Grafisk Maskinfabrik DC330mini Operating Manual Download Page 68

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GM · CONVERTING UNIT

To be signed of the customer:

Action

Sign

Comments

Buffer installed an working

Unwind system ok

Varnish station ok

Lamination ok

Die station ok

Slitting system ok

Matrix rewind ok

Rewinder ok

Training ok

Manual has been read

Summary of Contents for DC330mini

Page 1: ...GM CONVERTING UNIT OPERATING MANUAL DC330MINI NANO Grafisk Maskinfabrik A S Bregner dvej 92 DK 3460 Birker d Denmark Phone 45 4581 2300 Internet www gm dk e mail gm gm dk Fax 45 4581 9956...

Page 2: ...iance with the relevant requirements in the following directives Machinery Directive 2006 42 EC EMC Directive 2004 108 EC Harmonized specifications applied EN 60204 1 Safety of machinery Electrical eq...

Page 3: ...ons 16 6 1 Parameters 18 6 2 Die cut parameters 20 6 3 Speed control 23 6 4 Web tension and scale print adjustments 24 7 Alarms and messages 25 8 Language and units setup 29 9 Special parameters 30 10...

Page 4: ...nt 49 18 11 Troubleshooting 50 19 Spot varnish guide 51 19 1 Step by step guide 52 19 2 Trouble shooting 53 19 3 Pictures 53 19 4 The parameter screen 54 19 5 The run screen 55 19 6 Print scaling 56 2...

Page 5: ...y dangerous situation Removal of the cover behind this symbol may lead to direct or in direct exposure to high voltage parts This may lead to fatal personal injury Indicates a potentially dangerous si...

Page 6: ...module installed 3 Control panel The control panel is fitted with a touch panel and on the right side the POWER button Emergency Stop button the four torque adjustment knobs and the speed button The...

Page 7: ...t press with sharp objects To clean the touch panel soak a cloth in water with a mild detergent wring the cloth tightly and wipe the panel Never use strong detergents paint thinner organic solvents or...

Page 8: ...outs are placed on the lower part of the screen The converting unit is equipped with four spindles with different functions Unwinder Waste rewinder Rewinder 1 top Rewinder 2 bottom Each spindle will c...

Page 9: ...en they are off and yellow when they are on The varnish roller can be engaged and released by pressing the roller symbol on the top of the varnish station It can also be turned on and off automaticall...

Page 10: ...when activated A typical pressure setting is 1 2 bar The laminate unwinder will not rotate when the laminate nip is off This is to prevent the laminate foil from rotating freely through the laminating...

Page 11: ...es it goes in to a heating sequence which lasts about one minute When the lamp is finally on the lamp symbol turns white If the lamp is hot when it is engaged it will not turn on The machine will let...

Page 12: ...ith dustpan and brush and transfer it to a cardboard box or other expendable container Always put the container in a thick plastic bag to protect any operator dealing with the waste Dispose of the bag...

Page 13: ...tem NOTE When testing troubleshooting the system make sure that all cables are intact and all safety interlocks in place 5 7 The die cutting station This converting unit is equipped with a die cutting...

Page 14: ...ise only glue inward It is the only rewinder which can be started and stopped while the machine is running This is to make it easier to mount the waste grid 5 9 V knifes and Slitting knifes After stri...

Page 15: ...s the cutting quality When the safety cover is opened the motor is turned off and the blades are safe to move Do never tighten the blades too hard they just get harder to remove NOTE Never try to open...

Page 16: ...spindle becomes smaller than a value entered in the Parameter menu When in inline mode this function is bypassed The Automatic stop at label preset feature makes the converting unit stop when the labe...

Page 17: ...and features not directly related to the die cut station The Remote control window button or the button opens a window with a remote controlling feature for a digital press To stop the digital press...

Page 18: ...line with another machine e g a print engine the converting unit does not stop when the preset value has been reached This is to avoid web spilling on the floor or paper jam in the print engine The Au...

Page 19: ...e Rewinder 1 high torque and Rewinder 2 high torque options select the torque range for the two rewind spindles High range box checked is normally used for heavy webs or webs that have not been die cu...

Page 20: ...l rotate when the machine runs to reduce web friction Analog die cutting Traditional die cutting with a die cut cylinder between 10 and 25 The resolution is 1 8 1z Digital die cutting Semi rotation di...

Page 21: ...made for a 12 cylinder but is used on a 25 cylinder the labels will be too short and the space between frames will be too long This behaviour can be compensated for by changing the distortion factor t...

Page 22: ...ish deviation is the measured varnish register fault similar to the Die cut deviation UV lamp power is a readout of the momentary power output to the UV lamp Die cut offset is used for moving the die...

Page 23: ...revious marks and use the following mark as a registry mark 6 3 Speed control The web speed is mainly controlled by the speed potentiometer However the different modes and possibilities give different...

Page 24: ...ale dialog Web tension will change the gearing of the in and outgoing nips in the machine Tension can change from 1 very soft to 50 very hard The default value is 30 The spot varnish scale can alter t...

Page 25: ...fety cover has been opened while the web has been in motion This is not the correct way to stop the machine Stopping The machine is decelerating and stopping The unwinder is running out of paper The o...

Page 26: ...ller is initializing This can take upto 1 minut If this message is not cleared there could be a fault on one of the servo motors Servo position error Setup is incorrect or web speed is too high Servo...

Page 27: ...may be damaged by the braking die cut cylinder Die cut station failed to initialize Check that the gears are in position The die cut station has attempted to rotate the die cut cylinder but the gears...

Page 28: ...failed Program error Contact manufacturer Internal error in the spot varnish controller Contact manufacturer Spot varnish station failed Internal E stop Contact manufacturer Internal error in the spo...

Page 29: ...m min and linear measurements are in m or mm In Imperial mode the units are feet min feet and inches In the Time menu the clock 24h can be adjusted The UV hours readout is the number of hours that the...

Page 30: ...og 1 2 The Mark reader distance value is used for calibrating the register control in order to get the die cutting station in register quickly Basically this is the web distance between the mark reade...

Page 31: ...can be used Remember to put only one registration mark per plate length 2 Measure and check that the printed repeat length exactly matches the plate repeat 3 Measure and check that the plate edge to f...

Page 32: ...hows now 1st and the registration is made Find a clear spot to record on Press the OFF ENTER button shortly and the display shows the 2nd and GOOD will be shown in the display Remember to calibrate bo...

Page 33: ...not have the optimal dispro factor it will show as a to small or large gab between the repeats This can occur if the plate is made for a 12 full rotary cylinder and used on a 25 digital die It can al...

Page 34: ...mm 2 8mm gab 302 mm Ideal dispro factor for 25 die 99 69626 calculated using the results from the test plates Conclusion Remember that this factor can be altered by web stretching thick special web cu...

Page 35: ...3 The standard roller is 320 mm wide The roller can be tooled down to 300mm to prevent varnish build op on the sides of the web dripping due to wiper blades not being in tight contact with anilox roll...

Page 36: ...cut station adjustment and alignment The die cut must have washers on each side to prevent lateral movement and damage to the cylinders Remember when changing the die cut cylinders you need to make a...

Page 37: ...ount the bridge and put it on a table or stable surface 2 Use an allan key and a wrench to adjust the gab at the 4 set points 3 Make the top nut lose and turn the bolt until the clearance is 1 25mm 4...

Page 38: ...GM CONVERTING UNIT 38 17 General information for GM diecut station...

Page 39: ...air pressure must be 5 to 6 bar The air cylinders has an area of 400cm2 and will press down the piston plate with much higher pressure than is needed to die cut 20 000N not to give in The pressure fr...

Page 40: ...her If the machine has Kocher Beck pressure screws with manometers on the converting from the scaling on the manometers is 60 bar 2116N 100bar 3527N 160 bar 5642N 200 bar 7052N 1bar 35 26N The pressur...

Page 41: ...that the dimension of the Print roller diameter is correct It must be 97 5 0 3mm 18 1 Technical data Web widthmax 330 mm Plate cylinder diameter 97 02mm Print roller diameter replaces plate cylinder...

Page 42: ...the print head with the plate cylinder which can be raised and lowered The plate is inked up by the anilox roller which is adjusted with two handles to more or less pressure on the plate roller The an...

Page 43: ...ilox roller with a coarser screen low line number must be used If less ink is required e g for half tone printing an anilox roller with a finer screen higher line number is used Normally anilox roller...

Page 44: ...anilox is correctly aligned towards the varnish roller printing roller Slide in the inking roller and make sure its aligned towards the anilox roller An anilox roller is a precious piece of tool and o...

Page 45: ...wipe off the ink with a light pressure on the anilox roller The inking roller is pressed lightly against the anilox roller giving a thick coat of ink The blade is adjusted on the two knurled nuts so...

Page 46: ...ill become a problem 18 6 Filling of ink Fill in sufficient ink for the ink roller to be inked up during rotation It is possible to connect an ink pump for automatic filling of the ink tray If ink pum...

Page 47: ...ead in both sides can be adjusted so the plate is printing even and uniform all over the web If the plate only touches the web in one side the print cylinder is not parallel with the impression cylind...

Page 48: ...nter clockwise impression is shifted towards the rear of the press NOTE The ball bearing on the arm that pushes the print cylinder across should be greased once every week NOTE Never try to adjust the...

Page 49: ...etween the impression cylinder and the plate cylinder Now lower the plate cylinder until it is not possible to move the liner paper Do not tighten the plate cylinder too much against the paper You hav...

Page 50: ...im of ink behind the back edge of the plate Too strong impression between plate and paper gives an outline of ink at each letter The whole image can also be deformed by too strong impression The choic...

Page 51: ...cylinder symbol When the print cylinder is down only small 1mm corrections are possible This is done to protect the print plate cylinder from rapid movements when pressed against the web this could ca...

Page 52: ...letely out startup after install has been cleaned down or the here is a big difference in print plate cylinder size it may be needed The adjustment assures that all rollers in the unit are parallel an...

Page 53: ...ure can only be done with UV varnish Init fault gears not in grip Check that there is a hole in the plate cylinder tooth wheel and sensor is OK Can t lock on marks Check that there is one register mar...

Page 54: ...eck box selected Only use the automatic slow run when water based is used The automatic slow run will leave a blank spot on the web when starting up The automatic varnish roller will lift up the print...

Page 55: ...seen Please monitor them careful when printing spot varnish The spot varnish offset on the lower right side has the same function as the offset knob on the side of the print station It move the print...

Page 56: ...scaling When the tool icon is pressed the small dialog box above id displayed This will alow the operator to make the spot varnish system go faster or slower Print quality will be compromised but it c...

Page 57: ...the right side of lamination is used it is only treated on one side c Check that lamination foil is wider than substrate or anilox has deadband preventing varnish build up on the sides of the lam rol...

Page 58: ...ust be tight against the doctor blade 90 deg angel and anilox Converter Flexo unit 1 week Clean down unit completely and greas brass side movement adjuster UV cleaner standard machine greas Converter...

Page 59: ...replaced after 4 5 years Grease Grade NGLI 2 or 3 RL14 roll lifter to remove tool Please note that the lower cover of the die cut must be removed to do this Converter Knife box 1 day Check the sharpne...

Page 60: ...GM CONVERTING UNIT 60 22 Dimensions...

Page 61: ...heel and rubber coating blue type DC 003P Ductor Pick up roller 97 2 B 310 L 314mm SH40 X 014E Doctor blades 5 pcs DC330 320mm I5 M082 Strip roller 15mm complet with bracket VAL001C Nip roller sh 65 5...

Page 62: ...ize 12 to 25 Analog die size 12 to 25 Speed digital 40 m min depending on repeat and software version Speed analog 72m min Repeat range 2 20 8 Max repeat Die size 0 9 40mm Min repeat 2 Min distance be...

Page 63: ...GM CONVERTING UNIT 63 25 Clich roller drawing This Clich cylinder is the standard for GM Converting Unit An optinal sleevesystem can be ordered Call ur local GM sales office for further information...

Page 64: ...the distance between the magnetic cylinder magnetic zone and the anvil cylinder This is 0 48mm on all standard machines with a 25 die cylinder Please check the order confirmation for the specific mac...

Page 65: ...nit has to be placed at the same level if possible Add Texaco Havoline XLI 7 5 volume to the cooling water If the Cooling unit is in freezing surroundings use XLC 33 volume down tot 20 degree Celsius...

Page 66: ...t Solutions Akzo Nobel UVD 00100 405 UV Wash min 5L CLU00102 407 or UV Wash2 or Dowanol DPM A die plate and a job for the plate must be prepared and ready to run on the Xeikon DCP Drop 0 48mm see manu...

Page 67: ...chines more weeks can be needed We strongly recommend that only staff with printer experience operate the machine To prepare the training please respond on the following scheme Name Flexo Printing exp...

Page 68: ...o be signed of the customer Action Sign Comments Buffer installed an working Unwind system ok Varnish station ok Lamination ok Die station ok Slitting system ok Matrix rewind ok Rewinder ok Training o...

Page 69: ...GM CONVERTING UNIT 69 30 Notes...

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