FB LINE - MAINTENANCE MANUAL

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
www.nilpeter.com

Maintenance Manual.docx P a g e |1
 Contents
1 INTRODUCTION...................................................................................................... 3
2 SAFETY INSTRUCTIONS........................................................................................ 4
2.1 FUNDAMENTAL SAFETY ................................................................................ 4
2.2 ORGANIZATIONAL MEASURES ...................................................................... 4
2.3 SELECTION AND QUALIFICATION OF PERSONNEL..................................... 5
2.4 SAFETY INSTRUCTIONS ................................................................................ 5
2.5 NOISE............................................................................................................... 6
2.5.1 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES .......................... 6
2.6 Disposal ............................................................................................................ 7
3 MAINTENANCE & LUBRICATION ........................................................................... 8
4 TIMING BELT CHANGING PROCEDURE ............................................................. 11

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
Maintenance Manual.docx www.nilpeter.com P a g e |2
 1 INTRODUCTION

Flexographic printing technology is rapidly progressing. The development of the FB LINE is

based on Nilpeter’s experience with previous flexo presses combined with the latest technological
knowhow in several fields. The FB LINE is designed to meet the increased demands of today and
of the future in the production of prime labels. Additional flexographic printing units are available
and the modular design provides for expansion with additional auxiliary converting units such as:
reverse side printing (also with print on adhesive), laminating, hot foil stamping, screen, cold-foil,
hot air, corona treater, web cleaner etc. For more information, please consult Nilpeter’s sales
team.

IMPORTANT:
(refers to special information on how to use the machine most efficiently)
ATTENTION:
(refers to special information and/or orders and prohibitions directed towards preventing
damage)
DANGER:
(refers to orders and prohibitions designed to prevent injury or extensive damage)

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
Maintenance Manual.docx www.nilpeter.com P a g e |3
 2 SAFETY INSTRUCTIONS

This section provides important information on the fundamental safety procedures and rules when
operating or servicing the machine.
This section must be read carefully before the machine is used and all operators and personnel
working on the machine must be familiar with the information herein.
Complying with the rules and procedures described in this section helps achieve a safe working
environment around the machine.

WARNINGS
- Before attempting to use the machine, read, understand and know all the safety information in this
chapter. Pay particular attention to all warnings and cautions throughout this manual. If you do not
follow all the warnings and procedures in this manual, this could lead to serious injury to yourself or
others, including death.
- If there is any safety instruction or procedure that you do not understand, do not use the machine.
Contact your supervisor and arrange proper training on the use of the machine. Use of the machine
without understanding and following all the safety instructions and procedures in this manual could
lead to serious injury to yourself or others, including death.

WARNING
Do not use the machine until you are sure that the routine checks described have been completed
and that the routine preventive maintenance programme is up-to-date. If any part of the machine is
known (or suspected) to be defective or wrongly adjusted, do not use the machine until a repair has
been made. Operation of the machine with defective or wrongly adjusted components could create
safety hazards. This could lead to fatal or other serious personal injury.

WARNING
Do not use the machine until you have received adequate and proper training in its safe and effective
use. If you are unsure of your ability to use the machine safely and effectively, do not do so. The use
of the machine without proper and adequate training could lead to fatal or other serious personal
injury. Never attempt to remove, modify, over-ride or frustrate any safety device on the machine.
Interfering with safety devices could lead to fatal or other serious personal injury.

2.1 FUNDAMENTAL SAFETY

➢ The machine must only be used in technically perfect condition in accordance with its
designated use and the instructions set out in the operating manual, and only by safety
conscious persons who are fully aware of the risks involved in operating the machine.
Any functional disorders, especially those affecting the safety of the machine, should
therefore be rectified immediately.
➢ Having read and understood the instructions in the technical and operating manual is
important before using the press.
➢ Nilpeter decline all responsibility for direct or indirect damage, caused by incorrect
operation of the machine or because instructions, warnings and limitation of liability have
not been observed.
➢ The machine must only be used for printing labels with ink with a flashpoint above 21°C.
2.2 ORGANIZATIONAL MEASURES
➢ The operating manual must always be at hand at the place of use of the machine, e.g. by
stowing them in the tool compartment or tool box provided for such purpose.
➢ In addition to the operating instructions, observe and instruct the user in all other
generally applicable legal and other mandatory regulations relevant to accident
prevention and environmental protection.
➢ Personnel entrusted with work on the machine must have read the operating instructions
and in particular the chapter on safety before beginning work. Reading the instructions

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
Maintenance Manual.docx www.nilpeter.com P a g e |4
 after work has begun is too late. This applies especially to persons working only
occasionally on the machine, e.g. during setting up or maintenance.
➢ For reasons of security, long hair must be tied back or otherwise secured, garments must
be close-fitting and no jewelry - such as rings - may be worn. Injury may result from being
caught up in the machinery or from rings catching on moving parts.
➢ Use protective equipment wherever required by the circumstances or by law.
➢ Observe all safety instructions and warnings attached to the machine.
➢ See to it that safety instructions and warnings attached to the machine are always
complete and perfectly legible.
➢ Never make any modifications, additions or conversions which might affect safety without
written approval from Nilpeter! This also applies to the installation and adjustment of
safety devices and valves as well as to welding work on loadbearing elements.
➢ Spare parts must comply with the technical requirements specified by the manufacturer.
Spare parts from original equipment manufacturers can be relied to do so.
➢ Never modify the software of programmable control systems. If it happens Nilpeter's
responsibility will cease immediately.
➢ For the execution of maintenance work, tools and workshop equipment adapted to the
task on hand are absolutely indispensable.

➢ The UV lamps have not been secured against explosion. Never use explosive matter
near the UV-lamps when these are on. This applies to soaked cloth as well.
➢ Never approach the lowest limit of explosion by more than 75%. The safety values for
inflammable gas and vapors have been taken from chapter 1 in supplement to VDE
restrictions 0165/8.69.
➢ UV lamps produce UV-A, UV-B and UV-C radiation that may damage skin and eyes.
Never remove safety guards during operation.
➢ UV lamps decompose oxygen into the aggressive gas ozone that may damage skin,
mucous membranes and lungs. In time ozone will turn into oxygen. A sufficient exhaust
system has to be established in the room (even small quantities of ozone can be
smelled). The maximum value for ozone is 0.2 ppm.
2.3 SELECTION AND QUALIFICATION OF PERSONNEL
➢ Employ only trained or instructed staff and set out clearly the individual responsibilities of
the personnel for operation, set-up, maintenance and repair.
➢ Do not allow persons to be trained or instructed or persons taking part in a general
training course to work on or with the machine without being permanently supervised by
an experienced person.
➢ Work on the electrical system and equipment of the machine must only be carried out by
a skilled electrician or by instructed personnel under the supervision and guidance of a
skilled electrician and in accordance with electrical engineering rules and regulations.
2.4 SAFETY INSTRUCTIONS
➢ Standard operation
➢ Avoid any operational mode that might be prejudicial to safety.
➢ Take the necessary precautions to ensure that the machine is used only when in a safe
and reliable state.
➢ Operate the machine only if all protective and safety-oriented, such as removable safety
devices, emergency shut-off equipment, soundproofing elements and exhausts, are in
place and fully functional.
➢ Check the machine at least once per working shift for obvious damage and defects.
Report any changes (incl. changes in the machine's working behavior) to Nilpeter
immediately. If necessary, stop the machine immediately and lock it.
➢ Safety devices on the machine must be checked at least once a day.
➢ All guards must be fitted before starting the press.
➢ The yellow guards must only be removed during change of tools. When the tools are
removed, the yellow guards must be fitted again. This operation must only be carried out
when the power to the machine has been shut off.

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
Maintenance Manual.docx www.nilpeter.com P a g e |5
 ➢ UV lamps and drying devices must be switched-off during cleaning.
Indoor climate:
Room temperature max. 25° C
Thermal fluctuation (24 h) max. 10° C
Relative humidity min. 25 %
Relative humidity max. 60 %
Cooling unit ambient temp. max. 32°
➢ UV lamps and drying installations are to be shut off during cleaning.
➢ Safety guards to the press are only to be removed when the power to the press has been
shut off.
➢ Throttles to the ventilation systems are not to be shut too much as the heating elements
may be overheated /damaged.
➢ Filters for ventilators are to be kept clean. Dirty filters may result in increased temperature
in the power cabinets, so that the life of the components is reduced.
➢ Power cabinets are only to be opened by means of tools, and this has to be done by
skilled personnel.
➢ Filters for ventilators are to be kept clean, if not, the performance of the system will be
reduced and the air flow to the heating elements will be reduced as well, which may
cause overheating and risk of fi re.
➢ Never keep combustible material near to UV lamps and drying installations in operation
as this may cause fi re or explosion.
➢ Avoid skin contact with inks, UV inks, lacquers, utensils and detergents. It is advisable to
wear protective glasses and gloves.
➢ UV lamps and drying hoods become so hot that there is a risk of burns.
➢ Special work in conjunction with utilization of the machine, maintenance and repairs
during operation and disposal of parts and consumables must be kept. These activities
should only be carried out by skilled workers.
➢ Observe the adjusting, maintenance and inspection activities and intervals set out in the
operating instructions, including information on the replacement of parts and equipment.
These activities may be executed by skilled personnel only.
➢ If the machine is completely shut down for maintenance and repair work, it must be
secured against inadvertent start by locking the main switch with a padlock.
➢ Any safety device removed for set-up, maintenance or repair purposes must be refitted
and checked immediately upon completion of the maintenance and repair work.
➢ Ensure that all consumables and replaced parts are disposed of safely and with minimum
environmental impact.
➢ In case of interruption, e.g. caused by insufficient air cooling or web breaks, UV lamps
have to be shut off, as the web may burn owing to the heat from the UV lamps.
➢ In case of irregularities at the shutters in front of the UV lamps, these have to be shut off
2.5 NOISE
➢ During operation, all sound baffles must be closed.
➢ Always wear the prescribed ear protectors, as the noise level exceeds 85 dB(A) during
operation.
2.5.1 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES
➢ When handling oil, grease and other chemical substances, observe the product related
safety regulations.
➢ Be careful when handling hot consumables (risk of burning or scalding).

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
Maintenance Manual.docx www.nilpeter.com P a g e |6
 2.6 Disposal

Final Disposal

The use and maintenance of the machine includes no environmental dangers. Most parts can be
disposed in a regular way.

ENVIRONMENT
Ensure compliance with local legislation, regulations, instructions and precautions
concerning health, safety and environment.

Dismantle the machine as follows:

 Dismantle the machine in easy to handle parts.
 Have an expert supervise the dismantling process.
Dispose the dismantled parts according the regulations.

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
Maintenance Manual.docx www.nilpeter.com P a g e |7
 3 MAINTENANCE & LUBRICATION

Switch off and lock the main switch before inspection and maintenance.

As an operator, you should have received training in accordance with this

manual. If you have not, donot use the machine or enter the process
area. Arrange training with your supervisor or training manager.

The Nilpeter Press is designed to provide years of reliable service. It has been lubricated prior to
shipment. However, check all visible gears of the drive train before operating the press. It is
possible that the gears or lubricant became contaminated during shipment of installation. Clean
contaminated gears and re- lubricate.
Scheduled maintenance and lubrication checks are imperative to insure proper press function. All
metal surfaces that rub or roll against each other require a lubricating film to prevent metal to
metal contact, fretting and wear. Pressure, temperature and speed can affect the longevity of the
lubricant. This is especially true with the die-cut station gears. Inspect the die-cut station gears
each day during the first few months of operation to determine the lubrication needs of the
machine. The helical gear drive train of the print station is lubricated automatically, but should be
inspected weekly. The following maintenance schedule is provided for your convenience.

Important: The auto lubrication system should be inspected weekly and kept full

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
Maintenance Manual.docx www.nilpeter.com P a g e |8
 FREQUENCY
STATION POINTS TYPE OF LUBE 3 6
Daily Weekly Monthly
months months
Die Station Lubricate the felt on Die-cut support rolls #30 OIL Y
Lubricate the felt on Die-cut assist rolls and
Die Station #30 OIL Y
bearing
Die Station Lubricate the anvil roll blocks STP Y
Die Station Lubricate the die cut pillow block #30OIL Y
Die Station Lubricate the Die-cut roll gears ( SAE 90 oil ) STP Y
Die Station Inspect the Auto lubrication system and refill it ADD STD WHEN DOWN TO HALF FULL Y
Die Station Grease on all greasing points BLACK OR RED GREASE Y
Die Station Check functions of manual web guide Y
Die Station Check anvil rolls for wear and damage: Y
Die Station Check impression rolls for wear and damage: Y
Die Station Check gears for wear and damage: Y
Die Station Check nip roll for wear and damage: Y
Die Station Check belt tension in Exit Pacing Y
Infeed Clean the nip roll after every job Y
Infeed Check nip roll for wear and damage. Y
Print Lubrication of Plate roll shafts WD-40 Y
Print Lubrication of Plate roll cylinders - SAE 90 oil STP Y
Lubrication of the Impression roll gears ( SAE
Print STP Y
90 oil )
Check functions of Side Register on Plate roll
Print Y
shaft
Lubrication of Anilox roll gear Bearing Sub
Print PUMP WITH GREASE UNTIL IT ESCAPES Y
assy.
Print Oil / lubricate ink slides Y

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
P a g e |9
Maintenance Manual.docx www.nilpeter.com
 FREQUENCY
STATION POINTS TYPE OF LUBE 3 6
Daily Weekly Monthly
months months
Print Check plate roll shaft for wear and damage: Y
Print Check lubrication hose Y
Print Clean fan filters on main panel and sub panels Y
Print Check lubrication circuits for oil leaks: Y
Print Prime lubrication and ensure functioning Y
Print Clean and lubricate vertical slide assembly Y
Print Check bearings on Anilox roll: Y
Print Check bearings on fountain roll: Y
Print Check for anilox roll for backlash and bouncing: Y
Check register gear wheel for backlash: (front
Print Y
side)
Print Check slide way for backlash: Y
Check idler transfer gear on back side, for
Print Y
wear, damage and backlash:
Rewind Check tension of the toothed belt: Y
Rewind Check toothed belt for wear and damage: Y
Clean edge guide sensor on web guide: CLEAN LENS WITH GLASS CLEANER &
Unwind Y
Disconnect sensor, and clean PAPER TOWEL

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
P a g e | 10
Maintenance Manual.docx www.nilpeter.com
 4 TIMING BELT CHANGING PROCEDURE

This chapter discusses about the procedure to change timing belts of different stations in case of
a failure.

To replace the belts the tensioning idler pulleys are to be released. The tensioning pulleys for
each assembly is marked.

Unwind station

TENSIONING IDLER

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
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 TENSIONING IDLER

Nilpeter India Private Limited

P39/2, Mahindra World City
Chengalpattu
India
Phone : +91-44-27460259
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