01 LANŠKROUN
Tel.: 00420 465 323 007
Fax: 00420 465 324 222
Location:
KOMFI spol. s r.o., provozovna Svébohov, 789 01 Zábřeh na Moravě
Tel.: 00420 583 411 123
Fax: 00420 583 412 126
Location:
KOMFI spol. s r.o., provozovna Nové Město na Moravě, Mendlova ul., 532 01
Tel.: 00420 566 618 671
Fax: 00420 566 617 897

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ASPIRA

1. BASIC INFORMATION ....................................................................................................................................3

1.1 Description of machine use and function .......................................................................................................3

3.1 Machine installation .......................................................................................................................................8

4. TECHNICAL DESCRIPTION ........................................................................................................................19

4.1 Machine function ..........................................................................................................................................19

5.1 Individual groups..........................................................................................................................................37

10. LIST OF SERVICE CENTERS.....................................................................................................................54

1.2 Schematic drawing

levelling guiding pulling unw inding up per low er

MAIN PLACE OF SEC ONDARY PLACE OF

1.3 Diagram of machine process

2.2 Input and output material

Specification of swing stops

2.3.2 Adjustment of laminating temperature

2.4 Control logic

2.5 Conditions of machine operation

2.6 Working mode

3.2 Starting operation

3.3 Manipulation and transport

3.5 Different groups and subgroups

DANGERO US PLACE DANGEROUS AREA

3.5.2.2 Adjustment of the position of straightening strip

3.5.2.3 Drawing rolls

3.5.4.1 Swing stops

3.5.5.2 Snapping unit

3.5.5.3 Drive of separator

2. Be cautious at any maintenance or adjustment.

5. Be cautious at any maintenance and adjustment.

6. The machine may be adjusted by a specially trained and qualified worker.

9. It is not allowed to switch the machine on with removed covers.

16. Wear a protective shield for setting springs.

17. It is not allowed to clean the machine while it is running.

3.8 Disassembly and disposal

The machine is used for laminating sheets of paper.

The individual groups and subgroups of the machine:

4.1.2 Laminating section

4.1.2.1 Laminating and pressure mechanism

4.1.2.2 Straightening strip

4.1.2.3 Drawing rolls

4.1.3 Film unwinding

4.1.3.1 Guide roll

4.1.4.1 Belt conveyor

4.1.4.2 Automatical guarding of paper sheets overlaps

4.1.5 Snap roll

4.1.5.1 Snap rolls

4.1.5.2 Cover of snap rolls

4.1.5.3 Unloading table

4.1.5.4 Separator covers

4.1.5.5 Unloading table

4.1.6 Drive 4HG-6000

4.1.7 Covers 4HG-9000

4.1.7.1 Cover of laminating roll

4.1.7.2 Cover of drawing rolls

4.1.7.3 Peripheral covers of laminating section

4.2 Description of different groups and subgroups

4.2.2 Laminating section

4.2.2.1 Laminating and pressure

4.2.2.2 Straightening bar