MODULE MANUAL

starEX 800
Tape system
E-90 and E-105
extruders

Doc. no.: DBE-04568B 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.

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 TABLE OF CONTENTS

ABOUT THIS DOCUMENT............................................................................................... 5

1 TECHNOLOGICAL DESCRIPTION ............................................................................ 8
1.1 Method of operation ............................................................................................ 8
1.2 Standard model................................................................................................... 8
1.3 Option ................................................................................................................. 9
2 TECHNICAL DATA ................................................................................................... 10
2.1 E90 extruder ..................................................................................................... 10
2.2 E-105 extruder .................................................................................................. 11
2.3 Type plate ......................................................................................................... 11
3 INSTALLATION......................................................................................................... 12
3.1 Installation site .................................................................................................. 12
3.2 Assembly .......................................................................................................... 12
3.2.1 Electrical connection ................................................................................. 16
3.2.2 Water connection ...................................................................................... 16
4 SETTINGS ................................................................................................................ 17
4.1 Temperature ..................................................................................................... 18
4.2 Screw rotational speed...................................................................................... 18
4.3 Melt pump (optional) ......................................................................................... 18
4.4 Automatic filter .................................................................................................. 19
4.4.1 Filter tape feed .......................................................................................... 19
4.4.2 Adjusting the feed system of the hopper ................................................... 20
5 COMMISSIONING AND OPERATION ...................................................................... 21
5.1 Controls ............................................................................................................ 21
5.1.1 Switches ................................................................................................... 21
5.1.2 Push buttons ............................................................................................. 22
5.2 Tightening torques for melt-carrying parts ......................................................... 23
5.3 Automatic filter .................................................................................................. 25
5.3.1 Inserting the filter tapes............................................................................. 25
5.3.2 Adjusting the melt barrier .......................................................................... 27
5.3.3 Adjusting the filter tape brake.................................................................... 28
5.4 Forming a plastic plug during initial operation ................................................... 29
5.5 Moving the plastic plug manually on the E-105 extruder ................................... 30
6 MAINTENANCE ........................................................................................................ 32
6.1 Lubrication ........................................................................................................ 33
6.1.1 E-90 extruder ............................................................................................ 34
6.1.2 E-105 extruder .......................................................................................... 35
6.2 Lubrication chart ............................................................................................... 36
6.2.1 Oils ........................................................................................................... 36
6.2.2 Greases .................................................................................................... 37

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 TABLE OF CONTENTS

6.3 Maintenance overview ...................................................................................... 38

6.3.1 Daily maintenance tasks ........................................................................... 39
6.3.2 Weekly maintenance tasks ....................................................................... 39
6.3.3 Monthly maintenance tasks....................................................................... 39
6.3.4 Six-monthly maintenance tasks ................................................................ 39
6.3.5 Annual maintenance tasks ........................................................................ 39
6.3.6 Electrical system ....................................................................................... 40
6.3.7 Water circuit .............................................................................................. 40
6.4 Specific maintenance tasks ............................................................................... 40
6.4.1 Replacing the heating sleeve .................................................................... 41
6.4.2 Cleaning parts coated in plastic melt......................................................... 43
6.4.3 Maintenance work on the melt discharge unit ........................................... 45
6.4.4 Extracting the extruder screw.................................................................... 46
6.4.5 Cleaning the extruder screw ..................................................................... 55
6.4.6 Cleaning the screw cylinder ...................................................................... 56
6.4.7 Filter with melt mixer ................................................................................. 59
6.4.8 Filter with melt mixer and melt pump (optional) ......................................... 61
6.4.9 Checking the drive shafts .......................................................................... 63
6.4.10 Replace the drive shaft in the extruder gearbox ........................................ 64
6.4.11 Replacing the drive shaft in the belt pump (optional) ................................. 67
6.4.12 Metal separator ......................................................................................... 68
7 TROUBLESHOOTING .............................................................................................. 70
7.1 Extruder ............................................................................................................ 70
7.2 Automatic filter .................................................................................................. 71
7.3 Melt pump (optional) ......................................................................................... 72
8 ENCLOSURES ......................................................................................................... 73
Tightening torques .................................................................................................... 73

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 ABOUT THIS DOCUMENT

ABOUT THIS DOCUMENT

Information
This document is part of the family of documents on 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"
(Push) button, switch Angle brackets <Main switch>

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 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 module 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 burns

Warning: magnetic field

Prohibited for persons with heart pacemakers!

Wear safety gloves!

Wear eye protection!

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 ABOUT THIS DOCUMENT

Danger from electric current

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 E-90 and E-105 extruders are referred to in short as "the
extruder" or "the plant module", and the automatic filter as "the filter" or "the plant
module". 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.

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 1. TECHNOLOGICAL DESCRIPTION

1 TECHNOLOGICAL DESCRIPTION

1.1 Method of operation

The material is supplied to the extruder for processing.
In the extruder a screw transports the material through a heated cylinder and on
to the next plant module. At the same time the material is plasticised and
homogenised. The pressurised material passes through the filter, and then on to
the wide-slit die.

1.2 Standard model

The following figure provides an overview of the most important components of
the plant module:

Fig. 4568/1001

1 Extruder screw 4 Melt mixer

2 Extruder drive 5 Extruder gearbox
3 Automatic filter 6 Hopper with metal separator

The figure serves as an example only.

We reserve the right to modify the technical specifications as part
of the technological development process.

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 1. TECHNOLOGICAL DESCRIPTION

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.

1.3 Option
The following option is available for the plant module:

Melt pump
The melt pump is located between the automatic filter and the melt mixer. The
pump generates a consistent melt pressure, which improves the melt discharge
at the wide-slit die and increases the output rate of the extruder.

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 2. TECHNICAL DATA

2 TECHNICAL DATA

2.1 E90 extruder

Extruder
Screw diameter D 90 mm
Screw length L 30 D
Screw rotational speed 0 - 180 rpm
Drive power 138 kW
Number of heating zones 6
Heating capacity 37.8 kW
Max. melting capacity 300 kg/h*
*Standard value, deviations possible

Filter and melt mixer

Heating capacity of filter and cylinder flange 6.55 kW
Heating capacity of melt mixer and die flange 6.6 kW

Melt pump (optional)

3
Output 92.6 cm /rev.
Heating capacity of adapter and melt pump 5.25 kW
Drive power 7.5 kW
Heating capacity of melt mixer and die flange 6.05 kW

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 2. TECHNICAL DATA

2.2 E-105 extruder

Extruder
Screw diameter D 105 mm
Screw length L 30 D
Screw rotational speed 0 - 160 rpm
Drive power 151 kW
Number of heating zones 6
Heating capacity 50.4 kW
Max. melting capacity 430 kg/h*
*Standard value, deviations possible

Filter and melt mixer

Heating capacity of filter and cylinder flange 7.35 kW
Heating capacity of melt mixer and die flange 8.7 kW

Melt pump (optional)

3
Output 176 cm /rev.
Heating capacity of adapter and melt pump 7.25 kW
Drive power 7.5 kW
Heating capacity of melt mixer and die flange 6.45 kW

2.3 Type plate

The type plate of the extruder is located on the base frame.

Fig. 4568/2001

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 3. INSTALLATION

3 INSTALLATION

3.1 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 permissible loading
capacity of the floor must be at least 25,000 N/m².

3.2 Assembly
The plant module is 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!
Damaged hydraulic hoses can cause damage to property! Never
kink, crush, rupture, pull or drive over hoses!

NOTE!
Use the supplied special tools, supplies and spare parts, and then
store them in the proper manner after work is complete.

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 3. INSTALLATION

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.

Extruder

Fig. 4568/3003

1 Extruder frame 4 Bracket

2 Extruder 5 Nuts
3 Feet X Load attachment point

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 3. INSTALLATION

Procedure
1. Attach a lifting device to the load bearing points (X) on the extruder
frame (1)
2. Lift up the extruder (2) with a suitable lifting device
3. Position the extruder (2) in accordance with the Layout plan
4. Position the feet (3) under the bracket (4)
5. Align horizontally (level) with the nuts (5)
- Check that the safety bar is horizontally aligned (level) using a spirit
level
6. Remove all transport locks

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 3. INSTALLATION

Hopper with metal separator

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!

Fig. 4568/3004

1 Adapter 4 Metal separator

2 Extruder cylinder 5 Transfer piece
3 Pellet hopper

Procedure
1. Fit the adapter (1) onto the extruder cylinder (2)
2. Fit the pellet hopper (3) to the adapter (1)
3. Fit the metal separator (4) to the pellet hopper (3)
4. Fit the transfer piece (5) to the metal separator (4)

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 3. INSTALLATION

3.2.1 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.

3.2.2 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.

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 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!

For further information on switching off the plant, see the starEX
plant manual.

WARNING!
When working at heights, a suitable safety harness must be used!

For further information on the settings for purchased components,

see the manufacturer's documentation.

For further information on the settings, see the starEX plant

manual and starEX display user manual.

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!

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 4. SETTINGS

4.1 Temperature
The temperature for the temperature zones is adjusted on the display (see the
starEX display user manual).
Each heating zone is electrically safeguarded separately according to the heating
zone load anticipated for the plant.
If the measurement circuit is broken, the thermocouple circuit breaker responds
and the heater remains switched off.
The extruder switching cabinet contains the electronic controls for the heating
zones and the cooling fans.
The temperature must be adjusted for the following zones:
• Extruder
• Automatic filter
 The temperature depends on the material. The temperature of the
last extruder cylinder zone is useful as a guide.

4.2 Screw rotational speed

The screw speed depends on the kind of material being processed and is set in
the display (see starEX display user manual).

4.3 Melt pump (optional)

The speed of the melt pump depends on the thickness and width of the film web
and is set on the display (see the starEX display user manual).

For further information on the settings on the melt pump, see the
manufacturer's documentation.

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 4. SETTINGS

4.4 Automatic filter

The plastic plug (4) formed at the filter output (3) in the water-cooled area is
continuously under pressure. In the event of an automatic change of the filter
area, the installed heating elements soften the front of the plastic plug (4) at the
filter output (3). The filter tape (1) is stuck fast by this plug. If the plug becomes
flexible due to heating, the filter tape (1) moves on, resulting in a change in the
filter area.

Fig. 4568/4011

1 Filter tapes (coarse and fine) 4 Plastic plug

3 Filter output

4.4.1 Filter tape feed

The heat volume required for the filter tape feed is dependent on the material to
be processed and on the melt pressure. The amount of dirt determines the filter
tape feed interval necessary.
If the feed interval is too low, the temperature must be increased. The setting for
the automatic filter controller is adjusted on the display (see the starEX display
user manual).

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 4. SETTINGS

4.4.2 Adjusting the feed system of the hopper

During operation, the material in the hopper (1) must always be kept above the
min. fill level (2). The feed / fill level are adjusted on the display (see the starEX
display user manual).

Fig. 4568/4012

1 Hopper 2 Min. fill level

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 5. COMMISSIONING AND OPERATION

5 COMMISSIONING AND OPERATION

For information on the commissioning and operation of the plant,

see the starEX plant manual and the starEX display user manual.

5.1 Controls

5.1.1 Switches
The following figure shows the switch for manual operation of the automatic filter
on the E-105 extruder. The switch is located on the extruder switching cabinet
(see the Layout plan).

Fig. 4568/5005

<Filter tape> switch

Left Top heating element in operation
1
Centre Top and bottom heating elements in operation
Right Bottom heating element in operation

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 5. COMMISSIONING AND OPERATION

5.1.2 Push buttons

The following figures depict the push buttons for operating the extruder. The push
buttons are located on the water bath with integrated holding frame (see also the
starEX plant manual).

Fig. 4568/5009

<START extruder> push button

Lights up
1 Extruder is in operation
green
No indicator Extruder is not in operation

Fig. 4568/5010

<STOP extruder> push button

2 Pressing the <STOP extruder> push button stops the extruder.
The indicator in the <START extruder> push button goes out.

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 5. COMMISSIONING AND OPERATION

5.2 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!

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 5. COMMISSIONING AND OPERATION

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. 4568/5007

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 5. COMMISSIONING AND OPERATION

5.3 Automatic filter

To commission the automatic filter, proceed as follows:
• Insert the filter tapes
• Adjust the melt barrier
• Adjust the filter tape brake

5.3.1 Inserting the filter tapes

Fig. 4568/5001

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)

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 5. COMMISSIONING AND OPERATION

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. 4568/5011)
7. Fit the covers (4) with the knurled nuts (3)
8. Fit the cover (1) with the star knobs (2)

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 5. COMMISSIONING AND OPERATION

5.3.2 Adjusting the melt barrier

Once the filter tapes (12 and 13) have been inserted, the melt barrier (5) must be
adjusted.

Fig. 4568/5002

5 Melt barrier 8 Nuts

6 Bolts 12 Coarse filter tape
7 Grub screws 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)

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 5. COMMISSIONING AND OPERATION

5.3.3 Adjusting the filter tape brake

After adjusting the melt barrier, the filter tape brake must be adjusted.

Fig. 4568/5003

9 Springs 12 Coarse filter tape

10 Nuts 13 Fine filter tape
11 Nuts 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.

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 5. COMMISSIONING AND OPERATION

5.4 Forming a plastic plug during initial operation

To form a plastic plug, the heat-through period must have elapsed (see the
starEX plant manual and starEX display user manual).

Fig. 4568/5011

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 is switched off.
 The plastic melt hardening at the filter outflow (3) forms a plastic
plug (4).

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 5. COMMISSIONING AND OPERATION

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
(see Chapter 5.1.2)
 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!

5.5 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 5.1.1).

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.

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 5. COMMISSIONING AND OPERATION

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.

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 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"
position) and be safeguarded against being switched back on!

For further information on switching off the plant, see the starEX
plant manual.

WARNING!
When working at heights, a suitable safety harness must be used!

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

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 6. MAINTENANCE

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

NOTE!
Damaged hoses can cause property damage!
Never kink, crush, rupture, pull or drive over hoses!

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!

6.1 Lubrication
In order to achieve optimum performance and largely eliminate operational faults,
the plant module must be lubricated using suitable lubricants (see lubrication
chart in Chapter 6.2) at regular intervals.

NOTE!
Potential for damage to property from inadequate lubrication!
Mixing different oils and greases must be avoided at all costs!

The specified lubricant amounts are recommended amounts. The

decisive measure of the amounts to be used are the marks on the
respective component (sight glass, dipstick, etc.).

Special instructions on the proper lubrication of purchased

components can be found on the respective type plates or in the
manufacturer's documentation.
Follow the instructions of the manufacturer!

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 6. MAINTENANCE

6.1.1 E-90 extruder

Fig. 4568/6001

Lubrication point Lubricant DIN 51502 Quantity Interval

Gear oil After 8,000 operating
1.1 Gearbox for extruder mineral-oil CLP 220 50 litres hours (at least every
based 18 months)
Petamo
Drive shaft on Every 2,000 operating
1.2 GHY 441 - -
extruder drive hours
from Klüber
Gear motor for melt Synthetic gear CLP HC Every 25,000
1.3 6.5 litres
pump* oil 320 operating hours
Gear motor roller Petamo 133N Every 25,000
1.3 - -
bearing from Klüber operating hours
Petamo
Drive shaft on melt Every 1,500 operating
1.4 GHY 441 - -
pump* hours
from Klüber
* Optional

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 6. MAINTENANCE

6.1.2 E-105 extruder

Fig. 4568/6002

Lubrication point Lubricant DIN 51502 Quantity Interval

Gear oil After 8,000 operating
2.1 Gearbox for extruder mineral-oil CLP 220 50 litres hours (at least every
based 18 months)
Petamo
Drive shaft on Every 2,000 operating
2.2 GHY 441 - -
extruder drive hours
from Klüber
Gear motor for melt Synthetic gear CLP HC Every 25,000
2.3 14 litres
pump* oil 320 operating hours
Gear motor roller Petamo 133N Every 25,000
2.3 - -
bearing from Klüber operating hours
Petamo
Drive shaft on melt Every 1,500 operating
2.4 GHY 441 - -
pump* hours
from Klüber
* Optional

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 6. MAINTENANCE

6.2 Lubrication chart

The following tables provide information about which lubricants are suitable for
lubricating the plant. Other lubricants may only be used if they are shown to have
similar properties.

6.2.1 Oils

Labelling in
accordance with Lubricant
DIN 51502

Velocite Oil
HL 10 Hydraulic oil ---------- Hyspin AWS 10 ---------- Morlina S2 BL 10
No. 6

HL 32 Hydraulic oil ---------- Hyspin AWS 32 ---------- DTE Oil Light Tellus S2 M 32

HL 46 Hydraulic oil ---------- Hyspin AWS 46 ---------- DTE Oil Medium Morlina S2 B 46

Energol
HLP 32 Hydraulic oil Hyspin AWS 32 LAMORA HLP 32 DTE 24 Tellus S2 M 32
HLP HM 32

Energol
HLP 46 Hydraulic oil Hyspin AWS 46 LAMORA HLP 46 DTE 25 Tellus S2 M 46
HLP HM 46

Energol
HLP 68 Hydraulic oil Hyspin AWS 68 LAMORA HLP 68 DTE 26 Tellus S2 M 68
HLP HM 68

Energol
HLP 100 Hydraulic oil Hyspin AWS 100 ---------- DTE 27 Tellus S2 M 100
HLP HM 100

Energol Mobil Hydraulic Oil

HLPD 32 Hydraulic oil Hyspin DSP 32 ---------- Tellus S2 MA 32
HLP D 32 HLPD 32

Energol Mobil Hydraulic Oil

HLPD 46 Hydraulic oil Hyspin DSP 46 ---------- Tellus S2 MA 46
HLP D 46 HLPD 46

Energol Mobil Hydraulic Oil

HLPD 68 Hydraulic oil Hyspin DSP 68 ---------- ----------
HLP D 68 HLPD 68

Bartran
HVLP 32 Hydraulic oil Hyspin AWH-M 32 ---------- Mobil SHC 524 Tellus S2 V 32
HV 32

Bartran
HVLP 46 Hydraulic oil Hyspin AWH-M 46 ---------- Mobil SHC 525 Tellus S2 V 46
HV 46

Bartran
HVLP 68 Hydraulic oil Hyspin AWH-M 68 ---------- Mobil SHC 526 Tellus S2 V 68
HV 68

Gear oil Energol Klüberoil Mobilgear

CLP 68 ALPHA SP 68 Omala S2 G 68
mineral-oil based GR-XP 68 GEM 1-68 N 600 XP 68

Gear oil Energol Klüberoil Mobilgear

CLP 100 ALPHA SP 100 Omala S2 G 100
mineral-oil based GR-XP 100 GEM 1-100 N 600 XP 100

Gear oil Energol Klüberoil Mobilgear

CLP 150 ALPHA SP 150 Omala S2 G 150
mineral-oil based GR-XP 150 GEM 1-150 N 600 XP 150

Gear oil Energol Klüberoil Mobilgear

CLP 220 ALPHA SP 220 Omala S2 G 220
mineral-oil based GR-XP 220 GEM 1-220 N 600 XP 220

Gear oil Energol Klüberoil Mobilgear

CLP 320 ALPHA SP 320 Omala S2 G 320
mineral-oil based GR-XP 320 GEM 1-320 N 600 XP 320

Gear oil Energol Klüberoil Mobilgear

CLP 460 ALPHA SP 460 Omala S2 G 460
mineral-oil based GR-XP 460 GEM 1-460 N 600 XP 460

Gear oil Energol Klüberoil Mobilgear

CLP680 ALPHA SP 680 Omala S2 G 680
mineral-oil based GR-XP 680 GEM 1-680 N 600 XP 680

Synthetic Enersyn Alphasyn Klübersynth

CLPPG150 Glygoyle 22 Omala S4 WE 150
gear oil SG-XP 150 PG 150 GH 6-150

Synthetic Enersyn Alphasyn Klübersynth

CLPPG 220 Glygoyle 30 Omala S4 WE 220
gear oil SG-XP 220 PG 220 GH 6-220

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 6. MAINTENANCE

Labelling in
accordance with Lubricant
DIN 51502

Synthetic Enersyn Alphasyn Klübersynth

CLPPG 320 Glygoyle 320 Omala S4 WE 320
gear oil SG-XP 320 PG 320 GH 6-320

Synthetic Enersyn Alphasyn Klübersynth

CLPPG 460 Glygoyle 460 Omala S4 WE 460
gear oil SG-XP 460 PG 460 GH 6-460

Synthetic Enersyn Alphasyn Klübersynth

CLPPG 680 Glygoyle 680 ----------
gear oil SG-XP 680 PG 680 GH 6-680

Synthetic Enersyn Klübersynth

CLPHC 150 Alphasyn HTX 150 Mobil SHC Gear 150 Omala S4 GX 150
gear oil HTX 150 GEM 4-150 N

Synthetic Enersyn Klübersynth

CLPHC 220 Alphasyn T 220 Mobil SHC Gear 220 Omala S4 GX 220
gear oil HTX 220 GEM 4-220 N

Synthetic Enersyn Klübersynth

CLPHC 320 Alphasyn T 320 Mobil SHC Gear 320 Omala S4 GX 320
gear oil HTX 320 GEM 4-320 N

Synthetic Enersyn Klübersynth

CLPHC 460 Alphasyn T 460 Mobil SHC Gear 460 Omala S4 GX 460
gear oil HTX 460 GEM 4-460 N

CGLP 220 Track oil Maccurat D 220 Magnaglide D220 LAMORA D 220 Vactra Oil No. 4 Tonna S2 M 220

6.2.2 Greases

Labelling in
accordance with Lubricant
DIN 51502

Energrease SPHEEROL
K 2 K-20 Grease CENTOPLEX 2 Mobilux EP2 Gadus S2 V100 2
LS 2 EP 2

Energrease Olista STABURAGS

K 3 K-20 Grease Mobilux EP3 Gadus S2 V100 3
LS 3 Longtime 3 N 12

Energrease Optimol Klüberplex

KP 1 K-20 Grease Mobilkux EP1 Gadus S2 V220 1
LS-EP 1 Longtime PD 1 BEM 41-141

CENTOPLEX
KP 2 K-20 Grease Energrease LZ ALV Mobilux EP 2 Gadus S2 V220 2
2 EP

Energrease Optimol Klüberplex

KP 2 K-30 Grease Mobilith SHC 220 Naturelle EP 2
LS-EP 2 Longtime PD 2 BEM 41-132

Energrease SPHEEROL STABURAGS

K 3 G-20 Grease Mobilux 3 Gadus S2 V100 3
LS 3 AP 3 N 12

Olista STABURAGS
K3N Grease ---------- Unirex N3 Gadus S2 V100 3
Longtime 3 N 12

Klüberplex
GP 00 G-20 Grease ---------- CLS Grease Mobilux EP 004 Gadus S2 V220 00
GE 11-680

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 6. MAINTENANCE

6.3 Maintenance overview

The following table provides information about maintenance work to be carried
out and the corresponding maintenance intervals.

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

For further information on switching off the plant, see the starEX
plant manual.

WARNING!
When working at heights, a suitable safety harness must be used!

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

NOTE!
Damaged hoses can cause property damage!
Never kink, crush, rupture, pull or drive over hoses!

Refer to the manufacturer's documentation for special instructions

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

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 6. MAINTENANCE

6.3.1 Daily maintenance tasks

• Inspect plant module for coarse dirt, and clean if necessary
• Inspect fans of motors and blower filters for dirt and clean them as
necessary

6.3.2 Weekly maintenance tasks

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

6.3.3 Monthly maintenance tasks

• Check safety doors and protective guards for completeness; replace if
necessary
• Check safety stickers are intact; replace if necessary

6.3.4 Six-monthly maintenance tasks

• Check cables and protective sleeves for damage and replace if
necessary

6.3.5 Annual maintenance tasks

• Clean the extruder screw (see Chapter 6.4.5)
• Clean the extruder cylinder (see Chapter 6.4.6)

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6.3.6 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!
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!

• 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)

6.3.7 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

6.4 Specific maintenance tasks

Individual maintenance tasks are explained in detail in the following chapter. The
same safety instructions provided in the maintenance overview apply here.
Specific hazards are addressed individually.

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6.4.1 Replacing the heating sleeve

WARNING!
Hot surfaces and vapours!
Risk of injuries to the eyes and hands

Wear protective gloves when working on the extruder!

Wear eye protection when working on the extruder!

Fig. 4568/6010

1 Cover 4 Retaining straps

2 Heating sleeve 5 Body to be heated
3 Tensioning bolt

Procedure
1. Lift the cover (1)
2. Remove the faulty heating sleeve (2)

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 6. MAINTENANCE

3. Install new heating sleeve (2)

- Tighten the tensioning bolts (3)
4. Close the cover (1)

NOTE!
If the heating sleeve (2) is unevenly positioned, there is a risk of
local overheating, which can lead to the heating resistor burning
out.
The heating sleeve (2) can only give off heat reliably if the
retaining straps (4) press it evenly onto all of the objects to be
heated (5).
Tighten the tensioning bolts (3) for the retaining strap (4) evenly!
The retaining strap (4) elongates on being heated up.
Re-tighten the tensioning bolts (3) again after heating up!

When replacing heating sleeves, the following points must be noted:

• If the heating sleeve is laid over parts which feature large interruptions
in the load-bearing surface (e.g. screw holes), then the following points
should be noted:
- Lay a heat-conducting plate 1 to 3 mm thick under the heating
sleeve (2)

NOTE!
There is a risk of the heating sleeve burning out over a hole (2)!
Use a heat-conducting plate!

- In order to prevent loss of production due to faulty heating sleeves,

we recommend keeping at least one unit of each heating sleeve
design in stock.
- The size and heating power of the heating sleeve should be checked
when replacing defective heating sleeves.

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6.4.2 Cleaning parts coated in plastic melt

WARNING!
Hot surfaces and vapours!
Risk of injuries to the eyes and hands

NOTE!
In order to prevent damage, a suitable mat should be laid on the
assembly table. After the mat is used, all dirt particles must be
removed.

Wear protective gloves when working on the extruder!

Wear eye protection when working on the extruder!

Tools and cleaning materials required

Fig. 4568/6011

1 Brass or aluminium scraper 3 Copper wool

2 Die soap 4 Silicone oil

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 6. MAINTENANCE

Further equipment includes:

• Polishing paste
• High-temperature thread paste (Molykote HSC)
• Cylinder cleaning brush

Important note
• The parts to be cleaned must be brought up to operating temperature of
at least 10 to 20°C above the melt temperature of the particular plastic.
• Aluminium scrapers and brass brushes must be used exclusively in
order to prevent scratching to the sensitive surfaces and sealing faces,
most of which are polished.
- Remove any thick layers of stuck-on material with scrapers
- Remove finer residue with a brush
- Fine plastic residue should be rubbed off hot parts using a cloth
soaked in silicone or copper wool

CAUTION!
Potential for damage to the airways or chemical burns to the skin!
Never use petrol for cleaning!
Ensure that there is good ventilation.

• Areas of the polished surfaces that have become dull must be re-
polished with a commercially-available polishing paste.
• The material-transporting surfaces of the cleaned parts must be
sparingly sprayed or rubbed with silicone oil, in order to avoid oxidation
of the polished surfaces during the heating phase.

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.

CAUTION!
Potential material damage!
Normal machine oil must not be used under any
circumstances for rubbing on the parts, as it will burn and char at
high temperatures, rendering the parts unusable.

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 6. MAINTENANCE

• Parts that are subjected to very high temperatures must be thinly coated
with a high-temperature thread paste (Molykote HSC) prior to
installation!
- All fitted surfaces
- All screw/bolt threads
• In order to assure the leak-tightness of threaded connections, tighten all
screws to the prescribed tightening torques and retighten after approx.
10 min. Unless otherwise stipulated, use the tightening toques specified
in Chapter 8.

6.4.3 Maintenance work on the melt discharge unit

For the maintenance work described in Chapters 6.4.4 to 6.4.8, the insulating
hood must be lifted up.

WARNING!
Hot surfaces and vapours!
Risk of injuries to the eyes and hands

Wear protective gloves when working on the extruder!

Wear eye protection when working on the extruder!

Fig. 4568/6024

1 Insulating hood X Load attachment points

2 Star knobs

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 6. MAINTENANCE

1. Attach and secure the insulating hood (3) to a suitable lifting device
using the load attachment points (X)
2. Loosen the star knobs (2)
3. Lift up the insulating hood (3) with a suitable lifting device

After the maintenance work, position the insulating hood (1) and mount using the
star knobs (2).

6.4.4 Extracting the extruder screw

The extruder screw is driven out of the screw cylinder with the help of the screw
extractor device.

NOTE!
The extruder screw must be removed at 10 to 20°C above the
melting temperature of the plastic in question.

NOTE!
An extruder screw subjected to friction must not be removed using
the screw extractor device!
This can result in damage to the screw extractor device!

NOTE!
All components whose removal is described in this chapter and
the uncovered sealing faces must be cleaned immediately after
removal while still warm from operation (see Chapter 6.4.2 and
the Wide-slit die module manual).
If melt continues to emerge from the removed components, they
must be cleaned immediately while still warm from operation.
Before reinstalling all components, coat the melt pressure and
temperature sensor and the bolts with a high-temperature thread
paste (Molykote HSC).

WARNING!
Hot surfaces and vapours!
Risk of injuries to the eyes and hands

Wear protective gloves when working on the extruder!

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 6. MAINTENANCE

Wear eye protection when working on the extruder!

Removing accessory parts

In order to extract the extruder screw, the extruder must be run until empty and
accessory parts removed.

Procedure
1. Run the extruder until empty (see the starEX plant manual)

Fig. 4568/6023

1 Extruder hopper 2 Plug

2. Empty the extruder hopper (1)

- 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!

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 6. MAINTENANCE

- Insert the cover (2) and secure with a bolt

3. Allow the extruder to run until no more melt flows out of the wide-slit die
4. Stop the plant (see the starEX plant manual)
5. Move back the water bath (see the Water bath with integrated holding
frame module manual)
6. Switch off the heater on the display (see the starEX user manual)

The extruder screw must be dismantled speedily. If the melt is

allowed to go cold, the dismantling process can no longer be
carried out.

7. Unplug the electrical connections (see Circuit diagram)

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!

The heater must be switched off before pulling out the plugs!

8. Switch off the temperature and melt sensors

9. Shut off the cooling water circuit
10. Remove cooling water hoses on the melt filter

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 6. MAINTENANCE

11. Remove the wide-slit die (1)

Fig. 4568/6017

1 Wide-slit die X Load attachment points

- Hold and secure the wide-slit die (1) with a suitable lifting device
using the load attachment points (X)

Fig. 4568/6014

1 Wide-slit die 4 Melt pressure sensor

2 Die flange 5 Temperature sensor
3 Bolts

- Disconnect the melt pressure sensor (4)

- Remove the temperature sensor (5)

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 6. MAINTENANCE

- Undo the bolts (3)

- Remove the wide-slit die (1) with the die flange (2) and set down on
a suitable mat

NOTE!
In order to prevent damage, a suitable mat should be laid on the
assembly table. Before and after the mat is used, all dirt particles
must be removed.

12. Remove the melt mixer and melt pump (optional)

Fig. 4568/6015

4 Melt mixer 8 Temperature sensor

5 Melt pump (optional) 9 Flange joint
6 Pump flange (optional) 10 Nuts
7 Melt pressure sensor

- Attach and secure the melt mixer (4), melt pump (5) (optional) and
pump flange (6) to a suitable lifting device
- Disconnect the melt pressure sensor (7)
- Remove the temperature sensor (8)
- Unscrew the flange joint (9) between the melt pump (optional) (5)
and drive shaft
- Undo the nuts (10)
- Remove the melt mixer (4) with melt pump (optional) (5) and set
down on a suitable mat

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 6. MAINTENANCE

NOTE!
In order to prevent damage, a suitable mat should be laid on the
assembly table. Before and after the mat is used, all dirt particles
must be removed.

13. Remove the automatic filter

Fig. 4568/6016

9 Filter block 11 Temperature sensor

10 Melt pressure sensor 12 Cooling tubes

- Attach and secure the whole filter block (9) to a suitable lifting device

NOTE!
Potential material damage!
The cooling tubes (12) are not load-bearing components, and
must not be used as load attachment points!

- Disconnect the melt pressure sensor (10)

- Remove the temperature sensor (11)
- Remove the filter block (9) and set is down on a suitable mat

NOTE!
In order to prevent damage, a suitable mat should be laid on the
assembly table. Before and after the mat is used, all dirt particles
must be removed.

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Extracting the extruder screw

Fig. 4568/6013

1 Core 2 Extruder gearbox

Procedure
1. Fit the core (1) onto the extruder gearbox (2)

Fig. 4568/6018

3 Nut 5 Thrust spindle

4 Pressure piston 6 Clamping sleeve

2. Push the nut (3) and the pressure piston (4) onto the thrust spindle (5)
3. Secure the pressure piston (4) to the thrust spindle (5) with a clamping
sleeve (6)

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4. Coat the thrust spindle (5) and the pressure piston (4) with a high-
temperature thread paste (Molykote HSC)

Fig. 4568/6019

1 Core 5 Thrust spindle

3 Nut 8 Pin

5. Slide the thrust spindle (5) with the pressure piston (4) into the core (1)
and secure by turning it
- Insert the pin (8) into the nut (3) in the cut-outs of the core (1)
6. Apply a spanner to the end of the thrust spindle (5) and turn
- Screw in the thrust spindle (5) far enough that the end is located just
short of the nut (3)
7. Loosen the nut (3) from the core (1) by turning
8. Unscrew the thrust spindle (5) back to the start position
9. Remove the pressure piston (4) from the thrust spindle (5)
- Pull out the clamping sleeve (6) (see Fig. 4568/6018)

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 6. MAINTENANCE

Fig. 4568/6020

3 Nut 6 Clamping sleeve

4 Pressure piston 7 Extension
5 Thrust spindle

10. Fit the pressure piston (4) onto the extension (7)
- Secure with the clamping sleeve (6)
11. Fit the extension (7) with the pressure piston (4) to the thrust spindle (5)
12. Coat the extension (7) and the pressure piston (4) with a high-
temperature thread paste (Molykote HSC)
13. Slide the extension (7) with the pressure piston (4) into the core (1) and
secure by turning it
- Insert the pin (8) into the nut (3) in the cut-outs of the core (1) (see
Fig. 4568/6013)
14. Apply a spanner to the end of the thrust spindle (5) and turn
 The extruder screw will be extracted.
15. If necessary use a second extension piece
When approximately half of the extruder screw has been removed from the
cylinder, it can be pulled out of the cylinder by hand and then cleaned (see
Chapter 6.4.5).

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6.4.5 Cleaning the extruder screw

NOTE!
The extruder screw must be cleaned, immediately after
disassembly, at 10 – 20°C above the belting temperature of the
plastic type in question (see Chapter 6.4.2).

WARNING!
Hot surfaces and vapours!
Risk of injuries to the eyes and hands

Wear protective gloves when working on the extruder screw!

Wear eye protection when working on the extruder screw!

Procedure
1. Set the removed screw down on a suitable mat
- Remove any thick layers of stuck-on material with scrapers
- Remove finer residue with a brush
- The fine layers of plastic are then rubbed off with a rag soaked in
silicone oil

CAUTION!
Potential for damage to the airways or chemical burns to the skin!
Never use petrol for cleaning!
Ensure that there is good ventilation.

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Fig. 4568/6012

1 Drive pin 2 Extruder screw

2. Coat the extruder screw (2) drive pin (1) with a high-temperature thread
paste (Molykote HSC)

6.4.6 Cleaning the screw cylinder

After the extruder screw has been removed (see Chapter 6.4.4), the cylinder
must be cleaned.

WARNING!
Hot surfaces and vapours!
Risk of injuries to the eyes and hands

Wear protective gloves when working with the screw cylinder!

Wear eye protection when working with the screw cylinder!

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Fig. 4568/6021

1 Extruder flange

Procedure
1. Insert the cylinder cleaning brush at the front at the extruder flange (1)
and clean the cylinder

Fig. 4568/6022

2 Extruder gearbox bore hole 3 Recess for screw

2. Blow out the residual plastic particles in the cylinder towards the front
with compressed air

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CAUTION!
Risk of injury while working with compressed air!
Personal protective gear must be worn during all module
operational conditions where compressed air is utilised!
Compressed air must not be directed towards people!

- Hold the air gun on the hole (2) in the cylinder

NOTE!
The extruder screw drive pin recess (3) in the transmission shaft
must not be dirty!

Once the extruder screw and extruder cylinder have been cleaned, the removed
parts must be refitted and adjusted.

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6.4.7 Filter with melt mixer

NOTE!
The required tightening torques are specified on a sign under the
melt discharge unit (see Chapter 5.2).

If melt emerges between the filter (2), the melt mixer (1) or the die flange (4),
check the sealing surfaces and replace the squeeze seals (5) and (6).

Fig. 4568/6003

1 Melt mixer 5 Squeeze seal

2 Filter 6 Squeeze seal
3 Extruder A Max. tightening torque
4 Die flange B Max. tightening torque

Procedure
1. Remove temperature and melt pressure sensors
2. Remove the filter (2) with the melt mixer (1) and the die flange (4)
3. Remove the die flange (4) from the melt mixer (1)
4. Remove the melt mixer (1) from the filter (2)
5. Check and clean the sealing surfaces (see Chapter 6.4.2)
6. Fit the melt mixer (1) to the filter (2)
7. Fit the melt mixer (1) with the filter (2) to the extruder (3)

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 6. MAINTENANCE

NOTE!
Coat all nuts and bolts with a high-temperature thread paste
(Molykote HSC)!
All bolts must be tightened evenly and in a diagonal pattern, until
the part being fitted is entirely flush!

8. Replace the squeeze seals (5) and (6)

9. Fit the die flange (4) to the melt mixer (1)

NOTE!
Each time the die flange (4) is removed, a new squeeze seal (6)
must be inserted!

10. Fit the temperature and melt pressure sensors

NOTE!
Only fit the temperature and melt pressure sensors once operating
temperature has been reached!

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 6. MAINTENANCE

6.4.8 Filter with melt mixer and melt pump (optional)

NOTE!
The required tightening torques are specified on a sign under the
melt discharge unit (see Chapter 5.2).

If melt emerges between the filter (2), the flange (6), the melt mixer (1) or the die
flange (4), check the sealing surfaces and replace the squeeze seals (7), (8) and
(9).

Fig. 4568/6004

1 Melt mixer 7 Squeeze seal

2 Filter 8 Squeeze seal
3 Extruder 9 Squeeze seal
4 Die flange A Max. tightening torque
5 Melt pump B Max. tightening torque
6 Flange C Max. tightening torque

Procedure
1. Remove temperature and melt pressure sensors
2. Remove the melt mixer (1) with the die flange (4)
3. Remove the melt pump (5)
4. Remove the flange (6) with the filter (2)
5. Remove the die flange (4) from the melt mixer (1)
6. Remove the flange (6) from the filter (2)
7. Check and clean all sealing surfaces (see Chapter 6.4.2)
8. Replace the squeeze seals (7), (8) and (9)

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 6. MAINTENANCE

9. Fit the flange (6) onto the melt pump (5)

NOTE!
The required tightening torque is specified on the sign under the
melt discharge unit (see Chapter 5.2)

NOTE!
Coat all nuts and bolts with a high-temperature thread paste
(Molykote HSC)!
All bolts must be tightened evenly and in a diagonal pattern, until
the part being fitted is entirely flush!

10. Fit the melt mixer (1) to the melt pump (5)
11. Fit the filter (2) with the flange (6), the melt pump (5) and the melt mixer
(1) to the extruder (3)
12. Fit the die flange (4) to the melt mixer (1)

NOTE!
Each time the die flange (4) is removed, a new squeeze seal (9)
must be inserted!

13. Fit the temperature and melt pressure sensors

NOTE!
Only fit the temperature and melt pressure sensors once operating
temperature has been reached!

For information on maintenance work to be carried out on the melt

pump, see the manufacturer's documentation.

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 6. MAINTENANCE

6.4.9 Checking the drive shafts

The following maintenance work should be carried out annually:
• Check the flange joints for firm seating
- Tighten bolts on the melt pump to the specified tightening torque
(see Chapter 8)
- Tighten bolts on the main drive to 83 Nm (see Chapter 6.4.10)
• Lift up the joint and move longitudinally
 There must be visible or noticeable play.
• Check any occurrence of unusual noises or vibrations and remedy (see
Chapter 6.4.10 and 6.4.11)

Lubrication points:
• All the grease nipples on the drive shaft must be lubricated until the
grease emerges at the seals
• Clean the grease nipple each time after relubrication
• See Chapter 6.1 for lubricants

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 6. MAINTENANCE

6.4.10 Replace the drive shaft in the extruder gearbox

When replacing a drive shaft, proceed as follows:
1. Remove the cover

Fig. 4568/6005

5 Extruder drive shaft 7 Square bar

6 Extruder gearbox shaft

2. Check the parallelism of the two shafts (5) and (6)

- Attach the square iron bar (7)

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 6. MAINTENANCE

Installation instructions for clamping devices

The bolts (4) for fastening the clamping devices (7) must be tightened evenly in a
diagonal pattern, with a torque wrench, to a tightening torque of 83 Nm.
Before installation, lightly oil the drive shaft of the extruder drive (5) and of the
extruder gearbox (see Chapter 6.1).

Fig. 4568/6007

4 Bolt 7 Clamping devices

5 Extruder drive shaft

NOTE!
Do not use lubricants with MoS2 additives!

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 6. MAINTENANCE

Fig. 4568/6006

1 Fork position 5 Extruder drive shaft

2 Arrow markings 6 Extruder gearbox shaft
3 Bolts

1. Check the fork position (1) of the drive shaft

 The arrow markings (2) must be opposite one-another.

NOTE!
Do not turn the drive shaft with assembly levers in the joint!
This is a risk of damage to the bearing seals and grease nipples.

2. Tighten the bolts (3) evenly in a diagonal pattern

- Tightening torque: 73 Nm
3. Fit the cover

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 6. MAINTENANCE

6.4.11 Replacing the drive shaft in the belt pump (optional)

When replacing the drive shaft, proceed as follows:
1. Remove the cover

Fig. 4568/6008

1 Bolt 3 Melt pump drive shaft

2 Bolt

2. Tighten bolts (1) and (2) evenly in a diagonal pattern to tightening

torque (A) or (B), in order to secure the fork joints of the drive shaft (3)
- Tightening torque (A) for E-90 extruder: 22 Nm
- Tightening torque (B) for E-105 extruder: 43 Nm
3. Fit the cover

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 6. MAINTENANCE

6.4.12 Metal separator

Check the metal separator weekly for wear.

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!

Fig. 4568/6009

1 Star knobs 3 Magnetic discs

2 Inspection window 4 Housing

In the case of heavy soiling, proceed as follows:

1. Undo the star knobs (1)
2. Remove the inspection window (2), with the magnetic discs (3) fitted,
from the housing (4)
3. Clean the magnetic discs (3) with compressed air

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 6. MAINTENANCE

CAUTION!
Risk of injury while working with compressed air!
Personal protective gear must be worn during all module
operational conditions where compressed air is utilised!
Compressed air must not be directed towards people!

4. Insert the inspection window (2) with fitted magnetic discs (3) into the
housing (4) and fit with the star knobs (1)

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 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, see the starEX display

user manual.

7.1 Extruder
Jolting, thrusting movement in the pellet feed line
Causes Remedy
Blockage due to too-heavy material/air Check raw material feed (see the Raw
mixture material feed technical manual)

Rotating light on the water bath switches on

Causes Remedy
Fill up the material at the raw material
Insufficient material feed (see the Raw material feed technical
manual)

Temperature increases at intake zone cooler

Causes Remedy
No water flow Check water circuit (see Chapter 6.3.7)
Flow valve faulty Check (see the starEX plant manual)

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 7. TROUBLESHOOTING

7.2 Automatic filter

Filter tape does not move
Causes
Heating temperature too low
Differential pressure too high
Filter tape is tilted
Gap at inflow block too narrow
Pretension of the springs on the filter tape
brake too high
Remedy
Increase heating temperature (see the
starEX display user manual)
Reduce heating temperature (see the
starEX display user manual)
Pull through manually
Adjust the melt barrier (see Chapter 5.3.2)
Reduce pretension of the springs (see
Chapter 5.3.3)

Filter tape moves too much

Causes Remedy
Heating temperature too high Reduce heating temperature
No cooling Check cooling system
Pretension of the springs on the filter tape Increase pretension of the springs (see
brake too low Chapter 5.3.3)

Filter tape is moving up or down

Causes Remedy
• Move the filter tape manually (see
Uneven heat distribution at the filter tape Chapter 5.5)
extractor • Check the function of the heating
cartridges

Pressure upstream of filter too high

Causes Remedy
Adjust the differential pressure - Slide the
Filter dirty filter back and forth occasionally (see the
starEX display user manual)
Material melt flow index incorrect Check the material

Melt escaping at filter tape inflow/outflow side

Causes Remedy
Reduce filter tape feed (see the starEX
Filter tape feed too fast
display user manual)

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 7. TROUBLESHOOTING

Melt escaping on inflow side

Causes Remedy
Gap at inflow block too wide Adjust the melt barrier (see Chapter 5.3.2)

Melt escaping at connection flanges

Causes Remedy
Squeeze seals defective Replace (see chapters 6.4.7 and 6.4.8)
Water cooler is not active Check water cooler

7.3 Melt pump (optional)

Melt pump not pumping
Causes Remedy
Drive motor faulty Check
Replace (see the manufacturer's
Drive shaft faulty
documentation and Chapter 6.4.11)
Check (see the manufacturer's
Melt pump faulty
documentation)

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 8. ENCLOSURES

8 ENCLOSURES

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

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