Dbe 04567aeng

PLANT MANUAL
starEX 800
Tape system
Doc. no.: DBE-04567A Language: English

Translation of the original document
INTRODUCTION
Copyright
Drawings, installation plans and operating instructions as well as designs,
catalogues, brochures, diagrams etc. are the intellectual property of Starlinger.
Duplication, reproduction, dissemination and distribution to third parties are
prohibited. Moreover, they must not be used to produce or have produced plant
or plant components.
Great care was taken in the creation of this documentation. However, Starlinger
reserves the right to make changes and improvements to the documentation.
Warranty and liability

The individual contractual conditions pertaining to the liability and warranty or the
respective conditions of the general sales and delivery terms of Starlinger always
apply. Starlinger accepts no liability for damage arising due to the operator failing
to adhere to the intended use.
starEX 800 DBE-04567A PAGE 2 / 111

TABLE OF CONTENTS
ABOUT THIS DOCUMENT............................................................................................... 6

1 TECHNOLOGICAL DESCRIPTION .......................................................................... 10
1.1 Area of application and intended use ................................................................ 10
1.2 Method of operation .......................................................................................... 10
1.3 Plant design ...................................................................................................... 11
1.4 Options ............................................................................................................. 15
2 TECHNICAL DATA ................................................................................................... 17
3 INSTALLATION......................................................................................................... 19
3.1 Installation overview .......................................................................................... 19
3.2 Installation site .................................................................................................. 19
3.3 Assembly .......................................................................................................... 20
3.3.1 Sequence of installation ............................................................................ 21
3.3.2 Switching cabinets .................................................................................... 22
3.3.3 Installing the cooling water distributor ....................................................... 23
3.3.4 Electrical connection ................................................................................. 23
3.3.5 Pneumatic connection............................................................................... 24
3.3.6 Water connection ...................................................................................... 24
4 SETTINGS ................................................................................................................ 25
4.1 Operating pressure ........................................................................................... 26
4.2 Cooling water circuit .......................................................................................... 27
5 COMMISSIONING AND OPERATION ...................................................................... 29
5.1 Before initial commissioning .............................................................................. 29
5.2 Control and display components ....................................................................... 30
5.2.1 Overview................................................................................................... 30
5.2.2 EMERGENCY STOP command devices................................................... 32
5.2.3 Signal indicator on water bath ................................................................... 33
5.2.4 Signal indicator on the plug screw (optional) ............................................. 33
5.2.5 Signal indicator on the stretching unit ....................................................... 33
5.2.6 Display ...................................................................................................... 33
5.2.7 Operating pressure gauge ........................................................................ 33
5.2.8 Manual operating units.............................................................................. 34
5.3 Commissioning ................................................................................................. 40
5.3.1 Switching the plant on ............................................................................... 41
5.3.2 Tightening torques for melt-carrying parts ................................................. 42
5.3.3 Preparing the extruder .............................................................................. 44
5.3.4 Preparing the wide-slit die ......................................................................... 50
5.3.5 Preparing the hot air zone ......................................................................... 51
5.3.6 Preparing the water bath........................................................................... 51
5.3.7 Preparing the stretching unit ..................................................................... 58

TABLE OF CONTENTS
5.3.8 Preparing the precision fibrillator (optional) ............................................... 59

5.3.9 Preparing the raw material feed ................................................................ 62
5.3.10 Preparing the winding machine ................................................................. 63
5.4 Operation .......................................................................................................... 63
5.4.1 Workstations ............................................................................................. 66
5.4.2 Starting the plant....................................................................................... 67
5.4.3 Operating mode ........................................................................................ 80
5.4.4 Working on the plant ................................................................................. 81
5.4.5 Moving the plastic plug manually on the E-105 extruder ........................... 82
5.4.6 Replacing bobbins .................................................................................... 83
5.4.7 Reloading tapes ........................................................................................ 83
5.4.8 Rectifying wrap-arounds on godets ........................................................... 86
5.4.9 Checking the fill level on the tape extractor ............................................... 87
5.4.10 Changing the material ............................................................................... 88
5.4.11 Process-related instructions ...................................................................... 90
5.5 Switching off the plant ....................................................................................... 92
5.6 Shutting down the plant..................................................................................... 94
5.6.1 EMERGENCY STOP command devices................................................... 95
5.6.2 Method of operation .................................................................................. 96
6 MAINTENANCE ........................................................................................................ 97
6.1 Lubrication ........................................................................................................ 98
6.2 Maintenance overview ...................................................................................... 98
6.2.1 Daily maintenance tasks ........................................................................... 98
6.2.2 Weekly maintenance tasks ....................................................................... 98
6.2.3 Monthly maintenance tasks....................................................................... 99
6.2.4 Quarterly maintenance tasks .................................................................... 99
6.2.5 Six-monthly maintenance tasks ................................................................ 99
6.2.6 Chain drives ............................................................................................ 100
6.2.7 Belt drives ............................................................................................... 101
6.2.8 Electrical system ..................................................................................... 101
6.2.9 Pneumatic system .................................................................................. 102
6.2.10 Water circuit ............................................................................................ 103
7 TROUBLESHOOTING ............................................................................................ 104
7.1 Motor protection/thermal relay fault ................................................................. 106
8 ENCLOSURES ....................................................................................................... 107
8.1 Tightening torques .......................................................................................... 107
8.2 Testing methods ............................................................................................. 108
8.3 Calculating the tape width ............................................................................... 108

TABLE OF CONTENTS
8.4 Test report ...................................................................................................... 108

8.5 Blade spacer table .......................................................................................... 110

ABOUT THIS DOCUMENT
ABOUT THIS DOCUMENT
Information
This document is the controlling document of the family of documents belonging
to the "starEX 800" tape system. This documentation series comprises the
following documents:
• General safety instructions
• Plant manual and manuals for the individual modules
• Technical manuals
• Display user manual
• Manufacturer's documentation
The documentation series is intended for use by technically qualified and trained
personnel, who are responsible for the installation, operation, maintenance and
repair of the plant. It contains all the information needed to operate the plant
safely and in the proper manner, and as such should be followed to the letter.
Compliance with the stated instructions and guidelines will also increase the
service life and optimise the performance of the plant.
NOTE!
The documentation series must always be to hand where the plant
is used and must be read and applied by each person who works
on the plant.
Notation
This manual uses the following notation:
Notation Representation Example

Reference Italics See the Layout plan
Description, indicator Quotation marks "starEX 800"
(Push) button, switch Angle brackets <Main switch>
Button Square brackets [Cancel]

ABOUT THIS DOCUMENT
Indicator words
The following table provides an overview of the indicator words used and their
meaning:
Indicator word Meaning

Immediately hazardous situation which will lead to death or
DANGER!
serious injuries if the safety measures are not followed
Potentially hazardous situation, which may lead to death or
WARNING!
serious injuries if the safety measures are not followed
Potentially hazardous situation, which may lead to minor or
CAUTION!
slight injuries if the safety measures are not followed
Possible damage to property which may occur if the safety
NOTE!
measures are not followed
Pictograms
The plant bears a number of pictograms (see Information on the position of
pictograms). Pictograms which are missing, illegible or damaged must always be
replaced immediately. The following table provides information on the pictograms
which are used and their meaning:
Risk of injuries to the hands
Risk of cuts
Risk of being drawn in
Risk of foot injury
Risk of burns

ABOUT THIS DOCUMENT
Risk of crushing
Risk of tripping
Warning - fibrillating roller
Danger from electric current
Risk of being drawn in

Do not reach between the rollers during operation!
Maintain a distance of 1 m from the stretching unit
during operation!
Warning: magnetic field
Prohibited for persons with heart pacemakers!
Wear safety gloves!
Hearing protection mandatory!
Wear eye protection!

ABOUT THIS DOCUMENT
Switch off before performing work!
Pay attention to the operating instructions!
This document contains additional pictograms with various purposes. The

following table provides information on the pictograms which are used and their
meaning:
General warning
Important information
Reference to further information
Terms and abbreviations

In this document, the "starEX 800" is referred to in short as "the plant". The raw
material with which the plant is fed is referred to in the following text as "the
material". All important abbreviations are explained within the document.
Figures
The diagrams used in this document are example images, which may deviate
from your machine slightly, depending on the particular application. In the
interests of providing a clearer overview, in some diagrams the safety guards and
plant components are not shown.

1. TECHNOLOGICAL DESCRIPTION
1 TECHNOLOGICAL DESCRIPTION
1.1 Area of application and intended use

The tape system is used for the continuous manufacturing of stretched tapes
made from PP, HDPE and LLDPE (special design).
Working on the plant

• Loading the plant (see Chapter 5)
• Monitoring functions and processes on the plant (see Chapter 5)
• Quality control
• Adjustment work (see respective module manual)
• Lubrication and maintenance tasks (see Chapter 6 and respective
module manual)
• Troubleshooting (see Chapter 7 and the respective module manual)
The plant is designed for two-person operation.
1.2 Method of operation

The volumetric dosing unit mixes different types of pellet. Then the material is
supplied to the extruder for processing.
In the extruder a screw transports the material through a heated cylinder. At the
same time the material is plasticised and homogenised. The pressurised material
passes through the automatic filter, and then on to the wide-slit die.
The melt emerging from the wide-slit die is cooled in the water bath. The cutting
unit cuts the film web into strips of equal width. The edge strips are taken up,
ground up and fed to the extruder for reuse.
The hot air zone heats the tapes by means of circulating air. The tapes are
stretched by exposing them to heat. The stretching forces are produced by
setting the speed higher on the stretching unit.
At the end of the tape system, the tapes are wound onto bobbins.
A vacuum is created in a container using a radial blower. This picks up cut or torn
tapes via a pipe system and suction nozzles on the holding frame and stretching
unit. The tapes are then conveyed to a container.

1.3 Plant design

The plant consists of the following plant modules:
• Volumetric dosing unit with feed station
• Extruder
• Wide-slit die
• Water bath with integrated holding frame
• Hot air zone
• Stretching unit
• Precision fibrillator (optional)
• Tape extraction system
The following figure provides an overview of the position of the individual plant
modules:
Fig. 4567/1001
1 Volumetric dosing unit with feed station

2 Extruder
3 Wide-slit die
4 Water bath with integrated holding frame
5 Hot air zone
6 Stretching unit
7 Tape extraction system

voluTEC volumetric dosing unit with feed station

The pellet conveyor system conveys the material from the feed containers of the
feed station into the downpipes of the dosing unit. The downpipes of the
secondary components are connected to the downpipe of the main component by
adjustable dosing pipes. In this area, the secondary components flow in the set
mixing ratio with the main component into the collecting container. The completed
material mixture is conveyed from the collecting container to the extruder.
For further information on the volumetric dosing unit with feed

station, see the Technical manual for the voluTEC volumetric
dosing unit with feed station.
Extruder
Extruder screw
The extruder screw plasticises and homogenises the material in a cylinder
equipped with heating sleeves.
Automatic filter
The automatic filter is positioned between the extruder screw and the wide-slit
die. Two filter tapes, positioned one above the other, clean the melt of impurities.
After the automatic filter, the melt is mixed again in the melt mixer.
Wide-slit die
The heated wide-slit die has a die lip gap which is adjusted using pressure bolts.
The die lip has a reversible lip design (smooth and ridged).
For further information on the wide-slit die, see the manufacturer's

documentation.
Water bath with integrated holding frame

The ribbon of melt emerging from the wide-slit die is cooled in the water bath.
The water in the water tank is continuously circulated by a pump. A heat
exchanger maintains a consistent water temperature.
Take-down
A powered take-down roller and a pneumatically operated pressure roller wipe
the water off the film web.

Vibration dryer
Blowing air onto the film web causes it to vibrate. The water runs off and is taken
up by suction pipes.
Lengthways cutting mechanism

The lengthways cutting mechanism is located between the take-down and the
holding frame. A knife bar fitted with blades cuts the film web into strips of equal
width. The knife bar can be pivoted in and out.
Film web oscillator

Two rods are continuously moved up and down by a motor, ensuring that the
knives on the lengthways cutting mechanism wear evenly.
Edge strip extractor

The edge strips from the lengthways cutting mechanism are conveyed via a
suction pipe to a cutting mill for grinding. Then the ground-up edge strips are
blown by a high-pressure blower straight into the hopper of the extruder, where
they are melted down again for reuse.
Holding frame
The web tension necessary for the cutting process is created by the difference in
speed between take-down and holding frame.
Hot air zone

The hot air zone heats the tapes for further processing, by means of circulating
air. The temperature is set on the display and the air speed by means of
regulating valves.
Stretching unit
Stretching unit
The stretching unit runs at a speed corresponding to the stretch ratio, i.e. for a
ratio of 1:5.5 or 1:7, at a holding frame speed of 5.5 or 7. This results in intensive
stretching of the tapes. This is driven by an adjustable belt-driven motor.
Annealing unit
The annealing unit runs more slowly than the stretching unit and serves to
stabilise the tapes which are stretched in the stretching unit. This is driven by an
adjustable belt-driven motor.

Godets
The design of the stretching unit is determined by the specific requirements
placed on the tapes, and may consist of the following godet variants:
• Normal godet
• Cooling godet
• Tempering godet
 At approx. 90°C, the heated godets cause more intensive stretching
of the tapes. The temperature depends on the product.
• Heating godet
 At up to 140°C, the heated godets cause more intensive stretching
of the tapes. The temperature depends on the product.
Oil heating device

The tempering and heating godet is heated by one or more oil heating devices.
Pressure roller
The roller has a rubberised surface to prevent the tapes from slipping.
Ionising unit
The ionising unit reduces the static charge on the tapes. A discharge rod is fitted
behind the annealing unit.
Tape extraction system
Suction nozzles
The suction nozzles pick up cut and torn tapes at the holding frame and
stretching unit.
Pipe system
The pipe system conveys the tapes to the container.
Container
The tapes are stored in the container until they are disposed of.

Display (central control unit)

The display is the central control unit and is located on the water bath. It is used
to set and view all parameters (production speed, temperature inputs,
maintenance intervals, report management, etc.). In addition, you can select from
a series of predefined options.
For further information on the control unit, see the starEX display
user manual.
Other operating units

At the following locations on the plant you can find additional operating units:
• Gravimetric batch dosing unit with feed station (optional)
• Extruder (switching cabinet)
• Hot air zone
• Stretching unit
1.4 Options
The following options are available for the plant:
graviTEC gravimetric batch dosing unit with feed station

The pellet conveyor system conveys the material from the feed containers of the
feed station into the component container of the batch dosing unit. The batch
dosing unit weighs out the individual components in the set mixing ratio and
mixes them. The completed mixture is then conveyed into a collecting container,
and from there onward to the extruder.
For further information on the gravimetric batch dosing unit, see

the Technical manual for the graviTEC gravimetric batch dosing
unit.
Precision fibrillator
Fibrillating roller
The fibrillating roller is fitted with needle bars. The needle bars produce short
lengthways cuts in the tapes. This gives the tapes a fabric-like quality.

Wrap-around monitor
If a wrap-around occurs on the fibrillating roller, the wrap-around monitor pivots
out, lifting the lowering frame and shutting down the fibrillator.
Lowering frame with guide rollers

The guide rollers push the tapes against the fibrillating roller.
Tape oscillator
The tape oscillator is fitted to the stretching unit before the first godet. The
needles on the fibrillating roller are worn evenly across the full width of the web
by the tape oscillator's to-and-fro movement.

2. TECHNICAL DATA
2 TECHNICAL DATA
For information on space requirements for the plant as well as on

the required working area, see the Layout plan.
For information on the technical data for the individual plant

modules see the respective module manual and technical manual.
For information on the technical data for the individual purchased

components see the respective manufacturer's documentation.
Production data
Working width 800 mm
The output rate is dependent on the qualities and condition of the

material to be processed (viscosity, moisture, bulk weight, density
and additives) as well as compressive qualities, contamination
and size-reduction rate.
Compressed air requirements

Operating pressure 5-7 bar
Air consumption See the Layout plan
Electrical data
Connected load See the Layout plan
Electrical supply (voltage, frequency and conductor cross- See the Electrical
section) circuit diagrams
The plant is not suitable for outdoor use! The ambient temperature
for production and storage areas must be between 18 °C and
40 °C!
For further information on ambient conditions for the production

and storage areas, see the Technical specifications.

2. TECHNICAL DATA
Noise
Level 93 dB(A)
Hearing protection mandatory!
Type plate
The plant's type plate is located on the water bath and the type plate of the
extruder is located on the base frame of the extruder.
Fig. 4567/2001
1 Plant type plate 2 Extruder type plate

3. INSTALLATION
3 INSTALLATION
3.1 Installation overview
Fig. 4567/3001
1 Volumetric dosing unit with feed station

2 Extruder
3 Wide-slit die
4 Water bath with integrated holding frame
5 Hot air zone
6 Stretching unit
7 Tape extraction system
The figure serves as an example only. The precise installation

process for the plant will depend on the layout of your own facility,
and may therefore deviate from the above.
We reserve the right to modify the technical specifications as part
of the technological development process.
3.2 Installation site

The base on which the machine is positioned must be level and capable of
withstanding the resulting loads. The foundation must not transfer the vibration
which can be generated by the plant during operation. The acceptable loading
capacity of the floor must be at least 25,000 N/m².

3. INSTALLATION
3.3 Assembly
The plant modules are supplied in a pre-assembled state. For transport reasons,
certain parts can only be fitted after the machine has been unloaded from the
container or positioned.
WARNING!
Danger of death due to falling parts!
Hoists, forklifts and load-bearing equipment used for loading,
transportation and installation tasks must comply with applicable
legislation and be suitable for the load.
It is not permitted to stand under a suspended load!
WARNING!
Risk of injury from loose parts!
Be careful when lowering loose components, cables and hoses!
WARNING!
When working at heights, a suitable safety harness must be used!
NOTE!
Use the supplied special tools, supplies and spare parts, and then
store them in the proper manner after work is complete!
NOTE!
All nuts and bolts that are not exposed to high temperatures must
be secured during assembly with the supplied thread lock
(Loctite)!
NOTE!
Parts that are subjected to very high temperatures must be thinly
coated with a high-temperature thread paste (Molykote HSC) prior
to installation!
For precise information on setting up the plant, see the Layout

plan.
For information on setting up of the individual plant modules, see

the respective module manual and technical manual.

3. INSTALLATION
3.3.1 Sequence of installation

The components are assembled in the following order:
1. Install extruder
- Fit the hopper with metal separator
2. Set up the water bath with integrated holding frame
- Install the heat exchanger
- Fit the edge strip extractor
- Fit the dust return unit
- Fit the plug screw (optional)
- Install the side channel compressor for the vibration dryer
3. Install the hot air zone
4. Install the stretching unit
- Position the avivage coating unit and install (optional)
- Install the oil heating device
5. Install the precision fibrillator (optional)
6. Tape extraction system
- Install the container
- Fit the pipe system
- Fit the suction nozzles
7. Install the switching cabinets
8. Install the raw material feed, depending on version
- voluTEC volumetric dosing unit with feed station
- graviTEC gravimetric batch dosing unit with feed station (optional)
9. Install the cooling water distributor

3. INSTALLATION
3.3.2 Switching cabinets

The switching cabinets (1) should be installed in accordance with the Layout
plan.
Fig. 4567/3002
1 Switching cabinet 4 Forks of the lift truck or forklift

2 Ropes or chains 5 Switching cabinet base
3 Ring nuts A Tilt angle
Procedure
When using a rope or chain (2) for positioning, the lifting device must be attached
to the lifting-eye nuts (3). If using a lift truck or forklift, the forks (4) must be long
enough to reach all the way under the switching cabinet (1) and the base (5) at
the outer edge.
Positioning method Tilt angle (A) Max. loading capacity

45° 4,800 N
Rope/chain 60° 6,400 N
90° 13,600 N
Lift truck/forklift 14,000 N
NOTE!
If positioning using ropes or chains, ensure that all ropes or chains
are of even length!

3. INSTALLATION
3.3.3 Installing the cooling water distributor
Fig. 4567/3003
1 Bracket
Procedure
1. Attach a suitable lifting device to the bracket (1)
2. Position bracket (1) of the cooling water distributor, according to the
Layout plan, and fix to the floor using frame screws
3.3.4 Electrical connection

Work on the electrical equipment may only be performed by qualified electricians
and must comply with local regulations.
For further information on the plant's wiring, see the Circuit

diagrams.

3. INSTALLATION
3.3.5 Pneumatic connection
NOTE!
The pneumatic system is designed to be oil-free.
The supplied compressed air must be free of oil and water!
All lines for the compressed air supply up to the plant must be already installed.
The connection should be made in accordance with the Layout plan.
For further information on the pneumatic connections, see the

Layout plan.
3.3.6 Water connection

All lines for the water supply up to the plant must be already installed. The
connection should be made in accordance with the Layout plan.
NOTE!
If the limestone content of the water is too high then this will
increase the maintenance workload!
It is recommended to install a water-softening system upstream of
the plant in hard water areas.
For further information on the requirements for cooling water and

water required in the production process, see the technical
specification.
For further information on the water connection, see the Layout

plan.

4. SETTINGS
4 SETTINGS
DANGER!
When adjustments are made to the plant, the <Main switch>
must always be set to OFF ("0" position) and be safeguarded
against being switched back on!
WARNING!
Risk of injury due to residual pneumatic energy!
The pneumatic system is under pressure, even after the plant has
been switched off.
Before carrying out work on the pneumatic system, it is vital that
you depressurise the system!
WARNING!
For information on the settings for the individual plant modules,

see the respective module manual and the technical manual.
For information on the control unit, see the starEX display user
manual.

4. SETTINGS
4.1 Operating pressure

After the pneumatic connection has been established, the operating pressure on
must be set to approx. 6 bar on the maintenance unit (1). The maintenance unit
(1) is located on the drive side (A) in the side box at the water bath (2).
Fig. 4567/4001
1 Maintenance unit A Drive side

2 Water bath

4. SETTINGS
4.2 Cooling water circuit
CAUTION!
Trip hazard at the water supply unit!
Note the bracket (2)
Fig. 4567/4002
Lever
1 2 Bracket
• Lever closed position
The following plant modules are supplied with cooling water via the water supply
unit:
Switching cabinet heat

A Cooler supply F
exchanger return
B Cooler return G
exchanger supply
C Extruder supply H
exchanger return
D Return line, extruder I Display heat exchanger supply
E J Display heat exchanger return
exchanger supply

4. SETTINGS
The following must be observed with regard to the water supply unit:
• Max. cooling water supply temperature 15°C
• The difference in cooling water pressure between the cooler supply (A)
and return (B) must be at least 2 bar
• Open the ball valves (1) for operation
NOTE!
Possible negative impact on plant output.
The temperature of the cooling water at the sleeve on the extruder
cylinder must be above 20°C!
If the water temperature is reduced, the water condenses in the
extruder infeed zone and the cylinder bores and the screw oxidise.
For further information on cooling water requirements, see the

technical specification.

5. COMMISSIONING AND OPERATION
5 COMMISSIONING AND OPERATION
5.1 Before initial commissioning

Before initial commissioning, the following tasks must be performed:
• Check system installation (see Chapter 3 and respective module
manual)
• Check all basic settings (see the respective module manual and
technical manual)
• On the gear motors and gearboxes, replace transport bolts with bleed
screws
• On drive belts, check the belt tension and retension if required (see
Chapter 6.2.7 and the respective module manual)
• Check chain tension and retension if required (see Chapter 6.2.6 and
respective module manual)
• Check chains and sprockets for alignment
• Check lubrication points (see Chapter 6.1 and the respective module
manual and technical manual)
• Make sure that all electrical connections were carried out in accordance
with the circuit diagram
• Check all connection bolts and connection terminals on bus bars and
switchgear for firm seating and, if necessary, tighten them to the
specified tightening torque (see table in Chapter 8.1)
DANGER!
Danger from electric current!
Before work is done on connections bolts and on connection

terminals, the <Main switch> must always be set to OFF ("0"
position) and be safeguarded against being switched back on!
Before carrying out work on the connection bolts and connection

terminals on the <Main switch>, the supply line must be de-
energised!
• Have the condition and function of the safety switch, circuit breaker and
EMERGENCY STOP or EMERGENCY OFF system checked by a
qualified electrician (even for modifications or retrofitting of plant parts)
• Check the direction of rotation of all of the motors (see arrow direction
on the motors)

• If air-conditioned switching cabinets or switching cabinet units are

installed: Check seal
• Make sure that all safety guards are properly attached
• Ensure that all safety doors are closed and locked
• Before use, actuate the test button on the RC circuit breaker (with an
external socket)
• Pneumatic system: check connections, pressure and function
WARNING!
Danger due to malfunction of the pneumatic system!
Do not reach into the danger area!
Only perform trial actuation of sensors using the right tools!
• Check water connections
5.2 Control and display components
5.2.1 Overview
A number of control and display components can be found on the plant. The
<Main switch> on the plant is located on the switching cabinet. The <Volumetric
dosing unit main switch> is located on the operating side of the dosing unit. The
<Edge strip extractor main switch> is located on the cutting mill. Central control of
the machine is performed via a display in the operating area. In addition, there
are manual operating units in various locations, which provide the option to
intervene with the production process:
• E-105 extruder automatic filter (switching cabinet)
• Hot air zone
• Stretching unit

Fig. 4567/5005
1 Volumetric dosing unit operating unit

2 E-105 extruder automatic filter operating unit (switching cabinet)
3 Water bath operating unit (with display)
4 Hot air zone operating unit
5 Stretching unit operating unit (pressure gauge for pressure rollers)
6 <Plant main switch>
7 Plant pressure gauge
8 Signal indicator on water bath
9 Signal indicator on the plug screw (optional)
10 <Volumetric dosing unit main switch>
11 Stretching unit signal indicator
12 <Edge strip extractor main switch>

Volumetric dosing unit with feed station
For further information on the control and display elements on the

volumetric dosing unit with feed station, see the Technical manual
for the voluTEC volumetric dosing unit with feed station.
Gravimetric batch dosing unit with feed station (optional)
For further information on the control and display elements on the

gravimetric batch mixer, see the Technical manual for the
graviTEC gravimetric batch dosing unit with feed station
5.2.2 EMERGENCY STOP command devices
WARNING!
Risk of injury when triggering an EMERGENCY STOP command
device if the specified working positions are not observed!
Before triggering an EMERGENCY STOP command device,
ensure visual contact with the second person!
The plant is equipped with several EMERGENCY STOP command devices,

which are located in various places around the plant. The following figure
provides an overview of the locations of the EMERGENCY STOP command
devices.
Fig. 4567/5006
1 <EMERGENCY STOP> push button, water bath operating unit

2 <EMERGENCY STOP> push button, holding frame
3 <EMERGENCY STOP> push button, hot air zone operating unit
4 <EMERGENCY STOP> push button, stretching unit operating unit
5 <EMERGENCY STOP> pull cord, stretching unit
The precise execution of the EMERGENCY STOP command devices and their
method of operation is described in Chapter 5.6.

5.2.3 Signal indicator on water bath

The signal indicator takes the form of a flashing light.
Signal Indicator
Plant cannot be started
• Fault or warning has occurred (see the starEX display user
manual)
Flashes yellow • EMERGENCY STOP is active
• Observe indication on the display
The safety cover on the stretching unit has already been open for 3
min. during operation.
5.2.4 Signal indicator on the plug screw (optional)

Signal Indicator
Flashes yellow Plug screw is blocked
5.2.5 Signal indicator on the stretching unit

Signal Indicator
Flashes blue The entered number of metres has been reached.
5.2.6 Display
The display for the central control unit is located at the extruder operating unit. It
is used to set and view all plant parameters.
For further information on the individual functions of the display,

see the starEX display user manual.
5.2.7 Operating pressure gauge

The pressure display for the complete plant is located at the maintenance unit on
the water bath (see Chapter 4.1).

5.2.8 Manual operating units

Manual operating units are also attached to the plant in various locations, for
display purposes.
Controls on the water bath
Fig. 4567/5007
1 <Increase line speed> push button

2 <Reduce line speed> push button
<Pressure roller 4> switch
Left Pivot Pressure roller 4 toward the holding frame roller
3
Pivot Pressure roller 4 away from the holding frame
Right
roller
4 USB port


Left Pivot Pressure roller 3 toward the holding frame roller
5
Pivot Pressure roller 3 away from the holding frame
Right
roller
<Reset EMERGENCY STOP> push button
Lights up <EMERGENCY STOP> push button or pull cord was
6
orange operated
No indicator <EMERGENCY STOP> function is not active
7 <EMERGENCY STOP> push button
8 <START holding frame> push button
9 <STOP plant> push button
<Pressure roller 2> switch*
10 Left Pivot Pressure roller 2 toward the take-down roller
Right Pivot Pressure roller 2 away from the take-down roller
<START extruder> push button
Lights up
11 Plant in operation
green
Flashes green Plant not in operation
12 <STOP extruder> push button
13 Left Pivot Pressure roller 1 toward the take-down roller
Right Pivot Pressure roller 1 away from the take-down roller
14 Display
* Optional

Control for E 105 extruder in the switching cabinet
Fig. 4567/5008
<Filter tape> switch

Left Top heating element in operation
1
Centre Top and bottom heating elements in operation
Right Bottom heating element in operation
Controls on the hot air zone
Fig. 4567/5009
1 <Open hot air zone> two-handed push button

2 <Close hot air zone> two-handed push button
<START hot air zone> push button
Lights up
3 Hot air zone in operation
green
No indicator Hot air zone not in operation
<STOP hot air zone> push button
4 Lights up red Hot air zone is not in operation or a fault has occurred
No indicator Hot air zone in operation

Controls and displays on the stretching unit
The number and position of the control and display components

on the stretching unit is dependent on the specific requirements
for the tapes.
Fig. 4567/5010
<Pressure roller up/down> switch

1 Left Raise pressure roller
Right Lower pressure roller
<START vacuum extractor> push button
Lights up
2 Vacuum extractor in operation
green
No indicator Vacuum extractor not in operation
3 <STOP vacuum extractor> push button
4 <START avivage coating> push button
5 <STOP avivage coating> push button
6 <Increase line speed> push button
7 <Reduce line speed> push button
<Reset metre counter> push button
8 Flashes blue Number of metres has been reached
No indicator Number of metres has not yet been reached
9 <STOP plant> push button
* Optional

11 <Increase annealing> push button

12 <Reduce annealing> push button
13 <START stretching unit> push button
14 <STOP stretching unit> push button
<Production/Reload tape> key switch
Left The safety cover cannot be opened during operation.
15 The safety cover can be opened for 6 min. during
Right operation.
Once the 6 min. have elapsed, the plant stops.
“Reload tape” indicator
The <Production/Reload tape> key switch is turned to
the right.
16 Lights up red The safety cover can be opened during operation for 6
min.
Once the 6 min. have elapsed, the plant stops.
No indicator The safety cover cannot be opened during operation.
<Pressure roller up/down> switch
17 Left Raise pressure roller
Right Lower pressure roller
“Stretching unit overload” indicator
Lights up
18 Current consumption of the stretching unit is too high
orange
No indicator Current consumption is within the permissible range

Fig. 4567/5011
19 <Lift guide rollers> push button*

20 <Lower guide rollers> push button*
<START fibrillator> push button*
Lights up • Fibrillator is in operation
21 green • The speed of the fibrillating roller has been reached
Flashes green Speed of the fibrillating roller has not yet been reached
No indicator Fibrillator is not in operation
22 <STOP fibrillator> push button*
<Maintenance/Operation> key switch*
The precision fibrillator and the stretching unit are
Left
23 stopped, and cannot be restarted
Right
enabled for start-up
<Tape oscillator on/off> switch*
Left
24 stopped, and cannot be restarted
Right
enabled for start-up
“Fibrillator overload” indicator*
Lights up Current consumption value on the fibrillating roller is too
25
orange high
No indicator Current consumption value is OK
* Optional

Controls on the volumetric dosing unit with feed station
For further information on the controls on the volumetric dosing

unit with feed station, see the Technical manual for the voluTEC
volumetric dosing unit with feed station.
Controls on the gravimetric batch dosing unit with feed station (optional)
For further information on the controls on the gravimetric batch

dosing unit, see the Technical manual for the graviTEC
gravimetric batch dosing unit with feed station.
5.3 Commissioning
NOTE!
Dirty material will cause malfunctions!
Only use material sorted by type!
The material must not contain foreign materials such as:
• Metal
• Wood
• Rubber
• Paper
The residual humidity in the material stipulated in the technical
specification must not be exceeded!
NOTE!
Characteristics and composition of the material to be processed
must be known in advance!
To be able to run the plant without interruption, there must always

be a large amount of the material to be processed at hand.
For information on the control unit, see the starEX display user
manual.

5.3.1 Switching the plant on

1. On the maintenance unit, establish the air supply (see the Layout plan
and Chapter 4.1)
2. On the switching cabinet, switch on the <main switch>
 The control system starts up.
 The display starts automatically.
 EMERGENCY STOP is active.
 The flashing light on the water bath lights up yellow.
3. Switch on the raw material feed, according to the version
For further information on switching on the volumetric dosing unit

with feed station, see the Technical manual for the voluTEC
For further information on switching on the gravimetric batch

dosing unit (optional), see the Technical manual for the graviTEC
gravimetric batch dosing unit.
4. Turn on the <Edge strip extractor main switch> (see Chapter 5.2.1)
5. Oil heating device: Turn on the <Main switch> (see the manufacturer's
documentation)
6. Turn on the <Winding machine main switch> (see the manufacturer's
documentation)
7. On the cooling water supply, open the water line (see the Layout plan
and Chapter 4.2)
NOTE!
Possible damage due to the heated parts overheating.
Turn on cooling water!
8. Unlock all EMERGENCY STOP command devices (see Chapter 5.2.2)

9. Press and hold the <Reset EMERGENCY STOP> push button, until the
push button goes out (see Chapter 5.2.8)
10. Switch on the control voltage with the <Reset EMERGENCY STOP>
push button
11. There must be no fault message shown on the display, rectify if
necessary
12. Open the valves on the water distributor (see Chapter 4.2)
13. Switch on the cooling water pump on the display

14. Check temperature sensor, melt temperature and melt pressure

measurement wires and check connection cables for the heaters
15. Tap the [Heaters] button on the display and set the temperature for all
heating zones
- Extruder
- Automatic filter
- Adapter and wide-slit die
- Hot air zone
- Stretching unit
 The heating-up phase starts.
 The display of the actual values is highlighted in red on the display.
DANGER!
Hot plant components. Highest fire and explosion hazard!
• Do not lay/put flammable objects or combustible fluids on hot
plant components!
• The machine must be monitored by an expert during the
heating-up phase!
16. During the warm-up process, prepare the plant modules

(see Chapter 5.3.2 to 5.3.11)
17. After reaching operating temperature:
 The indication on the display changes from red to green.
 The timer for the heat up duration starts.
18. After the heat up duration has expired:
 The plant is ready for operation.
5.3.2 Tightening torques for melt-carrying parts
NOTE!
The required tightening torques are specified on a sign under the
melt discharge unit.
In the heated state, all the fastening bolts on the automatic filter with melt mixer
and melt pump (optional) and all the tightening points on all the heater elements
must be re-tightened to the max. tightening torque.

NOTE!
Potential material damage!
Damage due to failure to adhere to the specified tightening
torques!
All bolts in melt-carrying parts must be tightened cold to 80% of
the max. tightening torque.
WARNING!
Hot surfaces and vapours!
Risk of injuries to the eyes and hands
Wear protective gloves when working on melt-carrying parts!
Wear eye protection when working on melt-carrying parts!
Symbol Meaning
80 % of max. tightening torque when cold
100 % of max. tightening torque when heated up
Example of the tightening torque specifications for the automatic filter and
melt mixer:
Fig. 4567/5012

5.3.3 Preparing the extruder

When commissioning the extruder, the following steps must be performed on the
automatic filter:
• Insert the filter tapes
• Adjust the melt barrier
• Adjust the filter tape brake
Inserting the filter tapes
Fig. 4567/5015
The arrow indicates the direction of movement of the filter tape.

1 Cover 8 Pins
2 Star knobs 9 Spring
3 Knurled nuts 10 Nuts
4 Cover 11 Nuts
5 Melt barrier 12 Coarse filter tape
6 Filter tape cup 1 13 Fine filter tape
7 Filter tape cup 2
Procedure
1. Undo the star knobs (2) and remove the cover (1).
2. Undo the knurled nuts (3) and remove the covers (4).
3. Insert the fine filter tape (13) into the filter tape cup (6)

4. Insert the coarse filter tape (12) into the filter tape cup (7)
NOTE!
The filter tapes must be positioned precisely one over the other.
5. Thread filter tapes (12) and (13) through the pins (8) and into the filter
inflow at the melt barrier (5)
6. Push the filter tapes through in the direction of the arrow, until they
protrude from the filter outflow by approx. 12 mm (see Fig. 4567/5042)
7. Fit the covers (4) with the knurled nuts (3)
8. Fit the cover (1) with the star knobs (2)

Adjusting the melt barrier

Once the filter tapes (12) and (13) have been inserted, the melt barrier (5) must
be adjusted.
Fig. 4567/5016
5 Melt barrier 8 Nut

6 Bolt 12 Coarse filter tape
7 Grub screw 13 Fine filter tape
Procedure
1. Loosen the nuts (8) and bolts (6)
2. Then position the melt barrier (5) in relation to the filter tapes (12) and
(13)
- Turn the grub screws (7)
 The melt barrier (5) touches the filter tapes (12) and (13).
3. Tighten the nuts (8) and bolts (6)

Adjusting the filter tape brake

After adjusting the melt barrier, the filter tape brake must be adjusted.
Fig. 4567/5017
9 Spring 12 Coarse filter tape

10 Nut 13 Fine filter tape
11 Nut z Approx. 40 mm
Procedure
1. Pretension the springs (9) to a distance (z) of approx. 40 mm
- Turn the nuts (11)
2. Tighten the nuts (10)
The shorter the distance (z), the greater the braking effect.
The longer the distance (z), the smaller the braking effect.

Forming a plastic plug during initial plant operation

To form a plastic plug, the heat-through period must have elapsed (see the
starEX display user manual).
Fig. 4567/5042
1 Filter tapes (coarse and fine) 4 Plastic plug

3 Filter output
Procedure
1. Set the line speed to 50 m/min on the display
2. Start the extruder with the <START extruder> push button
- Indication: push button lights up green
3. Fill the automatic filter with material at a reduced extruder speed
(5 rpm), until it flows out of the filter outflow (3)
4. Stop the extruder for 30 min. with the <STOP extruder> push button
 The filter tape heater at the filter outflow (3) is switched off.
 The plastic melt hardening at the filter outflow (3) forms a plastic
plug (4).

5. Switch on the filter tape heater for 2 - 3 min. (see thestarEX display user
manual)
 The plastic plug (4) heats up.
6. Switch on the extruder with the <START extruder> push button
 The melt pressure causes the filter tapes (1) to move out of the filter
outflow (3).
7. Stop the extruder for 5 min. with the <STOP extruder> push button
 The plastic melt hardening at the filter outflow (3) forms a plastic
plug (4).
If the filter tapes (1) project out by between 500 and 1,000 mm at the filter outflow
(3) during operation, cut them off.
CAUTION!
Risk of cuts when cutting the filter tapes (1)!
Wear safety gloves!

5.3.4 Preparing the wide-slit die

The die gap on the wide-slit die (1) must be adjusted.
In order to carry out adjustment, the wide-slit die (1) must be

heated up to operating temperature.
WARNING!
Wear safety gloves!
Fig. 4567/5052
1 Wide-slit die 3 Die lips

2 Pressure bolt 4 Cover
Apply an Allen key to the respective pressure bolts (2) and adjust the gap
between the die lips (3) to approx. 0.5 - 0.6 mm across their full width. This
produces a film thickness of approx. 1 mm.
After commissioning, retighten the pressure bolts (2) and all bolts on the side
covers (4).

5.3.5 Preparing the hot air zone

Switch on the hot air zone with the <START hot air zone> push button
5.3.6 Preparing the water bath

To commission the water bath, proceed as follows:
• Filling the water bath with water
• Fitting the blades to the lengthways cutting mechanism
Filling the water bath with water
Fig. 4567/5018
1 Water bath 3 Lever

2 Float switch
Procedure
1. Close the ball valve with the lever (3)
2. Fill the water bath (1) with water until the float switch (2) is actuated

Fitting the blades to the lengthways cutting mechanism

Before blades are fitted to the knife bar, the required blade spacer width must be
established using the blade spacer table (see Chapter 8.5).
Example of a tape width of 2.5 mm (A):

• Required stretch: 6.1 (B)
• Blade spacer width: 6 mm (C)
Fig. 4567/5019
The arrow shows the area of the table for determining other required values.
A Tape width C Blade spacer width
B Total stretch ratio

• Working width: 930 mm (D) produces 146 tapes (E)

• A blade spacer width of 6 mm (F) requires two blade spacers (G),
each with a width of 3 mm (H).
Fig. 4567/5020
The arrow shows the area of the table containing the already-determined values.
D Working width (die width) G Number of blade spacers
E Number of tapes H Blade spacer width
F Blade spacer width

Once the blade spacer width has been determined, the knife bar (7) can be fitted
with the required number of blade spacers and blades.
If the blades are fitted centrally, the knife bar (7) can be rotated through 180° and
reused. The blades themselves may also be turned round and used again. This
means that the blades can be used four times.
CAUTION!
The edges of the blade are sharp!
Risk of cuts in the area of the blades!
Wear safety gloves when working with the blades!
Fig. 4567/5021
7 Knife bar 9 Safety cover

8 Bolt
Procedure
1. Install the safety cover (9)
CAUTION!
Sharp cutting edges!
Risk of cuts in the area of the blades!
Never carry the knife bar (7) without the safety cover (9)!
2. Undo the bolts (8)

3. Lift out the knife bar (7) and set down on an assembly table
NOTE!
In order to prevent damage, a suitable mat should be laid on the
assembly table.
4. Remove the safety cover (9)
Fig. 4567/5022
1 Bolts 4 Spacers
2 End 5 Bolt
3 Blades 6 Thrust piece
5. Loosen the bolt (5)

7. Remove the ends (2)
8. Fit the knife bar alternately with blades (3) and spacers (4) from the
centre, up to the determined blade spacer width

9. Use multiple spacers (4) in a row in the vicinity of the edge strips
When refitting the blades (3), the spacers (4) in the vicinity of the
edge strips can be removed.
NOTE!
Malfunctions can be caused by the formation of loops in the tape
extraction system.
The width of the edge strips should not be more than 10 mm.
10. Mount the ends (2) with the bolts (1)

11. Clamp the complete knife package with the bolts (5) and the thrust
piece (6)
- Tightening torque: 5 Nm
12. Install the safety cover (9)
13. Insert the knife bar (7) into the lengthways cutting mechanism and
mount with the bolts (8)
14. Remove the safety cover (9)

15. Feed a pretensioning film through the water bath with integrated holding
frame
WARNING!
Risk of falling when feeding in the film web!
Fig. 4567/5024
The arrows indicate the clamping direction of the pretensioning film.

Feed and pressure roller
1 Water bath 6
(optional)
2 Rod brake 7 Brush roller
3 Feed and pressure roller 8 Lengthways cutting mechanism
4 Vibration dryer 9 Lever for lengthways adjustment
5 Deflection roller 10 Holding frame rollers

Fig. 4567/5039
1 Die pipe 2 Clip
16. Close open slits on the die pipes (1) with clips (2)
5.3.7 Preparing the stretching unit

1. Switch on the oil heating device (according to the version)
For further information on the oil heating unit, see the

manufacturer's documentation.

Fig. 4567/5025
1 Ball valve 2 Expansion tank
2. Open the ball valve (1) on the expansion tank (2) for avivage coating
(optional)
5.3.8 Preparing the precision fibrillator (optional)

If the precision fibrillator is not being used, proceed as follows:
Fig. 4567/5041
1 Safety cover
1. Press and hold the <Lift guide rollers> push button until the lowering
frame has reached the top limit position (see Chapter 5.2.8)
2. Position the safety cover (1)

Tape oscillator
Adjusting the tape width
The distances between the guide pins (1) must be adapted to the particular tape
width.
Fig. 4567/5026
1 Spacer with guide pin 4 Bolt

2 Star knob 9 Seating
3 Oscillating beam
Procedure
1. Undo the bolt (4)
2. Undo the star knob (2)
3. Pull out the oscillating beam (3) and set down on an assembly table
NOTE!
In order to prevent damage, a suitable mat should be laid on the
assembly table.

Fig. 4567/5027
1 Spacer with guide pin 7 End

3 Oscillating beam 8 Thrust piece
5 Bolt 10 Spacer
6 Bolt
4. Loosen the bolts (5)

6. Remove the ends (7)
7. Fit the oscillating beam (3) alternately with spacers with guide pins (1)
and spacers (9)
- For a tape width > 2 mm, the spacer with guide pin (1) with a width
of 4.8 mm must be used.
- For a tape width < 2 mm, the spacer with guide pin (1) with a width
of 2.35 mm must be used.
8. Mount the ends (7) with the bolts (6)
9. Clamp the complete package with the bolts (5) and the thrust piece (8)
10. Insert the oscillating beam (3) into the seating (9) (see Fig. 4567/5026)
and attached with the bolts (4) and star knob (2)

Positioning the oscillating beam

The oscillating beam (3) must be positioned at a slight angle to the course of the
tape.
Fig. 4567/5028
1 Spacer with guide pin 3 Oscillating beam

2 Star knob
Procedure
1. Loosen the star knob (2)
2. Pivot the oscillating beam (3)
3. Tighten the star knob (2)
5.3.9 Preparing the raw material feed

The material mixture must be adjusted on the raw material feed, according to the
version.
For further information on the volumetric dosing unit with feed

station, see the Technical manual for the voluTEC volumetric
dosing unit with feed station.
For further information on the gravimetric batch dosing unit

(optional), see the Technical manual for the graviTEC gravimetric
batch dosing unit.

5.3.10 Preparing the winding machine
For further information on the preparations on the winding

machine, see the manufacturer's documentation.
5.4 Operation
The following safety instructions must be observed whilst operating the plant:
WARNING!
During operation, operating personnel are not permitted to enter
the working zone marked out on the floor!
Before switching operating mode, ensure that you are in visual
contact with a second person!
Wearing of hearing protection is mandatory!
Extruder
WARNING!
WARNING!
Strong magnetic field around the metal separator!
Danger to life for persons with pacemakers!
Personnel who are wearing a pacemaker must not stand within

the magnetic field!
Wear safety gloves!

Wide-slit die
WARNING!
DANGER!
Wear safety gloves!
WARNING!
Risk of crushing when moving the water bath!
When moving the water tank, do not climb between the water tank
and the wide-slit die.
Water bath with integrated holding frame
WARNING!
Risk of being drawn into the rotating rollers!
Carry out setup tasks with great care!
WARNING!
Risk of hand injuries when lowering the door on the vibration
dryer!
When lowering the door, do not have your hand between the side
box and the door!
WARNING!
Risk of cuts from the blades of the lengthways cutting mechanism!
Wear safety gloves!

WARNING!
Risk of injury to the feet when moving the water bath!
When moving the water tank, do not climb between the wheel
cover and the side box.
WARNING!
When moving the water tank, do not climb between the water tank
WARNING!
Risk of falling when feeding in the film web!
Hot air zone
WARNING!
Risk of crushing when closing the hot air zone!
When closing the hot air zone, assume a crouching position!
WARNING!
Risk of burns from discharged air up to 250°C!
Wear safety gloves!
Stretching unit
DANGER!
Maintain a distance of 1 m from the stretching unit
during operation!
WARNING!
Risk of burning from hot surface of hoses, connections and heated
godets!

Wear safety gloves!
Precision fibrillator (optional)
CAUTION!
Risk of injury on the fibrillating roller!
Wear safety gloves!
WARNING!
Risk of crushing when moving the carriage of the fibrillating roller!
Do not reach between the base frame and the fibrillating roller
carriage while the carriage is moving!
Tape extraction vacuum system
CAUTION!
Risk of crushing when closing the container doors!
Crushing injuries!
Do not loiter in the closing area of the container doors!
5.4.1 Workstations
The main workstations are located at the operating unit on the water bath with
integrated holding frame.
There is also a display for adjusting operating parameters and performing
troubleshooting at the operating unit on the water bath.
In addition, the plant is equipped with several maintenance positions.
For further information on the work stations and maintenance

positions, see the Layout plan.

5.4.2 Starting the plant

After reaching operating temperature and after the heating time has expired
(heating timer) the plant is ready for operation.
The controls listed are described in Chapter 5.2.8.
user manual.
Procedure
1. Turn <Add production run/tape> key switch anticlockwise
 The safety cover on the stretching unit cannot be opened during
operation.
 The stretching unit is enabled for operation.
2. Turn the <Maintenance/Operation> key switch for the precision fibrillator
(optional) clockwise
 The precision fibrillator (optional) is enabled for operation.
3. Press the <Raise guide rollers> push button (optional)
 The guide rollers on the precision fibrillator move into the upper limit
position.
4. The following values must be set on the display:
- Line speed: 50 m/min
- Speed of the fibrillating roller (optional)
- Reference position of the guide rollers (optional)
5. Start the precision fibrillator (optional) with the <START fibrillator> push
button
7. Allow the extruder to run until the melt is flowing evenly and cleanly
from the wide-slit die
 There must be no holes in the film web.

8. Switch off the extruder with the <STOP extruder> push button and clean
the die lip.
CAUTION!
Potential material damage!
With even the slightest damage, there can be no guarantee that
the wide-slit die will continue to perform at its best!
The wide-slit die must be handled very carefully and should only
be cleaned with the specified cleaning agents (see the Wide-slit
die module manual).
WARNING!
Wear safety gloves!
Fig. 4567/5029
- Scrape off the black coating on the discharge side with a brass or
aluminium scraper

Fig. 4567/5030
9. Clean the die lip with a cleaning cloth (copper wool) sprayed with
silicone oil
Applying silicone oil prevents melt from sticking to the lip again!
This silicone oil must be rinsed out as quickly as possible during

the start-up procedure, so that there is no risk of harmful effects
from the separating effect of the silicone oil.

11. Stick the ribbon of melt emerging from the wide-slit die to the
pretensioning film and pull it through the water bath
Fig. 4567/5031
The arrows indicate the conveying direction of the film web.

Feed and pressure roller
1 Water bath 6
(optional)
2 Rod brake 7 Brush roller
3 Feed and pressure roller 8 Lengthways cutting mechanism
4 Vibration dryer 9 Lever for lengthways adjustment
5 Deflection roller 10 Holding frame rollers
- Unlock the lever (9)

- Move the water bath (1) to the wide-slit die
WARNING!
When moving the water bath, do not climb between the wheel

WARNING!
When moving the water bath, do not climb between the water tank
- Turn the <Pressure roller> switch to the right

 The respective pressure roller is pivoted out by the take-down and
holding frame roller.
- Stick the ribbon of melt emerging from the wide-slit die to the
pretensioning film and pull it through the water bath
- Turn all <Pressure roller> switches to the left
 The respective pressure roller is pivoted in, to the take-down and
holding frame roller.
12. Wind up the pretensioning film and cut off
CAUTION!
Risk of cuts when cutting the pretensioning film!
Wear safety gloves!

Fig. 4567/5032
1 Hot air zone 2 Film web
13. Draw the film web (2) through the hot air zone (1)
14. Switch on the tape extractor with the <START vacuum extractor> push
button

Fig. 4567/5033
2 Film web 4 Suction nozzle

3 Godet 5 Safety cover
15. Position the film web (2) on the godets (3) of the stretching unit, and
guide it into the suction nozzle (4)
 The film web (2) is sucked into the container.
16. Turn the <Pressure roller up/down> switch to the right
- The pressure rollers on the stretching unit are lowered.
17. Close the safety cover (5)
18. Check the quality of the film web at the water bath
 There must be no holes in the film web.
- Check the mixing ratio
For further information on the composition and properties of the

material, see the technical specification.
19. Switch on the cutting mill for the edge strip return on the display

Fig. 4567/5023
View in the figure is from the drive side.

1 Lever 3 Adjuster wheel
2 Blade
20. Pivot in the lengthways cutting mechanism on the water bath with the
lever (1)
- The penetration depth of the blades (2) into the film web can be
adjusted during operation with the adjuster wheel (3) or on the
display
21. Cut off the edge strips and guide them into the suction nozzles
22. Increase the line speed to approx. 100 m/min on the display
Fig. 4567/5051
23. Cut off the tapes before the suction nozzle on the stretching unit and
pick up with an air gun

Fig. 4567/5050
24. Position the tapes one after another on the winding machine
For further information on positioning the tapes and the feed

diagram for the winding machine, see the manufacturer's
documentation.
25. Increase the line speed to approx. 250 m/min on the display
26. Check the tapes (see Chapter 8.2)
- Check the film web thickness across the entire width of the wide-slit
die, and correct if necessary (see Chapter 5.3.4)
27. Increase the line speed to production speed on the display
 The production speed is determined by the material.
28. Check the tapes again
29. Start the precision fibrillator (optional) with the <START fibrillator> push
button
30. Press and hold the <Lower guide rollers> push button until the guide
rollers have reached the reference position
- The reference position is adjusted on the display

31. Adjust the contact bar (3) on the water bath
Fig. 4567/5035
3 Contact bar 17 Bracket

15 Bolts 18 Film web
16 Bolt
- Loosen the bolts (15)

- Move the contact bar (3) horizontally
 The contact bar (3) should be just lightly touching the film web (18).
- Tighten the bolts (15)
- Undo the bolts (16)
- Turn the contact bar (3)
 The contact bar (3) should be just lightly touching the film web (18).
 The position of the contact bar (3) can be switched to the second
hole in the bracket (17).
- Tighten the bolts (16)

32. Adjust the wiper lips (6) on the water bath
Fig. 4567/5036
6 Wiper lip 20 Star knob

18 Film web 21 Grub screw
19 Star knob
- Loosen the star knobs (20)

- Loosen the nut on the grub screw (21)
- Position the rear wiper lip (6)
 The rear wiper lip (6) should be touching the film web (18).
- Tighten the star knobs (20)
- Tighten the nut on the grub screw (21)
- Loosen the star knobs (19)
- Position the front wiper lip (6)
 The front wiper lip (6) should be touching the film web (18).
- Tighten the star knobs (19)

33. Adjust the rod brake (7) on the water bath
Fig. 4567/5037
7 Rod brake 23 Locking plate

22 Stop bolt
- Pull out the stop bolt (22)

- Turn the rod brake (7)
- Allow the stop bolt (22) to engage in a hole on the locking plate (23)
34. Adjusting the vibration dryer
WARNING!
WARNING!
Risk of hand injuries when lowering the door on the vibration
dryer!
When lowering the door, do not have your hand between the side
box and the door!
For optimum drying, the film web must always be sufficiently

tensioned.

Fig. 4567/5038
1 Suction pipe 5 Grub screw

2 Suction pipe 6 Grub screw
3 Die pipe (blowing pipe) 7 Grub screw
4 Handwheel
- Adjust the distance of the die pipes (3) to the film web using the
handwheel (4) (even during operation)
35. Position the die pipes (3) in relation to the film web:
- Loosen the grub screws (7)
- Position the die pipes (3) by turning them
- Tighten the grub screws (7)
36. Position the suction pipes (1) and (2) in relation to the film web:
- Loosen the grub screws (5) and (6)
- Position the suction pipes (1) and (2) by turning them
- Tighten the grub screws (5) and (6)
In order to ensure optimal extraction of the remaining liquid, the

suction slits on the suction pipes (1) and (2) must be pointing
upwards (conveying direction of the film web). This ensures that
air is drawn in as well.

5.4.3 Operating mode

The following operating mode is available on the plant:
• Automatic mode
Automatic mode
After being started up, the plant operates in automatic mode. All plant parameters
(production speed, temperature settings, report management, etc.) can be
adjusted and read on the display when in automatic mode. The corresponding
settings are dependent on the properties and condition of the material to be
processed (viscosity, moisture, bulk weight, density and additives).
For further information on the individual functions of the central

control unit, see the starEX display user manual.
The following tasks must be performed by operating personnel when in automatic

mode:
• Monitoring the processes on the plant
- Checking the cooling water supply
- Regularly inspecting the tapes
- Regularly inspecting the tape extractor (no formation of loops)
- Troubleshooting (see Chapter 7 and the respective module manual)
• Loading the plant
• Check the fill level of the container in the tape extractor, and empty if
necessary
• Remove full bobbins from the winding machine
• Insert empty bobbins onto the winding machine and position the tapes

Interrupting automatic mode

Automatic mode can be interrupted at any time by pressing the <STOP plant>
push button on the manual operating unit on the water bath (see Chapter 5.2.8,
Fig. 4567/5007).
In the following situations, the plant stops automatically:
• A fault has occurred on the plant
- Troubleshooting, see Chapter 7 and respective module manual as
well as the starEX display user manual
NOTE!
The tapes stick together in the hot air zone!
When the plant is stopped, the tapes must cut off after the holding
frame and fed to the tape extractor.
Switching back to automatic mode

The plant must be restarted, as described in Chapter 5.4.2.
5.4.4 Working on the plant
Monitoring the processes on the plant

The plant may only be operated under the supervision of a trained person. The
plant must be shut down immediately if its operating behaviour changes.
Malfunctions may only be corrected by authorised persons (see Chapter 7)
Loading the plant

The raw material feed must be supplied appropriately for the particular design. In
automatic mode, all functions of the feed station which are necessary for
production are performed automatically.

5.4.5 Moving the plastic plug manually on the E-105 extruder

The E-105 extruder size allows the plastic plug to be moved manually during
operation, using the <Filter tape> switch, in addition to automatic control (see
Chapter 5.2.8).
If the plastic plug moves upwards during a filter change, the following steps must
be performed:
1. Turn the <Filter tape> switch to the left
 Only the top heating element is switched on at the filter outflow.
 The bottom heating element begins to heat up after the time delay
specified on the relay in the switching cabinet has elapsed.
- Time setting: 1 - 10 sec. (factory setting)
 The top of the plastic plug will melt and move down again sooner
than the bottom melts.
 The plastic plug moves in a straight line out of the filter outflow
again.
2. Move the <Filter tape> switch to the centre position
 The top and bottom heating elements are switched on at the same
time.
If the plastic plug moves downwards during a filter change, the following steps
must be performed:
1. Turn the <Filter tape> switch to the right
 Only the bottom heating element is switched on at the filter outflow.
 The top heating element begins to heat up after the time delay
specified on the relay in the switching cabinet has elapsed.
- Time setting: 1 - 10 sec. (factory setting)
 The bottom of the plastic plug will melt and move up again sooner
than the top melts.
 The plastic plug moves in a straight line out of the filter outflow
again.
2. Move the <Filter tape> switch to the centre position
 The top and bottom heating elements are switched on at the same
time.

5.4.6 Replacing bobbins
For information on replacing bobbins on the winding machine, see

the manufacturer's documentation.
5.4.7 Reloading tapes

Torn tapes are reloaded during operation at the godets, by means of grooves.
WARNING!
Risk of injury!
The tapes may only be reloading using an air gun!
WARNING!
When reloading tapes, maintain visual contact with the other
person!
The other person must be standing at an EMERGENCY STOP
command device!
Before triggering an EMERGENCY STOP command device,
ensure visual contact with the second person!
Procedure
1. Turn <Production/Reload tapes> key switch clockwise
 The safety cover on the stretching unit can be opened for 6 min.
 Once 3 min. have elapsed, the rotating light on the water bath
comes on.
 If the safety cover is not closed within the 6 min., the plant is
stopped.
2. Stretching unit safety cover open

3. Pick up the torn tapes on the holding frame with an air gun (3)
Fig. 4567/5047
1 Godet 3 Air gun

2 Grooves
4. Position the tapes on the grooves (2) on the godets (1)
Fig. 4567/5048
5. Cut off the tapes and guide then into the suction nozzle
6. If multiple of the tapes are torn, repeat steps 1 to 4

Fig. 4567/5049
3 Air gun 4 Winding machine
7. Pick up the tapes with the air gun (3) and position on the bobbins on the
winding machine (4)
For further information on positioning the tapes on the winding

machine, see the manufacturer's documentation.

5.4.8 Rectifying wrap-arounds on godets
WARNING!
When rectifying wrap-arounds on the godets, maintain visual
contact with the other person!
Procedure
1. The first person stops the plant with the <STOP plant> push button
(see Chapter 5.2.8)
2. The second person opens the safety cover on the stretching unit
3. The second person uses a suitable cutting tool to cut the wrap-around
from around the godet
CAUTION!
Risk of cuts when cutting the wrap-around on the godet!
Wear safety gloves!
4. The second person closes the safety cover on the stretching unit
5. The first person starts up the extruder with the <START extruder> push
button
WARNING!
During operation, operating personnel are not permitted to enter
the working zone marked out on the floor!
Before switching operating mode, ensure that you are in visual
contact with a second person!

5.4.9 Checking the fill level on the tape extractor

The fill level of the container (1) in the tape extractor must be checked hourly,
and can be viewed at the inspection window (2) on the container (1). If
necessary, the container (1) must be emptied.
Fig. 4567/5046
1 Container 3 Container door

2 Inspection window
Procedure
1. The first person stops the plant with the <STOP plant> push button
(see Chapter 5.2.8)
2. The second person opens the container doors (3)
3. Remove tape residue from the container (1)
4. Close the container doors (3)
CAUTION!
Risk of crushing when closing the container doors!
Crushing injuries!
Do not loiter in the closing area of the container doors!
5. Start the plant (see Chapter 5.4.2)

5.4.10 Changing the material

When performing a material change, the extruder must be run until empty.
Procedure
1. Switch off the <Edge strip extractor main switch> on the cutting mill (see
Chapter 5.2.1)
2. Reduce the production speed to 100 m/min
3. Cut off all tapes after the last godet on the stretching unit and feed to
the tape extractor
4. Switch off the raw material feed, depending on version
For further information on switching off the volumetric dosing unit

with feed station, see the Technical manual for the voluTEC
For further information on switching off the gravimetric batch

dosing unit (optional), see the Technical manual for the graviTEC
gravimetric batch dosing unit.
5. Empty the extruder hopper (1)
Fig. 4567/5053
1 Extruder hopper 2 Plug

- Loosen the bolt on the plug (2)

- Pull out the plug (2)
- Empty the material into a suitable container
NOTE!
There must be no material in the extruder hopper!
- Insert the cover (2) and secure with a bolt

6. Allow the extruder to run until no more melt flows out of the wide-slit die
7. Stop the plant with the <STOP plant> push button
 All drives are switched off.
8. Switch off the cooling water pump on the display (see the starEX
display user manual)
9. Switch off the oil heating device (according to the version)
For further information on switching off the oil heating unit,

see the manufacturer's documentation.
10. Stop the hot air zone with the <STOP hot air zone> push button
- Indication: push button is illuminated red
11. Start the plant (see Chapter 5.4.2)

5.4.11 Process-related instructions
Extruder
• High tear-resistance of the tapes
Extruder running relatively cold
• Low elongation of the tapes
Extruder running relatively hot High elongation of the tapes
Wide-slit die
Optimal gap width under pressure Gap width 0.4 - 0.6 mm
• Suitable for thin tapes
• Thick tapes
Gap width 0.3 mm
If throughput is high but melt quantity low,
pulsing is possible.
Primary film < 65 µm Gap width approx. 0.4 mm
Primary films > 65 µm <100 µm Gap width 0.5 - 0.6 mm
Primary films > 100 µm <150 µm Gap width 0.7 mm
Primary film > 150 µm Gap width 0.8 mm
Water bath
Water temperature approx. 30 to 40°C Fabric-like properties
Thin tapes (e.g. 3 mm and 700 den) Temperature recommendation: 40 - 45°C
Medium tapes (e.g. 3 mm and 900 den) Temperature recommendation: 35 - 40 °C
Heavy tapes Temperature recommendation: 25 - 35 °C
• Excessive stiffness – problems with
stretching
Water temperature too low • Creases in the film web - problems
with cutting
• Low elongation of the tapes
Steam bubbling in the film web - water
Water temperature too high begins to boil when coming into contact
with melt (trapped air)
• Results in smaller, finer crystals and
thus more effort in stretching
Fast cooling • Short distance from the surface of the
water
• Higher tendency of the tapes to split

Water bath
• Results in a lesser number of larger
crystals and thus more effort in
Slow cooling process stretching
• Greater distance from the surface of
the water
25 mm (for container tapes) – water must
not spray on the wide-slit die!
Minimum distance from the surface of the • Higher strength tapes
water
• Tapes are hard to stretch
• More tears in the hot air zone
60 mm (for thin tapes)
Maximum distance from the surface of the • Lower strength tapes
water • Better running characteristics in the
hot air zone
Blade change
Approx. every 150 operating hours • Tearing of the tapes increased

(dependent on the material being • Blades vibrating
processed) • Tapes have rough cut edges
Hot air zone

• PP • Approx. 140 to 160°C
• HDPE • Approx. 90 to 140 °C
• LLDPE • Approx. 90 to 120 °C
High temperature High elasticity of the tapes
Low temperature For thick tapes
Annealing temperature, approx. 100 to 140°C

Excessive temperature Tapes could stick to the godets

Stretch ratio
• Lower stretch ratio
• Low tendency of the tapes to split
Final stretching 1:5 to 1:6
• Increased elasticity
• High elongation
• Increased stretch ratio,
• Increased tendency of poles to pit.
Final stretching 1:6 to 1:7
• Low elasticity
• Low elongation
The higher the production speed, the lower the required overall
stretching.
5.5 Switching off the plant
Before every switching off of the plant, the following tasks must be performed:
1. Switch off the <Edge strip extractor main switch> on the cutting mill (see
Chapter 5.2.1)
2. Reduce the production speed to 100 m/min
3. Cut off all tapes after the last holding frame roller on the water bath and
feed to the tape extractor
4. Pivot out the lengthways cutting mechanism on the water bath (see
Chapter 5.2.4, Fig. 4567/5023)
5. Unwind 2 to 3 metres from the film web and cut off
 The film web in the water bath serves as a pretensioning film for the
next plant start-up (see Chapter 5.4.2).
CAUTION!
Risk of cuts when cutting the pretensioning film!
Wear safety gloves!

6. Stop the plant with the <STOP plant> push button

 All drives are switched off.
7. Switch off the cooling water pump on the display (see the starEX
display user manual)
8. Switch off the oil heating device (according to the version)
For further information on switching off the oil heating unit, see the
manufacturer's documentation.
9. Stop the hot air zone with the <STOP hot air zone> push button
- Indication: push button is illuminated red
10. Push back the water bath
- Unlock the lever (9) (see Chapter 5.4.2, Fig. 4567/5031)
WARNING!
When moving the water bath, do not climb between the wheel
The plant must always be switched off at the <Main switch>. The <Main switch>
is simultaneously designed as the <EMERGENCY STOP> switch and can be
found on the switching cabinet.
Fig. 4567/5043

Rotating the <Main switch> to the "0" position immediately interrupts the energy
supply and shuts down the plant.
DANGER!
Risk of serious injury!
Before starting the plant up it is always necessary to ensure that
this cannot place anyone at risk.
In order to prevent the accidental start-up of the plant, the <Main
switch> must be secured against being switched back on (e.g.
during adjustment and maintenance work).
user manual.
5.6 Shutting down the plant

In accordance with EN ISO 13850:2006, each person is required to trigger an
EMERGENCY STOP if doing so could avert the risk of personal injury, damage
to the plant or risks to ongoing work or existing danger can be lessened.
WARNING!
The EMERGENCY STOP must NEVER be used to shut down the
plant for maintenance work!
When doing maintenance on the plant, the <Main switch> must
always be set to OFF ("0" position) and be safeguarded against
being switched back on!

5.6.1 EMERGENCY STOP command devices

The plant is equipped with several EMERGENCY STOP command devices found
on the plant at various locations (see Overview in Chapter 5.2.2). Actuating an
EMERGENCY STOP command device shuts down the plant or associated plant
part.
EMERGENCY STOP push button
Fig. 4567/5044
EMERGENCY STOP pull cord
Fig. 4567/5045
1 Pull cord 2 <Reset push button>

5.6.2 Method of operation
Triggering an EMERGENCY STOP

1. Press <EMERGENCY STOP> push button or pull EMERGENCY STOP
pull cord
 EMERGENCY STOP is active.
 The plant is brought to a standstill.
 The power supply for the drives is interrupted.
 The 24V control voltage is maintained.
 The EMERGENCY STOP is indicated on the display as an error
message.
For further information on troubleshooting, see the starEX display

user manual.
Cancelling an EMERGENCY STOP

1. Rectify the cause of the EMERGENCY STOP
2. Unlock <EMERGENCY STOP> push button or actuate <Reset button>
at the pull cord
3. Press the <Reset EMERGENCY STOP> push button to acknowledge it
 The <Reset EMERGENCY STOP> push button is no longer lit.
 The indicator on the display goes out.
 The plant is ready for operation again.
4. Start up the plant again (see Chapter 5.4.2)

6. MAINTENANCE
6 MAINTENANCE
In order to ensure the full functionality and performance of the plant, all
instructions pertaining to maintenance work on the plant must be complied with to
the letter. All maintenance tasks carried out must be recorded in a system
logbook and identify the respective number of operating hours.
DANGER!
Before lubrication and maintenance work is performed on the
plant, the <Main switch> must always be set to OFF ("0"
WARNING!
been switched off.
Before carrying out work on the pneumatic system, it is vital that
you depressurise the system!
WARNING!
NOTE!
Potential for damage to property through failure to comply with the
stipulated lubrication and maintenance intervals!
Ensure that the lubrication and maintenance intervals listed on the
display are complied with (see the starEX display user manual)!
Confirm work carried out on the display!
WARNING!
Risk of injury from forgotten objects!
Ejected objects can cause serious injuries and property damage.
After maintenance work:
• Remove tools from the plant
• Make sure there are no foreign objects in the plant
CAUTION!
Risk of injury due to unsuitable tool!
• Observe the instructions on the use of special tools
• Only use tools that are in a flawless condition
• Remove tools after work is complete and store them properly

6. MAINTENANCE
NOTE!
Damaged hoses can cause property damage!
Never kink, crush, rupture, pull or drive over hoses!
6.1 Lubrication
In order to achieve optimum performance and largely eliminate operational faults,
the corresponding plant modules must be lubricated using suitable lubricants at
regular intervals.
Information on lubrication can be found in the individual module

manuals.
6.2 Maintenance overview

The following chapter provides information on maintenance tasks which apply for
the plant as a whole, as well as the maintenance intervals to be complied with.
For information on maintenance of the individual plant

components, see the respective module manual.
Refer to the manufacturer's documentation for special instructions

on the proper maintenance of purchased components.
Follow the instructions of the manufacturer!
6.2.1 Daily maintenance tasks

• Inspect the plant for coarse dirt and clean if necessary
• Inspect fans of motors and blower filters for dirt and clean them as
necessary
• Check the flow indicator on the water distributor (see Chapter 6.2.10)
6.2.2 Weekly maintenance tasks

• On the gear motors and gearboxes, check the oil level
• Inspect switching cabinet for dust and dirt and vacuum out as necessary
• Inspect cable ducts for dirt and infestation by small animals, clean as
necessary
• Clean the floor under the plant

6. MAINTENANCE
6.2.3 Monthly maintenance tasks

• Check smooth running of all cylinders and rollers; pay attention to any
running noises
• Check safety doors and protective guards for completeness; replace if
necessary
• Check safety stickers are intact; replace if necessary
• Have the condition and function of the safety switch, circuit breaker and
EMERGENCY STOP system tested by an electrician
For further information, see Circuit diagrams.
• Check lamp function

• Check pipework systems
6.2.4 Quarterly maintenance tasks

• Check cooling water circuit
6.2.5 Six-monthly maintenance tasks

• Check cables and protective sleeves for damage and replace if
necessary
• On switching cabinets:
- Seal the cable ducts and cable entry points
- Clean fans and filter mats (only for switching cabinets with air
cooling)

6. MAINTENANCE
6.2.6 Chain drives
Cleaning
The chains must be continuously supplied with free-flowing oil over their whole
surface, i.e. links and plates must be permanently moistened with oil.
NOTE!
Possible damage to the chain due to hydrogen embrittlement!
Cleaning must be performed exclusively with paraffin
derivatives:
• Diesel oil
• Paraffin spirit
• White spirit
Under no circumstance should cold cleaners, corrosive or acidic
substances, or steam jets be used!
If dirt on the chain becomes so heavy that penetration of the lubricating oil is no
longer guaranteed, the chain must be cleaned.
1. Remove coarse dirt deposits with a wire brush
2. Rinse the chain using a suitable agent
3. If the internal parts are soiled: Immerse the chain in a suitable agent for
24 hours and move back and forth several times
4. Check the chain for noises
 The movement of the chain links should not produce any noise.
Other maintenance work

• Check chain tension:
- before initial commissioning
- after a run-in period of roughly 1 week
- then after no longer than 6 months (depending on load and
temperature)
• At each lubricating interval, check chains and sprockets:
- for wear (unless otherwise instructed)
- for proper alignment (unless otherwise instructed)
• Check the secure attachment of the sprockets once a year
• In the case of heavy wear, replace the chains and sprockets without
delay
starEX 800 DBE-04567A PAGE 100 / 111

6. MAINTENANCE
6.2.7 Belt drives
Cleaning
Belt drives must be free of dirt and oil. Regular cleaning and care increases the
service life of the belts.
NOTE!
Improper cleaning can damage the belts.
Only use compressed air for cleaning!
Do not use sharp or pointed objects!
Other maintenance work

• Check belt tension:
- before initial commissioning
- after a run-in period of roughly 1 week
- then every 1,000 operating hours
• Check belts and belt pulleys every 3 to 6 months (depending on the
type of belt and on the loading):
- for damage and unusual wear patterns (unless otherwise instructed)
- for proper alignment (unless otherwise instructed)
- for heat build-up; temperature must not exceed the specified limit
values during operation
• Check the secure seating of the belt pulleys once a year
• In the case of heavy wear, replace the belts and belt pulleys without
delay
6.2.8 Electrical system

Extended, scheduled shut-downs of the plant can also be used as an opportunity
to check all connection bolts and connection terminals on bus bars and
switchgear. In any case, this check should be performed at least once a year, in
order to avoid possible damage to the electrical equipment.
DANGER!
Before work is done on connections bolts and on connection

terminals, the <Main switch> must always be set to OFF ("0"
starEX 800 DBE-04567A PAGE 101 / 111

6. MAINTENANCE
Before carrying out work on the connection bolts and connection

terminals on the <Main switch>, the supply line must be de-
energised!
• Check all connection bolts and connection terminals on bus bars and
switchgear for firm seating and, if necessary, tighten them to the
specified tightening torque (see table in Chapter 8.1)
6.2.9 Pneumatic system
WARNING!
been switched off.
Before performing maintenance work on the pneumatic system, it
is vital that you depressurise the system!
• Check the pneumatic lines once a week for leak-tightness, damage and
wear, and replace if necessary
• Check for proper fastening
• On the maintenance unit:
- Empty the water separator once a week
- Clean the filter once a week and replace if necessary
starEX 800 DBE-04567A PAGE 102 / 111

6. MAINTENANCE
6.2.10 Water circuit

• Check water circuit and cooling function of the air/water heat exchanger
• Perform a visual check of water pipelines for separated lagging, kinks,
dents or weak points.
• Check water connections
• Check the flow indicator (1) on the water distributor daily
Fig. 4567/6001
1 Flow indicator 3 Hex cap nut

2 Sieve 4 Lever
If the water distributor is soiled, the sieve (2) must be cleaned.
Procedure
1. Shut off the supply with the lever (4)
2. Undo the hex cap nut (3)
3. Pull out the sieve (2) and clean with water, check for damage, replace
with a new one if necessary
4. Insert the sieve (2)
5. Install the hex cap nut (3)
starEX 800 DBE-04567A PAGE 103 / 111

7. TROUBLESHOOTING
7 TROUBLESHOOTING
All troubleshooting tasks which are performed must be recorded in a system

logbook, including the respective number of operating hours.
For further information on troubleshooting for the individual plant

components see the respective module manual and technical
manual.
For further information on troubleshooting, see the starEX display

user manual.
Plant is stopped
Causes Remedy
Check the pneumatic system (see
Plant pressure was exceeded
Chapter 4.1, 6.2.9 and the Layout plan)
Film web torn at the water bath

Causes Remedy
• Check the take-down motor
• Motor protection (see Chapter 7.1)
• Stop the extruder
Fault on the water-bath take-down motor
• Remove the film web from the water
bath
• Clean the pan on the water bath
• Check the temperature on the display
(see the starEX display user manual)
• Check the water circuit (see Chapter
Water temperature > 60°C 6.2.10)
• Check the pumps
• Check the cooling unit
• Check the heat exchanger
starEX 800 DBE-04567A PAGE 104 / 111

7. TROUBLESHOOTING
Melt escaping at the automatic filter

Causes Remedy
• Check the temperature on the display
(see the starEX display user manual)
Cooling system on the extruder defective 6.2.10)
• Check the pumps
Bobbins on the winding machine are hot

Causes Remedy
6.2.10)
Cooling system of the chill roller on the • Check the pumps
stretching unit failed – tapes are hot
Heater is switched off

Causes Remedy
Check and replace if necessary (see the
Temperature sensor defective
manufacturer's documentation)
Max. temperature was exceeded: • Check the temperature sensor and

replace if necessary
• Heater (general): 350°C
• Check the adjustment on the display
• Oil heating device (see the starEX display user manual)
(according to the version): 180°C
• Check the connections (see thecircuit
• Hot air zone: 230°C diagram)
starEX 800 DBE-04567A PAGE 105 / 111

7. TROUBLESHOOTING
7.1 Motor protection/thermal relay fault

If the motor protection has tripped, proceed as follows:
• Compare set current value on the triggering device with the value on the
motor type plate
• Check mains supply
• Check motor temperature
• Check terminal connections for tight fit (also on the motor terminal
board)
• Check motor for ease of movement (bearings)
• Heed the direction of rotation
• Check the lines to the motor (short circuit and earth)
• Measure voltage/current
starEX 800 DBE-04567A PAGE 106 / 111

8. ENCLOSURES
8 ENCLOSURES
8.1 Tightening torques

The maximum permissible tightening torques in the table are based on VDI 2230
and apply to:
• Hex bolts, ISO 4014-4018
• Hex socket head cap screws, ISO 4762
• Bolts with analogous head rigidity and head bearing surfaces of
strength categories 8.8-12.9
at a 90% utilisation of the yield point ReL/0.2%-yield strength Rp0.2.
NOTE!
The tightening torques in the following table are permissible
maximum values and do not incorporate any safety factors!
Only use them where no other tightening torques are specified
(see particularly the information from the manufacturer)!
Strength categories in accordance with ISO

Width across 898/1
Thread
flats
M 8.8 10.9 12.9
s
Max. tightening torque (Nm)
M4 7 2.6 3.9 4.5
M5 8 5.2 7.6 8.9
M6 10 9 13.2 15.4
M8 13 21.6 31.8 37.2
M10 17 43 63 73
M12 19 73 108 126
M16 24 180 264 309
M20 30 363 517 605
M24 36 625 890 1041
M30 46 1246 1775 2077
M36 55 2164 3082 3607
starEX 800 DBE-04567A PAGE 107 / 111

8. ENCLOSURES
8.2 Testing methods
For information on the required testing methods, see the Testing

methods manual.
8.3 Calculating the tape width

bA = bV x √i
bA unstretched tape (width of cut) in mm
bV stretched tape (tape width) in mm
i Total stretch ratio
8.4 Test report

The test report must contain the following information:
• type and name of sample
• date of manufacture
• number of samples
• thread count in tex or denier
• test date
The following test report template can be used to enter the values for the
respective test.
starEX 800 DBE-04567A PAGE 108 / 111

8. ENCLOSURES
Test report
starEX: ______________________________ Date: _________________________________

Customer: ___________________________ Nominal denier value: ___________________
Test number: _________________________ Nominal tape width [mm]: ________________
Report number: _______________________ Material: ______________________________
Technician: __________________________ Additive 1: _____________________________
Screw speed [rpm]: ____________________ Additive 2: _____________________________
Melt pump speed [rpm]: ________________ Additive 3: _____________________________
Production speed [m/min]: ______________ Additive 4: _____________________________
Thick- Linear Linear Specific Specific Elongation Elongation Residual

Bobbin Tape width
ness density density strength strength F max at break shrinkage
no. [mm]
[µ] [tex] [den] [cN/tex] [g/den] [%] [%] [%]
10
11
12
Performed by:
Comments:
starEX 800 DBE-04567A PAGE 109 / 111

8.5
starEX 800
Knife width REQUIRED TAPE WIDTH WORKING WIDTH Knife SPACER REQUIRED
0,15mm 1 1,3 1,5 1,8 2 2,3 2,5 2,8 3 3,3 3,5 3,8 4 4,3 4,5 4,8 5 5,3 5,5 5,8 6 2100 1650 930 spacer 1 1,5 2 1,3 3 3,5 4 4,5 5
NUMBER OF TAPES width QUANTITY
2 4,6 2,15 1025 800 440 2 1
2,25 5,8 2,4 911 711 391 2,25 1 1
2,5 7,0 4,5 2,65 820 640 352 2,5 1 1
2,75 8,4 5,4
THEORETICALLY REQUIRED 2,9 745 581 320 2,75 1 1
3 9,9 6,4 4,4 3,15 683 533 293 3 1
3,25 11,6 7,4 5,1 STRETCHING RATIO 3,4 630 492 270 3,25 1 1
3,5 13,3 8,5 5,9 4,4 3,65 585 457 251 3,5 1
3,75 15,2 9,7 6,8 5,0 3,9 546 426 234 3,75 3
4 17,2 11,0 7,7 5,6 4,3
(Knife width = 0,15mm) 4,15 512 400 220 4 1
4,25 19,4 12,4 8,6 6,3 4,8 4,4 482 376 207 4,25 1 1
4,5 21,6 13,8 9,6 7,1 5,4 4,3 4,65 455 355 195 4,5 1
4,75 24,0 15,4 10,7 7,8 6,0 4,7 4,9 431 336 185 4,75 1 1
5 26,5 17,0 11,8 8,7 6,6 5,2 4,2 5,15 410 320 176 5 1
5,25 29,2 18,7 13,0 9,5 7,3 5,8 4,7 5,4 390 304 167 5,25 1 1
5,5 31,9 20,4 14,2 10,4 8,0 6,3 5,1 4,2 5,65 372 290 160 5,5 2 1
Blade spacer table
5,75 34,8 22,3 15,5 11,4 8,7 6,9 5,6 4,6 5,9 356 278 153 5,75 1 1
6 37,8 24,2 16,8 12,4 9,5 7,5 6,1 5,0 4,2 6,15 341 266 146 6 2
6,25 41,0 26,2 18,2 13,4 10,2 8,1 6,6 5,4 4,6 6,4 328 256 140 6,25 1 1
6,5 44,2 28,3 19,7 14,4 11,1 8,7 7,1 5,8 4,9 4,2 6,65 315 246 135 6,5 1 1
6,75 47,6 30,5 21,2 15,5 11,9 9,4 7,6 6,3 5,3 4,5 6,9 303 237 130 6,75 3 1
7 51,1 32,7 22,7 16,7 12,8 10,1 8,2 6,8 5,7 4,8 4,2 7,15 292 228 125 7 1 1
7,25 54,8 35,0 24,3 17,9 13,7 10,8 8,8 7,2 6,1 5,2 4,5 7,4 282 220 121 7,25 1 2
7,5 58,5 37,5 26,0 19,1 14,6 11,6 9,4 7,7 6,5 5,5 4,8 4,2 7,65 273 213 117 7,5 1 1
7,75 62,4 39,9 27,7 20,4 15,6 12,3 10,0 8,3 6,9 5,9 5,1 4,4 7,9 264 206 113 7,75 1 1 1
8 66,4 42,5 29,5 21,7 16,6 13,1 10,6 8,8 7,4 6,3 5,4 4,7 4,2 8,15 256 200 110 8 2
8,25 70,6 45,2 31,4 23,0 17,6 13,9 11,3 9,3 7,8 6,7 5,8 5,0 4,4 8,4 248 193 106 8,25 1 1 1
8,5 74,8 47,9 33,3 24,4 18,7 14,8 12,0 9,9 8,3 7,1 6,1 5,3 4,7 4,1 8,65 241 188 103 8,5 1 1
8,75 79,2 50,7 35,2 25,9 19,8 15,6 12,7 10,5 8,8 7,5 6,5 5,6 5,0 4,4 8,9 234 182 100 8,75 1 1 1
DBE-04567A
Fig. 4567/8001
9 83,7 53,6 37,2 27,3 20,9 16,5 13,4 11,1 9,3 7,9 6,8 6,0 5,2 4,6 4,1 9,15 227 177 97 9 2
9,25 88,4 56,6 39,3 28,9 22,1 17,5 14,1 11,7 9,8 8,4 7,2 6,3 5,5 4,9 4,4 9,4 221 172 95 9,25 1 2
9,5 93,1 59,6 41,4 30,4 23,3 18,4 14,9 12,3 10,3 8,8 7,6 6,6 5,8 5,2 4,6 4,1 9,65 215 168 92 9,5 1 1
8. ENCLOSURES
KNIFE SPACER WIDTH

9,75 98,0 62,7 43,6 32,0 24,5 19,4 15,7 13,0 10,9 9,3 8,0 7,0 6,1 5,4 4,8 4,3 9,9 210 164 90 9,75 1 1 1
10 103,0 65,9 45,8 33,6 25,8 20,4 16,5 13,6 11,4 9,8 8,4 7,3 6,4 5,7 5,1 4,6 4,1 10,15 205 160 88 10 2
10,25 108,2 69,2 48,1 35,3 27,0 21,4 17,3 14,3 12,0 10,2 8,8 7,7 6,8 6,0 5,3 4,8 4,3 10,4 200 156 85 10,25 1 2

10,5 113,4 72,6 50,4 37,0 28,4 22,4 18,1 15,0 12,6 10,7 9,3 8,1 7,1 6,3 5,6 5,0 4,5 4,1 10,65 195 152 83 10,5 1 1 1
10,75 118,8 76,0 52,8 38,8 29,7 23,5 19,0 15,7 13,2 11,2 9,7 8,4 7,4 6,6 5,9 5,3 4,8 4,3 10,9 190 148 81 10,75 1 1 1
11 124,3 79,6 55,3 40,6 31,1 24,6 19,9 16,4 13,8 11,8 10,1 8,8 7,8 6,9 6,1 5,5 5,0 4,5 4,1 11,15 186 145 80 11 1 2
11,25 130,0 83,2 57,8 42,4 32,5 25,7 20,8 17,2 14,4 12,3 10,6 9,2 8,1 7,2 6,4 5,8 5,2 4,7 4,3 11,4 182 142 78 11,25 1 2
11,5 135,7 86,9 60,3 44,3 33,9 26,8 21,7 17,9 15,1 12,8 11,1 9,7 8,5 7,5 6,7 6,0 5,4 4,9 4,5 4,1 11,65 178 139 76 11,5 1 1 1
11,75 141,6 90,6 62,9 46,2 35,4 28,0 22,7 18,7 15,7 13,4 11,6 10,1 8,9 7,8 7,0 6,3 5,7 5,1 4,7 4,3 11,9 174 136 74 11,75 1 1 1 1
12 147,6 94,5 65,6 48,2 36,9 29,2 23,6 19,5 16,4 14,0 12,1 10,5 9,2 8,2 7,3 6,5 5,9 5,4 4,9 4,5 4,1 12,15 170 133 73 12 1 1 1
12,25 153,8 98,4 68,3 50,2 38,4 30,4 24,6 20,3 17,1 14,6 12,6 10,9 9,6 8,5 7,6 6,8 6,2 5,6 5,1 4,7 4,3 12,4 167 130 71 12,25 1 2 1
12,5 160,0 102,4 71,1 52,3 40,0 31,6 25,6 21,2 17,8 15,2 13,1 11,4 10,0 8,9 7,9 7,1 6,4 5,8 5,3 4,8 4,4 12,65 164 128 70 12,5 1 2
12,75 166,4 106,5 74,0 54,3 41,6 32,9 26,6 22,0 18,5 15,8 13,6 11,8 10,4 9,2 8,2 7,4 6,7 6,0 5,5 5,0 4,6 12,9 160 125 69 12,75 1 1 1 1
13 172,9 110,7 76,9 56,5 43,2 34,2 27,7 22,9 19,2 16,4 14,1 12,3 10,8 9,6 8,5 7,7 6,9 6,3 5,7 5,2 4,8 13,15 157 123 67 13 2 1
13,25 179,6 114,9 79,8 58,6 44,9 35,5 28,7 23,7 20,0 17,0 14,7 12,8 11,2 9,9 8,9 8,0 7,2 6,5 5,9 5,4 5,0 13,4 154 120 66 13,25 1 1 1 1
13,5 186,3 119,2 82,8 60,8 46,6 36,8 29,8 24,6 20,7 17,6 15,2 13,2 11,6 10,3 9,2 8,3 7,5 6,8 6,2 5,6 5,2 13,65 151 118 65 13,5 1 1 1
13,75 193,2 123,7 85,9 63,1 48,3 38,2 30,9 25,5 21,5 18,3 15,8 13,7 12,1 10,7 9,5 8,6 7,7 7,0 6,4 5,8 5,4 13,9 149 116 64 13,75 1 1 1 1
14 200,2 128,1 89,0 65,4 50,1 39,6 32,0 26,5 22,2 19,0 16,3 14,2 12,5 11,1 9,9 8,9 8,0 7,3 6,6 6,1 5,6 14,15 146 114 62 14 2 1
Spe cial distance s for narrow tape s (1 - 1,25mm)
PAGE 110 / 111

8. ENCLOSURES
NOTES
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
..............................................................................................................................
starEX 800 DBE-04567A PAGE 111 / 111


Dbe 04567aeng

Uploaded by

Copyright:

Available Formats

Dbe 04567aeng

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Dbe 04567aeng

Uploaded by

Copyright:

Available Formats

PLANT MANUAL

Doc. no.: DBE-04567A Language: English

Warranty and liability

starEX 800 DBE-04567A PAGE 2 / 111

ABOUT THIS DOCUMENT............................................................................................... 6

starEX 800 DBE-04567A PAGE 3 / 111

5.3.8 Preparing the precision fibrillator (optional) ............................................... 59

starEX 800 DBE-04567A PAGE 4 / 111

8.4 Test report ...................................................................................................... 108

starEX 800 DBE-04567A PAGE 5 / 111

ABOUT THIS DOCUMENT

Notation Representation Example

starEX 800 DBE-04567A PAGE 6 / 111

Indicator word Meaning

Risk of injuries to the hands

Risk of being drawn in

Risk of foot injury

starEX 800 DBE-04567A PAGE 7 / 111

Warning - fibrillating roller

Danger from electric current

Risk of being drawn in

Warning: magnetic field

Prohibited for persons with heart pacemakers!

Wear safety gloves!

Hearing protection mandatory!

Wear eye protection!

starEX 800 DBE-04567A PAGE 8 / 111

Switch off before performing work!

Pay attention to the operating instructions!

This document contains additional pictograms with various purposes. The

Reference to further information

Terms and abbreviations

starEX 800 DBE-04567A PAGE 9 / 111

1.1 Area of application and intended use

Working on the plant

The plant is designed for two-person operation.

1.2 Method of operation

starEX 800 DBE-04567A PAGE 10 / 111

1.3 Plant design

1 Volumetric dosing unit with feed station

starEX 800 DBE-04567A PAGE 11 / 111

voluTEC volumetric dosing unit with feed station

For further information on the volumetric dosing unit with feed

For further information on the wide-slit die, see the manufacturer's

Water bath with integrated holding frame

starEX 800 DBE-04567A PAGE 12 / 111

Lengthways cutting mechanism

Film web oscillator

Edge strip extractor

Hot air zone

starEX 800 DBE-04567A PAGE 13 / 111

Oil heating device

Tape extraction system

starEX 800 DBE-04567A PAGE 14 / 111

Display (central control unit)

Other operating units

graviTEC gravimetric batch dosing unit with feed station

For further information on the gravimetric batch dosing unit, see

starEX 800 DBE-04567A PAGE 15 / 111

Lowering frame with guide rollers