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INSTRUCTION MANUAL Digital Light Engraver

2

Safety

Effective date

30.09.2013

2.6

Pneumatics

Any work to be carried out on the pneumatic systems of the machine or
equipment shall only be undertaken by a pneumatic system specialist.

Prior to working on pneumatic equipment, the moving parts of the pneumatic
system are to be placed in their home or park position. Depressurise the
pneumatic system before performing any work on it.

Caution is needed when looking for leaks in pneumatic lines that are under
pressure. Pressurized air can penetrate clothing and skin, which can result in
injury or severe infections.

Caution is needed when loosening or replacing pneumatic lines; incorrectly
connected pneumatic lines can result in operations not functioning correctly.

The movement area of the actuator should not be blocked and access to the
area of movement of the actuator must be sufficiently secured.

2.7

Hydraulics

Any work to be carried out on the hydraulic systems of the machine or
equipment shall only be undertaken by a hydraulic system specialist.

Prior to working on hydraulic equipment, the moving parts of the pneumatic
system are to be placed in their home or park position. Depressurise the hy-
draulic system before performing any work upon it.

Caution is needed when looking for leaks in hydraulic lines that are under
pressure. Pressurized hydraulic fluid can penetrate clothing and skin, which
can result in injury or severe infections.

Caution is needed when loosening or replacing hydraulic lines; incorrectly
connected hydraulic lines can result in operations not functioning correctly.

The movement area of the actuator should not be blocked and access to the
area of movement of the actuator must be sufficiently secured.

CST GmbH
Königsberger Straße 117
47809 Krefeld - Germany

Page 16 of 69

Betriebsanleitung DLE-AF 01.0 engl.docx

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Summary of Contents for DLE

Page 1: ...ORIGINAL INSTRUCTION MANUAL CST GmbH Königsberger Straße 117 47809 Krefeld Germany Telephone 49 2151 1592260 Fax 49 2151 520329 Email support c s t de office c s t de CST GmbH Königsberger Straße 117 47809 Krefeld Germany Page 1 of 69 Betriebsanleitung DLE AF 01 0 engl docx ...

Page 2: ...rts 17 2 10 Personal protective equipment 18 2 11 EC DECLARATION OF CONFORMITY 19 3 Transportation storage installation electrical connection 20 3 1 Special safety instructions 20 3 2 Transport 21 3 3 Storage 22 3 4 Installation 23 3 5 Electrical connection 23 4 Machine description 24 4 1 Machine housing 25 4 2 Screen frame clamping system 26 4 3 Bridge 27 4 4 Operating control units 28 5 Initial ...

Page 3: ... 2 8 DLE settings 45 6 3 Focus test for the DLE Engraver 49 6 4 Cleaning 53 7 Dealing with faults 56 8 Service and Maintenance 61 8 1 Special safety instructions 61 8 2 General 64 8 3 Weekly monthly intervals 65 8 4 Biannual annual interval 65 8 5 Maintenance plan 67 8 6 Maintenance Logbook 68 9 Technical Annex 69 CST GmbH Königsberger Straße 117 47809 Krefeld Germany Page 3 of 69 Betriebsanleitun...

Page 4: ...rs A fully automatic loading and unloading system in cooperation with other vendors Customer specific adaptation This instruction manual contains important information that needs to be taken into account in all stages of the life cycle of the machine including the trans portation installation operation maintenance and disposal Therefore it is imperative that this instruction manual is read by the ...

Page 5: ...al damage the envi ronment and property Action that has to be avoided to prevent hazards from arising Caution Nature and source of hazard This symbol warns of a possible dangerous situation to the life and health of people as well as damage to the environment and property Failure to observe such instructions could result in moderate to slight health effects or even injuries as well as damage to th...

Page 6: ...oting fork lift trucks in operation Warning symbol denoting hazardous voltage Warning symbol denoting UV radiation Warning symbol denoting hot surface Warning symbol denoting suspended load Warning symbol denoting hand injury Always wear protective safe ty glasses against UV radia tion Please follow these instructions and act accordingly in all cases Instruct all other users in regard to these saf...

Page 7: ...d equipment Ensure that there is sufficient lightning when the machine and equipment are in operation Do not climb on or through the machine and equipment The CST Digital Light Engraver is intended to be used in the print industry for imaging screen stencils The machine is designed to be used only in the field of application listed in the Technical Information section of the order confirmation or ...

Page 8: ...the machine and equipment under normal working conditions Special attention must be given to mounting and removing screen frames and screens on the machine and equipment as it has to be carried out carefully If work is carried out in an inattentive or careless manner there exists the hazard of limbs items of clothing and objects being crushed impacted and sheared which is due to moving parts There...

Page 9: ...ult in the following hazards Failure of important functions of the machine Failure of specified procedures of maintenance and repair Exposure of people to electrical mechanical physical and chemical hazards 2 2 1 Obligation of the personnel All work on with the machine shall be carried out only by personnel who by virtue of their training and qualifications are authorised to do so Responsibilities...

Page 10: ...2 2 3 Important rules of conduct Danger Increased risk of accidents as a result of moving masses The movement of masses can lead to serious fatal injuries People who operate power driven machinery must make sure that they do not endanger themselves or others through hazardous motions Access to the interior of the machine housing is only permitted when the machine has been switched off and measures...

Page 11: ...he coolant used in machine The coolant contains 1 2 Ethanediol The following precautions are recom mended by the manufacturer supplier of the heat transfer concentrate R22 Harmful if swallowed S2 Keep out of the reach of children S24 25 Avoid contact with skin In case of contact with skin rinse imme diately with plenty of water S46 If swallowed seek medical advice immediately and show the con tain...

Page 12: ...rder Do not remove or modify any protective equipment Operators and users are responsible for operating the machine in the correct manner Danger zones that cannot be eliminated by constructional measures are fit ted with protective equipment and where appropriate the machine is marked with warning signs moreover relevant information relating to safe working practice is specified in the instruction...

Page 13: ...e main switch is located on the main control panel 01 An EMERGENCY STOP button 02 is located on the vertical protective cover 03 of the traversing head unit A protective cover 03 covers the traversing head unit Warning and information signs 04 indicate possible danger zones CST GmbH Königsberger Straße 117 47809 Krefeld Germany Page 13 of 69 Betriebsanleitung DLE AF 01 0 engl docx ...

Page 14: ... to be taken when faults occur Do not switch on the machine Disconnect from the mains supply Arrange for qualified electrician to carry out maintenance Protective cover Intervals When the machine is switched and before it is opened Scope Functionality the machine must switch off when the protec tive cover is opened Inspector Operating personnel Action to be taken when faults occur Do not switch on...

Page 15: ...ring protection Advice for when to wear personal hearing protection Up to 70 dB A In this case no special measures are required People s sensitivity to noise varies Therefore people who feel that they are bothered or even harmed by such noise should wear hearing protection From 80 dB A People constantly working in this particular area should wear hearing pro tection From 85 dB A Hazardous noise ar...

Page 16: ...d access to the area of movement of the actuator must be sufficiently secured 2 7 Hydraulics Any work to be carried out on the hydraulic systems of the machine or equipment shall only be undertaken by a hydraulic system specialist Prior to working on hydraulic equipment the moving parts of the pneumatic system are to be placed in their home or park position Depressurise the hy draulic system befor...

Page 17: ...n hazardous voltages which satisfy the safety regula tions Electrical parts such as motors which have been stored for a long time should not be used until they have undergone prior isolation tests When electrical equipment parts or components have become wet some parts which would normally be voltage free in a dry condition could be live Before touching a component that has become damp or wet plea...

Page 18: ...t fitting protective safety glasses with side protection refer to Occupational Health and Safety Regulations of the Trade Associations regulation 192 BGR 192 Body Not required in normal operation Adjust appropriately to surroundings Ears Not required Adjust appropriately to surroundings Hands When there is the danger of a hot surface suitable protective gloves e g protective gloves in respect of m...

Page 19: ...ON MANUAL Digital Light Engraver 2 Safety Effective date 30 09 2013 2 11 EC DECLARATION OF CONFORMITY CST GmbH Königsberger Straße 117 47809 Krefeld Germany Page 19 of 69 Betriebsanleitung DLE AF 01 0 engl docx ...

Page 20: ...ds can lead to injuries or fatal accidents as well as the hazard of damage to the machine and equipment Secure the load before any lifting and transport work is to be undertaken Use cranes hoists lifting devices slings and lifting tackle which are in accordance with the applicable on site safety and accident prevention regulations and are designed for the weight of the machine and equip ment Use c...

Page 21: ...g transport crate should be lifted only using the specially designated lifting points These are clearly marked on the exter nal surface Do not lift the packaging transport crate using any other point other than those designated The machine should always be transported and moved in an upright posi tion Avoid any unnecessary sharp sudden movements impacting and or ex cessive vibrations during transp...

Page 22: ...ge of chemicals in the area Information Machines and equipment can be damaged due to improper storage Improper storage can result in damage to the machine equipment as well as parts and accessories Store the machine equipment as well as parts and accessories in the original packaging Take into account the maximum permissible floor loading limit Please take special care when stacking wooden boxes a...

Page 23: ...tioning of the machine and equip ment It is recommended that the access areas around the Digital Light Engraver should not go below a minimum width of 1m 3 5 Electrical connection For information about the electrical connection please refer to the wiring dia grams Danger Injuries and fatal accidents can occur as a result of hazardous voltage If there is a fault with an electrical component or cabl...

Page 24: ...d according to the data As the DMD chip moves over the screen the data scrolls through the chip so that a still image is projected onto the screen The image is created in strips and is executed in a continual and scrolling motion on the screen The scrolling process has been patented by CST GmbH Each micromirror exposes one pixel Therefore given the high frequency rate and the amount of mirrors the...

Page 25: ...ad unit is located under a protective cover moves along the two linear guiding elements 01 The screen frame 04 which is to be imaged is held in place by two hor izontally placed U channels 03 The upper U channel 05 can be vertically adjusted to accommodate dif ferent sizes of screen frames 04 The screen frames 04 can be secured in both of the U channels 03 by means of pneumatically operated clamps...

Page 26: ...umber of pneumatic cylinders 01 which are positioned on the C channels move rubberized clamps 02 mounted on piston rods A light barrier 03 which is mounted on the upper C channel checks the presence of the screen frame CST GmbH Königsberger Straße 117 47809 Krefeld Germany Page 26 of 69 Betriebsanleitung DLE AF 01 0 engl docx ...

Page 27: ...ight units 05 are cooled by a closed loop cooling system 02 that is also located in the head unit The light beams that are generated by the two light units 05 are com bined in a prism unit 04 and then transmitted to the Digital Micromirror Device 03 The micromirrors located in the Digital Micromirror Device 03 are elec tronically controlled to produce the image on the screen frame screen CST GmbH ...

Page 28: ...There is the risk of crushing injury to the fingers hands and feet when insert ing the screen in the upper and lower screen frame area and closing the clamps Wear personal protective equipment in the form of safety shoes and gloves when inserting the screen frame screens in the screen clamps Ensure that nobody is in the danger zone area when closing of the clamps Please instruct people to leave th...

Page 29: ...m of safety shoes and gloves when operating the screen clamps Ensure that nobody is in the danger zone when operating the upper clamps Please instruct people to leave the danger zone Information When the screen clamp closes the screen could drop out When the screen clamp is closing there is the danger that the screen could suddenly drop Hold onto the screen frame when the screen clamp is closing T...

Page 30: ...pment please use suitable safety equipment such as stepladders pallet jack or the like Do not remove or change any protection devices Danger Injuries and fatal accidents can occur as a result of hazardous voltage If there is a fault with an electrical component or cable the direct or indirect contact with live parts could result in serious or fatal in jury through electric shock Do not work on the...

Page 31: ...substances Improper use of equipment or ancillary substances could result in serious health risks or fatal injuries It could even lead to extensive environmental and property damage Read the rules applicable to the current materials material safety sheets MSDS and the manufacturer s instructions for the equipment and ancil lary substances Wear appropriate protective equipment e g gloves safety sho...

Page 32: ...onents All screw connections are tight and check the screw connection torque levels and correct if necessary Utilities such as electricity and compressed air are provided on site e g compliance with the working materials Power connections Terminals and protective fixtures Carry out for example the set up and then functional tests of the electri cal and programmable logic controller PLC Carry out f...

Page 33: ...ine or equipment when it is switched on All electrical work is to be always performed with power supply switched off turn off the main switch and secure it with a padlock or U lock to pre vent it from being inadvertently switched on After switching off the machine and equipment check for the presence of residual voltage Wear appropriate protective equipment e g gloves safety shoes hard hat etc and...

Page 34: ... is sufficiently ventilated Exercise caution when handling hot equipment or ancillary substances Contact can result in burns and scalds When there is a leak from equipment or of ancillary substances use a suit able bonding material to bind this and dispose of it in accordance with on site regulations Avoid skin contact with the equipment or ancillary substances Do not breathe in any fumes from the...

Page 35: ...of the machine and equipment Do not climb on or through the machine and equipment Do not remove or change any protection devices No cleaning work is permitted when the machine is in operation Danger Increased risk of accidents can occur as a result of moving masses This symbol warns of an immediate danger to the life and health of people People who operate power driven machinery must make sure tha...

Page 36: ...ock Replace faulty electrical cable and components immediately Do not touch any components or cables that may be electrically live Information Improper operation could lead to damage to the machine and equip ment Improper operation can lead to serious damage to the machine and equip ment Make sure that all operations are carried out by qualified authorized and trained personnel Follow the instruct...

Page 37: ...y double clicking on this desktop icon Click on the R reference button on the software interface and wait until the reference run is finished The LEDs on the light switch should now be switched on Now you will see that the LED status indicator has changed to the active mode LED OFF LED ON These displays indicate the LED s current power con sumption when the LEDs are in imaging mode These displays ...

Page 38: ...age size as well as the correct design After clicking on the arrow a drop down list of the image sizes will ap pear bitte in Grafik einfugen Once you have made your selection confirm the selection by clicking OK The image will be shown in the imaging area at a scale of 1 1 To display the entire image area select the Fit option To start the imaging process select Expose Expose from the menu CST Gmb...

Page 39: ... upon the chip frequency in combination with the exposure head resolution Enter the values for the imaging rows The values entered here specify how many rows will be imaged by the chip In the example below the chip will cover 640 rows The maximum number of rows is stored in the DLE settings To reduce the imaging intensity you need to reduce the number of rows CST recommends doing this gradually us...

Page 40: ...2 M 444 Y 666 When large Speed Quality values are to be used you must reduce the start shift function value 200 Select which final motion should occur upon completing the imaging se quence You can choose between Park after jet and Screen change after jet When no option is selected the head will stop in the final position where the previous imaging was completed Click on the Move button in order to...

Page 41: ... set tings Opening the X change image function You will see the file name of the last completed imaging Old image Click on the Browse button and select the next image You will see both the old as well as the newly selected file names By clicking on the OK button the program will replace the imaging without changing the previously used parameter settings CST GmbH Königsberger Straße 117 47809 Krefe...

Page 42: ... head to the camera position Start the DLE calibration programme The program will prompt you to enter a password Enter cst The main program will close and the calibration process will commence Click on the Lightvalue button to perform the photometry Machine activities The head moves towards the camera The system adjusts the focus to the camera The head turns on all selected mirrors and carries out...

Page 43: ... shown that LEDs can remain stable for a period of up to 500 hours When a recalibration is carried out the current correction curve is deleted The system calculates a new curve from several measure ments Improper use of this function can lead to a loss of quality in the production and may cause banding 6 2 5 Finishing work Move the head close to the reference position park or screen change po siti...

Page 44: ...e presence of residual voltage The machine and equipment are not neces sarily isolated Wear appropriate protective equipment e g gloves safety shoes hard hat etc and especially tight fitting clothes Access to the machine and equipment must only be via the approved ar eas Before undertaking any work on the machine and equipment cordon off the area with a temporary barrier such as red and white safe...

Page 45: ...ell as the ways to control the chip and LED system Here you can find the DLE settings under the Utilities tab The program will prompt you to enter a password cst The interface pictured above allows you to specify a number of different parameters The head positions can be determined using the X and Y co ordinates CST GmbH Königsberger Straße 117 47809 Krefeld Germany Page 45 of 69 Betriebsanleitung...

Page 46: ...be determined by the operator Service work can be performed when this position is selected The work position is the starting point defined by the user This position is used for calculating all other positions required for imaging Attention Changing the work position at this point in time will mean that the start positions that have already been saved in the DLE main settings menu will no longer co...

Page 47: ...etermine the maximum value of the lines during the imaging These value are set by the service technician during installation and should not be changed by the user The Start offset value sets a deviation for the head in the Y direction at the start of the imag ing The optimum value is set by the service technician The Bidirectional corr value sets the correction value in the system so that when the...

Page 48: ... on but the micromirrors on the chip are not ac tivated This can be recognised by a faint bluish light Upon clicking the Mirrors on button both LEDs are turned on and the micromirrors on the chip are activated After operating and checking the LEDs and micromirrors the mirrors off button must be pressed upon completion Upon clicking the Print Test Image button the LEDs are turned on and the micromi...

Page 49: ...ged In order to carry out the test you will need a printed sample which you can use to evaluate the quality required In order to find the best focus a number of imaging passes must be per formed with different focus values The focus value in the software moves in a range from 9 to 9 Open the DLE software click on the Utilities tab and select Test in the drop down menu In the new window you will be...

Page 50: ...tart button The triangulation test window will now open To activate the triangulation system press the Init TRIA button If you get an error message please check if the hardware is connected to the correct COM port on the PC We strongly recommend not changing any parame ters apart from those that are de scribed in this manual This could lead to a machine fail ure CST GmbH Königsberger Straße 117 47...

Page 51: ... have noted down the original value Gradually change the original value up and down before each test run In the example shown the original value is 0 This is changed in this example to 1 After you have set the new focus value Head Height confirm the selec tion by clicking the Set servo button Close the window by clicking on the Cancel button CST GmbH Königsberger Straße 117 47809 Krefeld Germany P...

Page 52: ...w We recommend performing a number of imaging passes with different fo cus values on one screen frame In many cases you will find that a num ber of pre defined imaging sizes already exist in your screen size defini tion these were saved during the installation of the machine You can then load one of the imaging samples recommended by CST based on this size or try out one that you have created your...

Page 53: ... lead to serious injury Wear tight fitting clothing Long hair can be protected by wearing a hair net Remove jewellery It is not permitted to climb on the machine while it is in operation Danger Increased risk of accidents as a result of partly intense high levels of ultraviolet radiation When monitoring checking the ultraviolet light please remember there is al ways the risk of serious eye injurie...

Page 54: ... 2013 Turn off the main switch 01 and secure it with a padlock or U lock to prevent it from being inadvertently switched on Disassemble the vertical cover 02 of the traversing head CST GmbH Königsberger Straße 117 47809 Krefeld Germany Page 54 of 69 Betriebsanleitung DLE AF 01 0 engl docx ...

Page 55: ...om coated surfaces with common household cleaners Do not use solvent based cleaners After removing the dirt and cleaning wipe the surface dry with a linen or cotton cloth Cleaning conditions that need to be avoided Do not let the dirt stay on the surface for a long period Do not use solvent based cleaning agents Do not use scouring powder scouring pads and steel wool with a rough sur face Do not u...

Page 56: ...Computer then Properties and then open Hardware Look for the Baran USB board in the list of USB adaptors Driver not installed correctly When prompted for a driver you should only run the set up USB cable is bro ken or faulty Try connecting a replacement cable A cause of the fault could be that the cable has been incorrectly laid The cable should not be laid close to strong electrostatic fields and...

Page 57: ...erence run the bridge should not move tension caused by cover remove the lower screws holding the cover Rough running Lubricate rail and check for damage Gear or clutch are defective for checking purposes loosen the coupling control on one side and then turn the trans mission and coupling by hand there should be no noise or uneven running An X motor is de fective replace the motor System stops dur...

Page 58: ...time The exposure time must be aligned to the film type of mesh and emulsion film thickness must always correspond to the established optimum speed Screen was not sufficiently dry with damp emulsions the chemical reaction to cure the emulsion is much slower check screen drying with measuring instru ment Screen was not cured properly dur ing exposure operator forgot to activate the screen curing no...

Page 59: ...ive chip or card The resolution of the system is defined by the lens It must not be changed Check DLE set tings in Utilities Data on edge is missing or exchanged deactivate the area by switching off the mirror area Machine stops during exposure showing the error mes sage USB buffer not plotted USB connection in terrupted See above Machine stops after 1st exposure pass and gives an error message In...

Page 60: ...or or controller is defective Machine can not be switched on or it immedi ately switches off again Emergency stop circuit has been in terrupted Check the position of all emergency stop switches Emergency stop bridge circuit in the control box and try again If the attempt was success ful remove the bridging and look for the fault in the circuit using continuity tester Power switch was not pressed l...

Page 61: ...se use suitable safety equipment such as stepladders pallet jack or the like Do not remove or change any protection devices Danger Injuries and fatal accidents can occur as a result of hazardous voltage If there is a fault with an electrical component or cable the direct or indirect contact with live parts could result in serious or fatal injury through electric shock Avoid working on the machine ...

Page 62: ... use of equipment or ancillary substances could result in serious health risks or fatal injuries It could even lead to extensive environmental and property damage Read the rules applicable to the current materials material safety sheets MSDS and the manufacturer s instructions for the equipment and ancil lary substances Wear appropriate protective equipment e g gloves safety shoes protec tive clot...

Page 63: ... the manufacturer s instruction manual carefully and comply with them accordingly Make sure that workplaces are clean during service and maintenance of the machine and equipment Do not place any tools appliances or the like on the machine and equip ment Do not commence the service and maintenance without having prior ade quate training on the machine and equipment or without first having read the ...

Page 64: ...rried out by trained personnel Biannually Test linear actuators refer to technical documenta tion Annually Electrical devices and connections Annually Security equipment refer to the capital tled Safety Annually Checks carried out by our service personnel Measures to be taken before restarting following maintenance work Check security equipment Check that the operation sequence of the machine is r...

Page 65: ...he fluid level of the coolant system We would recommend using the fluid delivered with the machine as a liquid coolant 8 4 Biannual annual intervals Inspect and lubricate the ball bearing carriage and the rails of the linear guide system Clean the horizontal and vertical guide rails Lubricate the ball bearing carriage with grease or oil Use grease that is in compliance with DIN 51 825 KP 2 K lubri...

Page 66: ...too thickly and that it is never put below rubber coated lips This could damage the machine Check the controller cooling fans in the control cabinet See if they are dirty and need cleaning Check the power consumption and temperature of the power supply The temperature check is to be carried out manually Drain the condensate from the compressed air supply filter unit and in spect the compressed air...

Page 67: ...ar guide systems and toothed belt drives X 6 Clean rubber lips on linear encoder X 7 Lubricate rubber lips on linear encoder X 8 Drain condensate and inspect the entire compressed air system X 9 Clean and lubricate guide rails of the upper screen clamp as well as those of the bearings X 10 Clean inner side of the screen mount X 11 Clean camera X 12 Clean the lens X 13 Inspect screen clamp cylinder...

Page 68: ...e maintenance work undertaken should be entered in the following table In this way you record the complete maintenance work for the life of the machine Date LED hours LED power Maintenance Intensity Speed Name Signa ture CST GmbH Königsberger Straße 117 47809 Krefeld Germany Page 68 of 69 Betriebsanleitung DLE AF 01 0 engl docx ...

Page 69: ... equipment plans parts lists vendor documentation to name but a few are included Technical information pertaining to parts supplied by vendors are shown in extracts Extensive information is available from CST GmbH All spare parts can be ordered from the manufacturer CST GmbH Königsberger Straße 117 47809 Krefeld Germany Telephone 49 2151 1592260 Fax 49 2151 520329 Email office c s t de CST GmbH Kö...

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