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MBO RW500 Operating Manual

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RW500
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Summary of Contents for MBO RW500

  • Page 1 Rewinder Translation of the original operating manual RW500 Keep for future reference!
  • Page 2 Version: Author: 8/20/2015 Status as Machine no.: US English BA_RW500_V1.2_usen Language: File name: MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG PO Box 1169 71567 Oppenweiler GERMANY Manufacturer: Tel.: +49 7191 46 0 Fax: +49 7191 46 34 http://www.mbo-folder.com info@mbo-folder.com...
  • Page 3 For all questions relating to your machine, please contact your CE marking MBO agency. You can find the address on our home page: www.mbo-folder.com. For the identification of the machine and the most important machine data, see the name plate on the machine.
  • Page 4 EC Declaration of Conformity according to EC Machine Directive 2006/42/EC, Annex II, No. 1 A. The manufacturer MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG Grabenstraße 4-6 71570 Oppenweiler GERMANY hereby declares that the machine described below: Designation Rewinder Type RW500 Commissioning no.

  • Page 5: Table Of Contents

    Normal operation ........... . 25 Rewinder RW500...
  • Page 6 Web break detection ..........53 Rewinder RW500...
  • Page 7 Variant RW500 ........
  • Page 8 Insert the core shaft with empty sleeve ........113 Rewinder RW500...
  • Page 9 Disposal/recycling ..........139 Rewinder RW500...
  • Page 10 List of contents Rewinder RW500...

  • Page 11: About This Manual

    • Give this operating manual to any subsequent owner or user of the ma- machine chine. We reserve the right to make technical changes to improve the machine, even if these changes are not taken into account in this operating manual. Rewinder RW500...

  • Page 12: Additional Documents

    About this manual Additional documents Additional documents In addition to this operating manual, there are these documents about the machine: Type Designation MBO part number Wiring diagram Pneumatic diagram Spare parts list Supplier documentation Table 1: Additional documents 1.1.1 Supplier documentation...
  • Page 13 • Operating personnel machine back into • Storage • Maintenance personnel operation • Recommissioning • Service technicians Disposal Details for the environmentally friendly • Operator disposal • Maintenance personnel • Service technicians Table 3: Structure of the operating manual Rewinder RW500...

  • Page 14: Signs And Symbols Used

    Here you will find the result of a sequence of instruc- tions for action. <STOP> Push button with the label between the brackets (e.g. Stop). Additional information for use of the machine. Important notice, please observe. Table 4: Symbols, terms, and abbreviations Rewinder RW500...

  • Page 15: Description Of Safety Messages

    • Type and source of the hazard • Possible consequences of the hazard • Measure(s) for avoiding the hazard Example: DANGER! WARNING! CAUTION! ( Signal word) Type and source of the hazard. Possible consequences of the hazard. Measure(s) for avoiding the hazard. Rewinder RW500...

  • Page 16: Safety Sign

    Fire protection sign Red background, white symbol. Safety sign, which in case of hazard marks the location of fire alarm and fire extinguishing equipment and/or the path to this equipment. Table 6: Safety sign Rewinder RW500...
  • Page 17 Warning of oxidizing substances. You will see this warning-triangle next to activi- ties during which there is a hazard of oxidizing substances, possibly with deadly conse- quences. Table 7: Warning sign Rewinder RW500...
  • Page 18 Warning of cutting hazard. You will see this warning sign in front of activi- ties during which there is a cutting hazard due to the moving web. Table 7: Warning sign Rewinder RW500...
  • Page 19 You will see this mandatory sign next to activi- ties for which you should heed the mainte- nance chapter. Activate before maintenance or repair. You will see this mandatory sign next to activi- ties for which the machine must be de-ener- gized. Table 8: Mandatory sign Rewinder RW500...

  • Page 20: User Assessment Of The Operating Manual

    This marking is affixed to constant danger spots and hindrances. Table 9: Marking of danger spots User assessment of the operating manual Our operating manuals are updated regularly. Help us with your suggestions for improvement; they make the manuals user-friendly. Rewinder RW500...

  • Page 21: Basic Safety Instructions

    • Adhere to the inspection and maintenance intervals. • Use only original wearing parts and spare parts. Use the machine only as intended and when the protective device is working perfectly. This is the only way to guarantee the machine's operating safety. Rewinder RW500...

  • Page 22: Reasonable Foreseeable Misuse

    The use of spare parts and wear parts from third-party manufacturers can cause risks. Use only original parts or parts approved by the manufacturer. The manufacturer assumes no liability for damage from the use of spare parts and wearing parts not approved by the manufacturer. Rewinder RW500...

  • Page 23: Obligation And Liability

    • Is not maintained or not maintained properly or serviced. The machine is only to be used: • For the intended use. • If it is in perfect condition with respect to safety. Faults that can compromise safety must be remedied immediately. Rewinder RW500...

  • Page 24: Warranty

    • Defective monitoring of machine parts that are subject to wear, such as belts, tapes, brushes, and couplings. • Installation of spare and wearing parts that were not ordered from the manufacturer. • Cases of catastrophe and acts of God. Rewinder RW500...

  • Page 25: Residual Risks

    • Overloading of the roll lift. • Crushing hazard when loading and unloading the paper roll • Rotating machine parts. • Rotating machine parts in setup mode. • Drawn-in hazard between paper roll and floor. • Crushing hazard when lowering the pressure arm. Rewinder RW500...

  • Page 26: Maintenance

    • Crushing and drawn-in hazards due to rotating machine parts. • Unsuitable tool. • Improper maintenance. • Use of non-approved safety components. • Trip hazards due to cables and hoses lying around. • Incorrect maintenance intervals during multi-shift operation. Repair: • Improper maintenance. Rewinder RW500...

  • Page 27: Decommissioning, Storage

    Secure the paper webs between the machines via stationary enclo- sures fitted (e.g. hook-up chains, barrier tapes, etc).  Fit the enclosures with a minimum distance of 50 cm to the web edge.  Cutting injuries are avoided. Rewinder RW500...

  • Page 28: Life Time

    Life time of the machine The life time of this machine is designed for 20 years. 2.8.2 Service life of the control-technical safety components. All components of the control-technical safety circuits have a life time of more than 20 years. Rewinder RW500...

  • Page 29: General Safety Instructions

    Only use suitable and tech- nically-perfect lift equipment and load suspension devices with suffi- cient carrying capacity. Secure components and parts so that they present no hazard. Do not linger or work under suspended loads. Rewinder RW500...

  • Page 30: Maintenance And Repair

    • Only an electrically qualified person is permitted to perform work on the machine's electrical system. • In case of faults in the electrical power supply, the machine must be switched off immediately. • Only use original fuses with the prescribed amperage. Rewinder RW500...

  • Page 31: Personnel, Qualification And Duties

    • have understood and can implement practically the operating manual with respect to responsibilities, tasks, and activities for the machine. 2.10.1 Qualification of the personnel This table lists the necessary qualification of the personnel related to the various activities at or on the machine. Rewinder RW500...
  • Page 32 Personnel, qualification and duties Transportation Interim storage Set-up Electrical connections Stationary mains connection Commissioning Troubleshooting (mechanical/ electrical Setting Operation Operational mainte- nance (cleaning) Maintenance Repair Decommissioning Storage Disposal Table 10: Qualification of personnel Legend: X permitted, - not permitted Rewinder RW500...

  • Page 33: Duties Of The Operator

    Germany The requirements of the German Labor Protection Act (ArbSchG) and the German Health and Safety at Work Regulations (BetrSichV) must be adhered to. EC countries The requirements of the directives 89/391/EEC and 2009/104/EU must be adhered to. Rewinder RW500...

  • Page 34: Duties Of The Operating Personnel

    • use the machine as intended. • wear the necessary personal protective equipment. The maintenance personnel is responsible for • protecting the machine against unauthorized use, • the maintenance being carried out according to the maintenance sched- ule. Rewinder RW500...

  • Page 35: Personal Protective Equipment

    This personal protective equipment must be provided and worn for the op- eration and set-up of the machine: • Safety shoes 2.11.2 Operational maintenance (cleaning) This personal protective equipment must be provided and worn for the proper maintenance (cleaning) of the machine: • Safety shoes Rewinder RW500...

  • Page 36: Work Areas And Workstations

    100 cm . • The service area is highlighted shaded. • The possible workstations are marked with an "X." 2.12.1 Layout from right to left RW500 Unit of measurement in cm 1 Workstations Illustration 1: Work area and workstations RW500 Rewinder RW500...

  • Page 37: Markings And Safety Messages On The Machine

    These markings and safety labels must be on the machine and in an easily legible condition. If the markings and safety labels are damaged or illegible, they must be re- placed. For the appropriate MBO part number, see chapter "2.13.1 Position and meaning". 2.13.1 Position and meaning Pos.
  • Page 38 Basic safety instructions Markings and safety messages on the machine Pos. 3 MBO part number: 4002643 Meaning: Mandatory sign <Read operating manual> • The operating manual must be heeded by all people who work on or at the machine. • Read and understand the operating manual before working with the machine.
  • Page 39 Basic safety instructions Markings and safety messages on the machine Pos. 5 MBO part number: 4003327 Meaning: <Drawn-in hazard> warning sign With the relevant rewind direction, there is a hazardous entanglement zone between the paper roll and pressure roller. Non-observance could result in serious injury or death.
  • Page 40 Basic safety instructions Markings and safety messages on the machine Pos. 7 MBO part number: 719.0071.0004 Meaning: Notice <Web trajectory, right to left> Non-observance could result in property damage. Observe the specified web trajectory. Illustration 8: Notice, web trajectory, right to left Pos.8...
  • Page 41 Basic safety instructions Markings and safety messages on the machine Pos. 9 MBO part number: 4003327 Meaning: <Drawn-in hazard> warning sign With the relevant rewind direction, there is a hazardous entanglement zone between the paper roll and floor. Non-observance could result in serious injury or death.
  • Page 42 Basic safety instructions Markings and safety messages on the machine Pos. 11 MBO part number: 718.8171.0001 Meaning: <Maximum load weight, maximum roll diameter> notice Non-observance could result in serious injury or death. • Never overload the maximum load weight. •...

  • Page 43: Directions For Emergencies

    What injuries? • Who's calling? • Wait for queries! • Provide help as necessary. 3 First aid • Check consciousness and breathing. • Protect against heat loss. • Provide support and assistance. Table 12: Behavior in case of accidents Rewinder RW500...
  • Page 44 Basic safety instructions Directions for emergencies Rewinder RW500...

  • Page 45: Product Description

    • Electric roll lift (7) • Pneumatic core shaft (6) • Pneumatic dancer (3) • Weight force dancer (1) 3.1.3 Options • Various core shaft diameters (6) • Splice table • Splice detection sensor • Web guide (2) Rewinder RW500...

  • Page 46: Technical Data

    Product description Technical data Technical data 3.2.1 Floor plan 3.2.1.1 Layout from right to left Unit of measurement cm Height 145 cm Illustration 15: Floor plan RW500 from right to left Rewinder RW500...

  • Page 47: Performance Characteristics

    4) Minimal web diameter that can be processed + 144 mm (height of a Europool pallet (EPAL) 5) Any larger size required as an option. 6) Depending on the core shaft diameter 3.2.3 Acceleration data Acceleration [m/s²] Hard stop deceleration (Web) [m/s²] Emergency stop deceleration [m/s²] Table 14: Acceleration data Rewinder RW500...

  • Page 48: Emissions

    3) Heed operating manual for the fork lift, load capacity depends on the load center of gravity (c). 4) Minimum load capacity of the floor where the machine will be set up 5) In the area of the machine, the total height difference may not exceed 20 mm. Rewinder RW500...

  • Page 49: Electrical Supply

    4) In accordance with table 10 EN 60204-1:2006, with double safety 5) In accordance with table 10 EN 60204-1:2006 6) Required if the leakage currents of the RFI filters > 10 mA. Not required if the cross-section of the power supply connection > 10 mm Rewinder RW500...

  • Page 50: Compressed Air Supply, Control Air

    1) At temperatures below or above the permissible room temperature, special measures must be taken. 2) For installation at an altitude of 1000 m above sea level or higher, a power reduction of 1 % per 100 m should be incorporated. Avoid direct sunlight and drafts. Rewinder RW500...

  • Page 51: Structure And Function

    This chapter describes the components and function of the rewinder. Structure 4.1.1 Components of the rewinder The components are distributed across four sides of the rewinder. 1 Control cabinet side 3 Operator side 2 Infeed side 4 Roll side Illustration 16: Views of the rewinder Rewinder RW500...
  • Page 52 8 Pressure arm with pressure shaft 4 Module, WebGuide (option) 9 Module, roll lift 5 Interlocking movable guards with guard locking 10 Touchscreen 11 Control panel with EMERGENCY STOP palm button Illustration 17: Components of the operator side Rewinder RW500...
  • Page 53 4.1.1.2 Components of the control cabinet side 1 Module, roll lift 4 Module, pneumatic dancer 2 Main switch 5 Module, WebGuide (option) 3 Control cabinet 6 Module, weight force dancer Illustration 18: Components of the control cabinet side Rewinder RW500...
  • Page 54 Components of the roll side 1 Retainers for core shaft 4 Roll diameter sensor 2 Paper roll drive 5 Compressed air pistol 3 Core shaft 6 Pressure arm with pressure shaft Illustration 19: Components of the roll side Rewinder RW500...
  • Page 55 Structure and function Structure 4.1.1.4 Components of the infeed side 1 Weight force dancer 2 Infeed rolls Illustration 20: Components of the infeed side Rewinder RW500...

  • Page 56: Functional Description

    Structure and function Functional description Functional description The RW500 rewinder is a center-driven rewinder with servo drive and elec- tric roll lift. 4.2.1 Compressed air supply The compressed air is supplied via an external compressed air hose. The compressed air supply is required to: •...

  • Page 57: Web Break Detection

    4.2.8 Web guide (optional) The web guide holds the web in an exact side position. Variants 4.3.1 Variant RW500 Definition of terms The designation "RW500" means: Rewinder Maximum web width = 520 mm Rewinder RW500...

  • Page 58: Protective Devices

    When the protective device is lifted, the electric locking causes the ma- chine to stop. Only when the hazardous function has been eliminated safely is the locking reset and then the protective device can be opened completely. The machine can be restarted only after the protective device is closed. Rewinder RW500...

  • Page 59: Explanation Of The Term "Protective Devices

    Protective devices include: • Two-hand switches • Sensitive protective devices such as: Contact mats, safety strips, switch rods and switch wires. • Optoelectronic, protective devices such as: Light barriers, laser scanners and camera-controlled safety systems. Rewinder RW500...

  • Page 60: Main Switch

    • it is equipped with a device that enables it to be locked in the OFF po- sition (e.g. by a padlock). When switching off the main switch during production: • the machine is stopped, • the drives gradually run down, Rewinder RW500...

  • Page 61: Emergency Stop Palm Button

    Press the <Reset EMERGENCY STOP> illuminated button (2). The <Reset EMERGENCY STOP> illuminated button (2) does not light up.  The machine is ready for operation. When the EMERGENCY STOP palm button is pressed, the machine is stopped immediately. Rewinder RW500...

  • Page 62: Interlocking Movable Guards With Guard Locking

     Service faulty protective devices immediately. 4.4.7 Checking protective devices All protective devices must be checked regularly. For the corresponding inspection intervals, see chapter "4.4.8 Checklist for protective devices" For the corresponding procedure, see the Maintenance chapter. Rewinder RW500...

  • Page 63: Checklist For Protective Devices

    Safety switch for pos. 5 Daily Safety switch for pos. 4 Daily All safety screws are secured Weekly with screw locking (e.g. Loctite 222). Guard Weekly Guard Weekly EMERGENCY STOP palm but- Daily Table 20: Checklist for protective devices Rewinder RW500...
  • Page 64 Structure and function Protective devices Visual Function- Inspection Pos. Designation inspec- Result ing control interval tion Guard Weekly Guard Weekly Date: Name: Signature: Table 20: Checklist for protective devices Rewinder RW500...

  • Page 65: Operating And Display Elements, Operating Modes

    Illustration 24: Overview, operating and display elements 1 Main switch. See chapter "5.1.2 Main switch". 2 Control panel. See chapter "5.1.3 Control panel". 3 TOUCHSCREEN. See chapter "5.1.6 Touchscreen structure" 4 Control panel, web guide (optional). See chapter "5.1.4 Control panel, web guide (optional)". Rewinder RW500...

  • Page 66: Main Switch

    • It has only one OFF and one ON position, labeled as 0 and I. • It is equipped with a device that enables it to be locked in the OFF po- sition (e.g. by a padlock). Rewinder RW500...

  • Page 67: Control Panel

    Off = <Production> operating mode is active. 7 <Open / close brake> illuminated button. Only active in the <Setup> operating mode. Status indicator of the light ring: Yellow = brake is open. Green = brake is closed. Off = <Production> operating mode is active. Rewinder RW500...
  • Page 68 Red = <Production> operating mode is active, printer is active. The following functions are automatically moved to the <Production> po- sition after switching to the <Production> operating mode (3): • Weight force dancer (9) • Pneumatic dancer (4) • Pressure arm (8) Rewinder RW500...

  • Page 69: Control Panel, Web Guide (Optional)

    11 <F4 multiple operation> button 12 <F3 Change> button 13 <F2 Motorized sensor positioning> button 14 <F1 Changeover of sensors/drives> button For a detailed functioning description, see the separate operating man- ual from the company Erhardt + Leimer. Rewinder RW500...

  • Page 70: Usage Of The Touchscreen

    Operating and display elements 5.1.5 Usage of the touchscreen • Only use your finger or a stylus pen (MBO part number 0131900) to operate the touchscreen. • Ball-point pens or other metallic objects may damage the surface of the touchscreen.
  • Page 71 3 <Machine status> display. Displays the current status of the machine. See chapter "5.1.7 Displaying machine status" 4 <Password> button. Displays the current password level. See Chapter "5.1.8 Entering the password". 5 <Current date> display. 6 <Current time> display. Rewinder RW500...
  • Page 72 9 <Display favorite pages> button. Pressing the button displays the <Favorite> page. See chapter "5.1.10 Selecting favorite pages". 10 <Select favorite pages> button. Pressing this button saves this page as a <Favorite>. See chapter "5.1.10 Selecting favorite pages" Rewinder RW500...

  • Page 73: Displaying Machine Status

    Operating and display elements 5.1.7 Displaying machine status Illustration 31: Displaying machine status The <Machine status> display is used to diagnose functional faults. The relevant operating condition of the machine is displayed as a number and in the corresponding color. Rewinder RW500...

  • Page 74: Entering The Password

    Area and authorization Symbol Area: • Diagnosis (look at all/change something). Authorization for: Operator Area: • Diagnosis (look at all/change something). • Service (look at all/change some- XXXX thing). Authorization for: Machine setter with supervision. Table 21: Password level Rewinder RW500...
  • Page 75 Press the <Password> button (1). The password input window is opened.  Press the <C> button (7).  Press the <Enter> button (8). The <Password> button (3) displays a closed lock.  The password level is reset. Rewinder RW500...

  • Page 76: Description Of The Screens

    The operating condition of production is displayed. Gray = production operating mode is not blocked. Red = production operating mode is blocked. In other words, it is not possible to switch over to the <Setup> operating mode in this status. Rewinder RW500...
  • Page 77 Pressing the input field (4) displays a numeric keypad (3). Enter the required reduction factor. 5 <Minimum reduction factor> input field. No function with Rewinder RW500. 6 <Set rewind direction> button. With this button is used to set the winding direction of the winding drive.

  • Page 78: Selecting Favorite Pages

    (1).  Pressing the <Favorite page changeover> button (2) displays a selec- tion list with a maximum of five favorite pages.  Press the required favorite page in the selection list.  The required favorite page is displayed. Rewinder RW500...

  • Page 79: Diagnosis> Page

    See chapter "5.1.11.3 <Diagnosis/output signal> page". 6 <Type 1 interface> keypad. Pressing the keypad opens the <Type 1 interface> page. See chapter "5.1.11.4 <Diagnosis/type 1 interface> page". 7 <Password management> keypad. Pressing the keypad opens the <Password management> page. Rewinder RW500...
  • Page 80 This page displays the signals of the inputs. Active inputs are displayed in green. Inactive inputs are displayed in gray. Illustration 39: <Diagnosis/input signals> page 1 <Scroll diagnostic pages forwards> function key 2 <Scroll diagnostic pages backwards> function key Rewinder RW500...
  • Page 81 Illustration 40: <Diagnosis/output signals> page 5.1.11.4 <Diagnosis/type 1 interface> page This page displays the signals of the type 1 interface. Active in/outputs are displayed in red. Inactive in/outputs are displayed in gray. Illustration 41: <Diagnosis/type 1 interface> page Rewinder RW500...

  • Page 82: Fault Displays

    > illuminated button is lit Color of the light Error description ring No error present. Blue <EMERGENCY STOP> palm button (in the machinery) was or is activated. Yellow Error according to the error list. Table 22: Error display Rewinder RW500...

  • Page 83: Touchscreen

    Press the display field (1) or the <Alarms> function key (2).  The <Alarm list> page is displayed. Display Here’s how to display the <History> page: <History> page  Press the <History> function key (3). The <History> page is displayed. Rewinder RW500...

  • Page 84: Operating Modes

    • Web breaks to be corrected. 5.3.2 Production In the Production operating mode the rewinder is ready for production; i.e. when the previous machine (printer, etc.) delivers paper, the rewinder winds this with the relevant: • Web speed • Web tension. Rewinder RW500...

  • Page 85: Transport And Interim Storage

    Qualification of personnel This table lists the necessary qualification of the personnel related to "Transport and interim storage" of the machine. Transportation Interim storage Table 23: Qualification of personnel; Transport, interim storage Legend: X permitted, - not permitted Rewinder RW500...

  • Page 86: Safety Messages

    Check the properties and condition and load rating of the subsurface in the set-up location. • For necessary minimum requirements, please see the "Technical data" chapter. CAUTION! Incorrect storage. Non-observance could result in property damage. Observe the specified storage conditions. Rewinder RW500...

  • Page 87: Packaging Of The Machine

    Check that the shipment is complete based on the delivery note. 6.2.4 In case of damage Procedure:  Notify the transport company immediately of any damage.  Contact your transport insurance carrier immediately.  Safeguard the machine and accessories from further damage. Rewinder RW500...

  • Page 88: Transporting The Machine

    Only lift the transport pallet as high as absolutely necessary for the transport.  Transport the transport pallet as close as possible to the intended lo- cation.  Set the transport pallet down carefully.  Machine is transported. Rewinder RW500...

  • Page 89: Interim Storage Of The Machine

    (danger of corrosion).  Loosen cover film from the transport pallet and lift it so that the air can circulate.  Machine is stored temporarily. 6.4.2 In a storage room For storage conditions, see chapter "3.2.8 Ambient conditions" Rewinder RW500...
  • Page 90 Transport and interim storage Interim storage of the machine Rewinder RW500...

  • Page 91: Installation, Commissioning

    This table lists the necessary qualification of the personnel related to "Set up and commissioning" of the machine. Set-up Electrical connections Stationary mains connection Commissioning Table 24: Qualification of personnel; Set-up, commissioning Legend: X permitted, - not permitted Rewinder RW500...

  • Page 92: Safety Messages

    For necessary minimum requirements, please see the "Technical data" chapter. WARNING! Trip hazards due to cables and hoses lying around. Non-observance could result in serious injury or death. Lay the machine connections (cables, hoses, pipes) so that there are no tripping points. Rewinder RW500...

  • Page 93: Installing The Machine

    • Separate installation and commissioning instructions are required for this. Only have the machine installed by MBO Service or by a customer ser- vice technician authorized by MBO. Making the stationary mains connection The electrical supply of the machine must be performed by a stationary mains connection.

  • Page 94: Heed Network Prerequisites

    NFPA 70, as well as the technical connection require- ments of the local power supply company. • This may not be connected by an MBO technician or a customer ser- vice technician. • For the electrical installation, EN 60204-1, Clause 6.3.3. "Protection through automatic switching off of the supply"...

  • Page 95: Observe The Design Of The Stationary Mains Connection

    • The N conductor is loaded (for 400 VAC power supply). • A right rotating field is absolutely necessary. • The machine sockets of the MBO machines may be used exclusively for the connection of MBO folding units, units, or deliveries.

  • Page 96: Making The Stationary Mains Connection On The Main Control Cabinet

    Connect the power cable to the terminal strip for stationary mains con- nection (1) according to the wiring diagram. Ensure finger safety by fastening the yellow protective plate via the open connection terminals. Use the red plastic screws included to do this.  The stationary mains connection is complete. Rewinder RW500...

  • Page 97: Connecting The Protective Equipotential Bonding Conductor

    Insert the protective equipotential bonding conductor into the main control cabinet through the cable grommet (1). Connect the protective equipotential bonding conductor to the PE con- nection terminal strip (2).  The protective equipotential bonding conductor is connected. Rewinder RW500...

  • Page 98: Checking The Protective Conductor Connections

    • Separate installation and commissioning instructions are required for this. Only have the machine commissioned by MBO Service or by a customer service technician authorized by MBO. Conducting a final check of the protective devices After commissioning the machine, be absolutely certain to carry out a final check of the protective devices.

  • Page 99: Conducting An Inspection After Commissioning

    Here's how to carry out an inspection:  spection Check all tapes and belts to make sure they run centered and have the necessary tension.  If required, readjust these. See Maintenance chapter.  The inspection has been carried out. Rewinder RW500...
  • Page 100 Installation, commissioning Conducting an inspection after commissioning Rewinder RW500...

  • Page 101: Adjustment And Operation

    Qualification of personnel This table lists the necessary qualification of the personnel related to "Op- eration and setting work" of the machine. Operation Setting Table 26: Qualification of personnel, operation and setting work Legend: X permitted, - not permitted Rewinder RW500...

  • Page 102: Safety Messages

    Do not stand in the area of the paper roll when the machine is run- ning. • Never crawl underneath the paper roll. • Never reach into the rotating paper roll while the machine is running. • Ensure that there are no objects located in this danger zone. Rewinder RW500...
  • Page 103 Risk of burning due to hot braking resistors. Non-observance could result in injury. Never touch the hot braking resistor. CAUTION! Cutting hazard. Edges of running webs can cause cutting injuries. • Never touch the edges of running webs. Rewinder RW500...

  • Page 104: Operation

    Here's how to switch the main switch off:  Turn the main switch (1) to switch position 0. The display turns off.  The machine is turned off now. To save energy, a machine that is not being used should be switched off. Rewinder RW500...

  • Page 105: Press The Emergency Stop Palm Button

     The machine is ready for operation. If there is another fault, the <Reset emergency stop> illuminated button is lit in red. Before the machine can be started, the fault must be rectified. See chapter "5.2 Error displays" Rewinder RW500...

  • Page 106: Switching On Operating Modes

    The illuminated button (1) is lit green.  The <Production> operating mode is switched on. The following functions are automatically moved to the <Production> po- sition after switching to the <Production> operating mode (3): • Weight force dancer • Pneumatic dancer • Pressure arm. Rewinder RW500...

  • Page 107: Raising/Lowering The Roll Lift

    The roll lift has been raised. • To simplify the engaging of the gear wheels, the web drive automat- ically rotates at a slow speed. • Ensure that the gear wheels are intermeshing correctly and not run- ning tooth on tooth. Rewinder RW500...

  • Page 108: Switching Off/On The Paper Roll Brake

    Here’s how to switch the brake on: the brake  Press the <Brake on/off> (1) illuminated button. The illuminated button (1) is lit green.  The brake is switched on. The brake is switched on automatically after switching to the <Produc- tion> operating mode. Rewinder RW500...

  • Page 109: Adjusting The Rewind Direction Of The Paper Roll

    The LED in the button (1) is gray. Here’s how to set the rewind direction clockwise:  Press the <Set rewind direction> button (1). The LED in the button (1) is green. The paper roll rotates clockwise.  The rewind direction is set. Rewinder RW500...
  • Page 110 Standard rewind direction counter-clockwise. The web must be moved underneath the pressure shaft. Rewind direction clockwise. The web must be moved over the pressure shaft. See chapter "8.3.3 Feeding in the web". Rewinder RW500...

  • Page 111: Pneumatic Dancer, Set Position

    > illuminated button (1). position position The illuminated button (1) is lit green. The dancer moves downwards.  The dancer is in the <Production> position. The dancer is automatically moved to the <Production> position after switching to the <Production> operating mode. Rewinder RW500...

  • Page 112: Weight Force Dancer, Set Position

    > illuminated button (1). position position The illuminated button (1) is lit green. The dancer moves downwards.  The dancer is in the <Production> position. The dancer is automatically moved to the <Production> position after switching to the <Production> operating mode. Rewinder RW500...

  • Page 113: Raising/Lowering The Pressure Arm

    Press the <Raise/lower pressure arm> (1) illuminated button. The illuminated button (1) is lit green. The pressure arm moves upwards.  The pressure arm is raised. The pressure arm is automatically lowered after switching to the <Pro- duction> operating mode. Rewinder RW500...

  • Page 114: Move The In-Feed Shaft In Inching Mode

    The <Inching> illuminated button (1) lights up in white.  Press and hold the <Inching> illuminated push button (1). The illuminated button (1) is lit green. The in-feed shaft rotates.  The in-feed shaft is moved in inching mode. Rewinder RW500...

  • Page 115: Creating Production Readiness

    11) Switch the <Production> operating mode (2) on. The illuminated button (2) is lit green. The <Reset emergency stop> illuminated button (1) does not light up. The <Stop request> illuminated button (8) lights up in red.  The system is ready for production. Rewinder RW500...

  • Page 116: Adjustment

    See chapter "8.3.5 Setting the internal web tension". 16) <Set the full paper roll> position. See chapter "8.4 Set <Full paper roll>". 17) Troubleshooting. See chapter "8.6 Identification and handling of malfunctions".  The machine has been adjusted. Rewinder RW500...

  • Page 117: Insert The Core Shaft With Empty Sleeve

    Actuate the compressed air pistol (1) until the maximum pressure has been built up (6 bar).  Only remove the compressed air pistol (1) from the compressed air valve (2) when activated. Otherwise the core shaft would be vented again.  The core shaft has been inserted. Rewinder RW500...

  • Page 118: Feeding In The Web

    9 Guide shafts 3 Guide shaft 10 Guide shaft 4 Guide shaft 11 Infeed shaft 5 Web 12 Movable dancer shaft 6 Guide shafts 13 Guide shaft 7 in-feed shaft 14 Movable dancer shafts Illustration 59: Feeding in the web Rewinder RW500...
  • Page 119 11) Fasten the end of the web with adhesive strips onto the empty sleeve. 12) Turn the core shaft by hand until there are approx. 2 - 3 windings over the splice. 13) Switch the paper roll brake on.  The web has been fed in. Rewinder RW500...

  • Page 120: Open/Close The Nip Roller On The In-Feed Shaft

    Pull the handle (1) on the nip roller (2) upwards.  The nip roller is open. When opening the nip roller, ensure that there is no web break in the re- winder. Otherwise the web is retracted by the external web tension. Rewinder RW500...

  • Page 121: Setting The Internal Web Tension

    Illustration 61: Setting the web tension 1 Web tension run with reduction factor = 0% 2 Web tension run with reduction factor = 25% 3 Web tension run with reduction factor = 30% 4 Web tension setting = 20% Rewinder RW500...
  • Page 122 Enter the value for the required reduction factor.  The reduction factor is set. Minimum No function with Rewinder RW500 reduction factor (3) The web tension is set based on the paper weight. • Light papers = low web tension.

  • Page 123: Set

    These prerequisites must be fulfilled: • The compressed air supply is connected. • There is a network pressure of at least 6 bar. • The <Production> operating mode is switched on. • The web moves at production speed. Rewinder RW500...
  • Page 124 Push in the adjustment element (1). The adjustment element is locked.  The contact pressure is set. Set the contact pressure so that: • the pressure shaft is parallel on the paper roll. • no air pillows are created in the coil. Rewinder RW500...

  • Page 125: Identification And Handling Of Malfunctions

    1030 Contact roller on in-feed • The pressure roller on the in- • Close the pressure roller open, in <Setup> operating feed shaft is open. mode 1033 Time error when starting • • Notify service the weight dancer Table 27: Error/Cause/Remedy Rewinder RW500...
  • Page 126 1037 Compressed air pres- • No compressed air. • Check the compressed air sure roller, setup supply. 1038 Compressed air pres- • No compressed air. • Check the compressed air sure roller, production supply. Table 27: Error/Cause/Remedy Rewinder RW500...

  • Page 127: Maintenance

    See chapter "4.4.7 Checking protective devices". 9.1.1 Qualification of personnel This table lists the necessary qualification of the personnel related to "Maintenance" of the machine. Operational maintenance Maintenance Repair Table 28: Qualification of personnel Legend: X permitted, - not permitted Rewinder RW500...

  • Page 128: Safety Messages

    Operation without protective devices. Non-observance could result in serious injury or death. The protective devices protect against danger spots. • Never operate the machine without protective devices. • Check that all protective devices are refitted after maintenance or repair work. Rewinder RW500...
  • Page 129 Unsuitable tool. Non-observance could result in injury or property damage. • You should only use tools that are in perfect condition. • Make sure that after maintenance work, there are no tools left on or in the machine. Rewinder RW500...

  • Page 130: Service

    Ordering spare and wear parts You can obtain the spare and wear parts worldwide via the corresponding MBO agency near you. For all questions relating to your machine, please also contact your MBO agency. You can find the address on our home page: www.mbo-folder.com.

  • Page 131: Spare Part List For The Protective Devices

    Guard 719.6362.0008 Guard 719.6360.0002 Guard, disc 719.6466.0001 Safety switch with 0801472 guard locking 0801498 Guard 719.7864.0017 Guard 719.7864.0015 EMERGENCY STOP palm button See wiring diagram Guard 719.8160.0001 Guard 719.6260.0001 Table 29: Spare part list for the protective devices Rewinder RW500...

  • Page 132: Performing Operational Maintenance

    Non-observance could result in serious injury or death. • Make sure that the specifications for the respective gap are adhered • If a gap is too large, it must be re-adjusted by MBO Service or autho- rized customer service. • Never dismantle, bridge or bypass safety switches.
  • Page 133 The <Reset EMERGENCY STOP> illuminated button (2) does not light up.  The EMERGENCY STOP palm button has been checked. Before the machine can be restarted, all illuminated buttons <Reset EMERGENCY STOP> on the system must be activated in line with the system's EMERGENCY STOP concept. Rewinder RW500...
  • Page 134 Press the <Setup/production> illuminated button for approx. 3 sec- onds to switch to <Production> operating mode. The illuminated button is flashing green.  The interlocking movable guard is checked. The interlocking moveable guards are not permitted to be openable in the <Production> operating mode. Rewinder RW500...

  • Page 135: Check That All Protective Devices Are Present

    Never clean the machine using compressed air. (bearing damage) CAUTION! Incorrect use of cleaning agents. Non-observance could result in injury. • Be sure to follow the manufacturer's safety instructions. • Avoid any skin contact. • Wear suitable safety gloves. • Wear safety glasses. Rewinder RW500...
  • Page 136 Shafts and rollers MBO Binder GmbH & Co. KG recommends "Varn" cleansing agent with the designation: "VM 111 or VWM Wash". The "Varn“ company delivers to the printing industry worldwide. Therefore, it cannot be excluded that in certain other countries different designations are used.

  • Page 137: Cleaning The Optical Sensors

    • EMERGENCY STOP palm button is pressed. Cleaning the optical Here’s how to clean the optical sensors: sensors  Clean the optical elements of the sensors or reflectors with a dry, lint- free cloth.  The optical sensors are cleaned. Rewinder RW500...

  • Page 138: Performing Maintenance

    • Heed the local occupational safety regulations. • Carry out a function test after the maintenance. Only have repair work performed by MBO Service or by an authorized customer service agent. Separate instructions are required for this. Rewinder RW500...

  • Page 139: Maintenance Schedule

    "Check interlocking mov- Daily able guard with guard locking" 9.4.3 "Cleaning the machine" Weekly 9.4.4 "Cleaning the optical sen- Weekly sors" Mainte- nance Table 30: Maintenance schedule MBO recommends attaching a copy of this maintenance schedule to the machine. Rewinder RW500...

  • Page 140: Performing Repair

    Heed the local occupational safety regulations. • Carry out a function test after the repair. • Only have repair work performed by MBO Service or by an autho- rized customer service agent. • Separate instructions are required for the repair .

  • Page 141: Decommissioning, Storage

    Observe the corresponding storage conditions. 10.2 Decommissioning 10.2.1 Temporary shutdown Proceed as follows to shut the machine down temporarily. Prerequisites These prerequisites must be fulfilled: • Main switch is switched off. • Compressed air supply is cut off. Rewinder RW500...

  • Page 142: Final Decommissioning

    Observe the specifications regarding the weight and size of the ma- chine when selecting the premises. See chapter "3.2 Technical data"  Use a suitable fork lift for transport. See chapter "3.2.5 Shipping and transport data".  Cover the machine with foil.  The machine is stored. Rewinder RW500...

  • Page 143: Disposal

    EC countries • Comply with the corresponding European directives. • Comply with the corresponding national and regional laws and regula- tions. Non-EU countries: • Comply with the corresponding national and regional regulations, laws and directives. Rewinder RW500...
  • Page 144 The machine is disposed of. All parts, consumables, and supplies of the machine: • Separate by type • Dispose of in accordance with local regulations, laws, and directives. If you have any further questions regarding disposal, please contact the manufacturer! Rewinder RW500...
  • Page 145 FRANCE Tel.: +33 1 6935 5090 Fax: +33 1 6935 5099 www.mbo-folder.com info@mbofrance.fr MBO China MBO Binder Graphic Systems (Beijing) Co. Ltd. Haishunde Building, 201 room, No.A1, Donghuanbei Road, BDA Beijing 100176 P.R. CHINA Tel.: +86 10 6786 4021 Fax: +86 10 6787 3502 www.mbo-folder.com.cn...

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