operating manual dc330/500 - converting made easy · gm · converting unit 9 3. touch panel the...

· GM CONVERTING UNIT ·

OPERATING MANUAL

DC330/500

Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød · Denmark · Phone: +45 4581 2300

Internet: www.gm.dk · e-mail: [email protected] ·Fax:+45 4581 9956

http://www.gm.dk/

mailto:[email protected]

GM · CONVERTING UNIT

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Rev 1.26 (V6 machines) 09/01-2014


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EU Declaration of Conformity

We Manufacturer:

Grafisk Maskinfabrik A/S Bregnerødvej 92

DK-3460 Birkerød Denmark Telephone: + 45 45 81 23 00 Fax: + 45 45 81 99 56

Herewith declare that the product

Equipment: D500 basic unit Model number: DC5V8-BX

Serial number / production year: 113215 / 2013

Is in compliance 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 equipment of machinery. EN 13849 Safety of machinery -- Safety-related parts of control systems EN 12100 Safety of machinery

Person authorised to compile and hold the technical documentation: Bjarne Nielsen Managing Director Uffe Nielsen (Mr.) Grafisk Maskinfabrik A/S 17/12- 2013 Birkerød Uffe Nielsen . Date Signature


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EU Declaration of Conformity ..................................................................................................................... 3

1. Safety instructions ............................................................................................................................... 7

2. Control panel ........................................................................................................................................ 8

3. Touch panel .......................................................................................................................................... 9

4. The main screen ................................................................................................................................. 10

4.1. Web entry ............................................................................................................................................ 11

4.2. The varnish station ............................................................................................................................ 12

4.3. The spot varnish option ..................................................................................................................... 12

4.4. The laminating station....................................................................................................................... 12

4.5. The UV lamp ...................................................................................................................................... 13

4.6. The die-cutting station ....................................................................................................................... 13

4.7. Waste rewinder .................................................................................................................................. 14

4.8. V-knifes and Slitting knifes .............................................................................................................. 14

4.9. Rewinding ........................................................................................................................................... 15

5. Menu buttons ..................................................................................................................................... 16

5.1. Parameters .......................................................................................................................................... 18

5.2. Die-cut parameters ............................................................................................................................ 20

5.3. Speed control ...................................................................................................................................... 23

5.4. Web tension and scale print adjustments ....................................................................................... 25

6. Unwinder as rewinder ...................................................................................................................... 26

7. Alarms and messages ........................................................................................................................ 27

8. Language and units setup ................................................................................................................. 31

9. Special parameters ............................................................................................................................ 32

10. Registration accuracy ....................................................................................................................... 33

11. Markreader SUNX LX series .......................................................................................................... 34

12. Distortion and dispro factor ............................................................................................................. 35

13. Varnish station – prevent dripping ................................................................................................. 37

14. Dust problems with V-knifes & damages to anvil roller. ............................................................ 38

15. Die cut station adjustment and alignment ..................................................................................... 38

16. Die cut bridge adjustment ................................................................................................................ 39

17. General information for GM diecut station .................................................................................. 40

18. Pneumatic air cylinders .................................................................................................................... 41

19. Varnish station ................................................................................................................................... 43

19.1. Technical data .................................................................................................................................... 43

19.2. Anilox roller types .............................................................................................................................. 45


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19.3. Mounting of the anilox roller ........................................................................................................... 46

19.4. Mounting of the ink roller ................................................................................................................ 46

19.5. Mounting of side blades and doctor blade ..................................................................................... 47

19.6. Filling of ink ........................................................................................................................................ 48

19.7. Mounting of print cylinder ............................................................................................................... 48

19.8. Adjustment of impression ................................................................................................................. 49

19.9. Cross register ...................................................................................................................................... 50

19.10. Triangle adjustment of the flexo unit (Coarse adjustment) ........................................................ 51

19.11. Troubleshooting ................................................................................................................................. 52

20. Spot varnish guide. ............................................................................................................................ 53

20.1. Step by step guide .............................................................................................................................. 54

20.2. Trouble shooting ................................................................................................................................ 55

20.1. Pictures ................................................................................................................................................ 56

20.2. The parameter screen ........................................................................................................................ 57

20.3. The run screen .................................................................................................................................... 58

20.4. Print scaling ........................................................................................................................................ 59

21. Lamination (Tips and tricks) ........................................................................................................... 60

22. Operator Maintenance Chart .......................................................................................................... 60

23. Dimensions.......................................................................................................................................... 63

24. Spare parts and consumables .......................................................................................................... 64

25. Specification ....................................................................................................................................... 65

26. Cliché roller drawing ........................................................................................................................ 66

Specification die cylinder............................................................................................................................. 68

27. Installation guide ............................................................................................................................... 69


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1. Safety instructions

This chapter describes the safety guidelines that must be observed under all circumstances when

installing,commissioning, operating and maintaining the CONVERTING UNIT.

In this operating manual and on the unit, the following symbols will draw your attention especially to

hazards, risks and safety relevant information:

Indicates a potentially dangerous situation. Non-observance of the warning instructions

may lead to slight or medium personal injury or damage to machine.

Indicates a potentially 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 situation. Possible trapping of hand between rotating

rollers. Removal of the cover behind this symbol may lead to slight or medium personal

injury.

Indicates a potentially dangerous situation. Possible trapping of hand between rotating

rollers with sharp points (gears or other blunt parts). Removal of the cover behind this

symbol may lead to slight or medium personal injury.

Indicates general instructions, useful tips for application and recommendations for

working that do not have any influence on the safety and health of the personnel.


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2. Control panel

The control panel is fitted with a touch panel in the center, and separate sections on each side of the touch

panel. On the right side, the POWER button, Emergency Stop button, and the speed button is located. On

the left side, the five torque adjustment knobs are placed. The symbols indicate which spindle a torque

control knob is related to.

To power up, first check that the main switch is turned on, and the Emergency Stop button is released.

Press the POWER button. The touch panel will light up.


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3. Touch panel

The touch panel is the main control unit on the converting unit. All values regarding a job are entered

through the panel. It responds to light pressure onto the panel, thus responding when the user pushes a

virtual button or numeric value shown in the panel.

NOTE! Never hit the touch panel.

Do not 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 acid on the panel.

When the machine is turned on, the panel will light up, and after a few seconds the startup screen

emerges:

In the upper right corner, software versions are printed. This can be useful in maintenance situations.

To set language, units and clock, press 'Setup' (see appendix). To continue to the main screen, press

'Startup'.


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4. The main screen

The majority of machine functions are operated on the main screen. A large graphic representation of the

machine is used for controlling

mandrel expansion

spindle modes

nip rollers

varnish roller

die-cut cylinder

UV lamp

slitter knives

A number of buttons, checkboxes and readouts are placed on the lower part of the screen.

The converting unit is equipped with six spindles with different functions:

Unwinder

Laminate unwinder

Laminate rewinder

Waste rewinder

Rewinder 1 (top)

Rewinder 2 (bottom)


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Each spindle will change mode when the attached rotation mode button is pressed. Three of the

spindles can run in both directions (the two main rewinders and the laminate rewinder), and the rest can

run in only one direction. All spindles can be turned off.

When the center of a spindle is pressed, the air operated mandrel will expand (lock) or release.

4.1. Web entry

The web entry into the machine can be run in four different modes:

In Stand-alone mode, a roll is placed on the unwinder, labels out or labels in. The web must be fed

through the dancer, which creates web tension, and controls the unwinder.

In Inline mode, the web is fed into the converting unit from another machine, e.g. a print engine. Again,

the web must be fed through the dancer, which now controls the web speed together with the speed knob

on the control panel.

In the last mode, neither the unwinder or the dancer is used. This mode is necessary if an external unit

with its own dancer arm is feeding the converting unit. This could be a buffer or an external slave

unwinder.


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4.2. The varnish station

The varnish station contains the input nip roller and the varnish unit. Under normal operation, the input

nip must always be turned on, in order to create web tension. The nip roller is turned on and off by

pressing the small nip symbol in the lower part of the varnish station. Nips are coloured green when 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 automatically when the web starts and stop. If the feature

'Automatic varnish roller' is turned on, the varnish roller will be engaged when the web moves, and

released when the web stops.

4.3. The spot varnish option

If the spot varnish option is installed, the varnish station can be used for full-rotation spot varnishing,

with varnish rollers from 10 to 19". In addition, a "slow run" feature is available, which is suitable for

varnish types which are not UV varnish. The spot varnish features are accessed in the Parameter menu.

4.4. The laminating station

The laminating station consists of two spindles, with the laminating nip and the UV lamp in between.

The laminate unwinder is above the UV lamp, and the laminate rewinder is below.

The laminate unwinder can run one way only, meaning that the outer surface of the foil will be the side

touching the web when laminating.

When laminating, the laminate nip roller will press the foil against the web. This nip roller can be

engaged only if the laminate unwinder is activated. This is to prevent the rubber roller from accidentally

being pressed into wet varnish or glue.

The pressure that the laminating nip applies onto the web can be adjusted with the air pressure regulator.

The pressure gauge will only display the pressure when the nip is engaged. If the regulator is turned all

the way to zero, the nip will not move when activated. A typical pressure setting is 1-2 bar.

The laminate unwinder and rewinder will not rotate when the laminate nip is off. This is to prevent the

laminate foil from rotating freely through the laminating station.

In the output end of the laminating station, the center nip is located. Under normal operation, the center

nip must always be turned on, in order to keep web tension through the die-cut station.


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4.5. The UV lamp

The UV lamp is turned on and off be pressing the light bulb with the text 'UV'. When turned on, a few

seconds will pass before an attempt is made to ignite the lamp. When the UV lamp ignites, 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 the lamp cool for a few

minutes, and will then try again automatically.

The UV lamp gets very hot, and proper cooling is necessary. Please check the cooling unit regularly.

When the lamp is lit, the cooling unit must be running.

4.6. The die-cutting station

This converting unit is equipped with a die-cutting station, which can run in several modes. Correct setup

is crucial to the operation of the die-cutting station. To enter the die-cut setup menu, press the button 'Die-

cut parameters'.

To raise and lower the die-cut cylinder, press the cylinder symbol. When the cylinder is up, the symbol is

green. When the cylinder is down (engaged), the symbol is yellow.

When the cylinder is activated in the touch panel, it will not be physically engaged if the die-cut station is

initializing, or if the die-cut feature has been turned off in the die-cut parameters menu.

To lower the die do the following:

1) Make sure the handles on the pressure bridge are lose

2) Turn on the air by pressing the cylinder symbol on the touch screen.

3) Turn the handles on the pressure bridge softly until they are firm.

NOTE: Turning them down with excessive force will damage the die cylinder.

Once set, the die bridge can be operated by pressing up/down on the touch screen.

Remember to check that the die is always well oiled (oil pads) and there are no burn/track marks on the

sides.


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4.7. Waste rewinder

The waste rewinder runs counter-clockwise 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.

4.8. V-knifes and Slitting knifes

After stripping, the web enters the output nip roller, which should normally be on, to create web tension

through the die-cut station.. The output nip is turned on and off by pressing the nip symbol next to the

slitting knife.

The slitter knives come right after the output nip. They are either air operated , and are turned on and off

by pressing the knife symbol (see. Figure1)

Or with a handle activated manually. (Both sytems are optional)

The slitter knives (optional). They are operated manually by the handle at the station (see figure2).

When produceing with slitting knives, it is very important to remember to mount the clamp (see figure3).

It will stabilize the two axles and ensure a clean cut . When not using slitting knifes, the handle must only

be moved when the clamp is removed. The clamp can NOT be mounted when slitting knifes are

disengaged.

Figure 1 - Airpressured V-knifes

Figure 2 – Manual handle

Figure 3 - Clamp mounted in slitting mode.


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The slitting blades are running synchronised with web at a speed around 5% higher than the web. This

speed increase improves 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 or close the slitter knife shafts with the knife clamp mounted

on the shafts. It will damage the balance in the shafts, and the knife clamp to lock the

shafts.

4.9. Rewinding

The two rewinders can run both ways, and can be individually turned off. As with all the other spindles,

the rotation mode is set with the rotation mode buttons, and the mandrel is engaged and released by

pressing the spindle.

The knife clamp


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5. Menu buttons

Just below the machine drawing, you will find two white boxes. In the left box, two counters are placed:

A meter counter and a label counter. Each can be cleared by pressing the clear button [0]. Additionally,

the label counter can be turned on and off with the checkbox next to the counter. In the right box, info

messages, warnings and alarms will show up when the machine has something to report.

The 'Automatic stop at low unwinder diameter' feature makes the converting unit stop when the roll on

the unwinder spindle becomes smaller than a value entered in the Parameter menu.

The 'Automatic stop at label preset' feature makes the converting unit stop when the label counter reaches

or exceeds the preset value entered in the Parameter menu.

'UV min. power' is the minimum power that the UV lamp will deliver when the web is moving. When

web speed increases, the output power will also be increased. The value is altered by pressing the two

arrow-buttons to the left.

'UV power gradient' is the rate at which the power increases when web speed increases. The actual unit is

[W/(m/min)], i.e. with a web speed of 20 m/min, and a gradient of 200, the output power will be 4000 W.

The absolute maximum output power is 5000 W.


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The green button in the center bottom part of the screen is the start button. Press this to start the machine.

Pressing the 'Use unwinder as rewinder' button will open the Unwinder as rewinder menu, which allows

the operator to rewind web directly onto the unwinder. In this mode, the speed of the unwinder spindle

(now rewinder) is controlled by the dancer.

Pressing the 'Die-cut parameters' button will enter the die-cut setup menu.

Pressing the 'Parameter menu' button will open the parameter menu, which contains values 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, use the 'Remote Stop' button. The red lamp will light up briefly.

To make the remote control window disappear, press 'Close'.

To shut down the machine, press and hold 'Power off'. If the UV lamp is on, or has been on recently, the

machine will stay on (lamp off), and let the lamp cool before shutting down.


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5.1. Parameters

The 'Automatic stop at low unwinder diameter' feature makes the converting unit stop when the roll on

the unwinder spindle becomes smaller than the value. The diameter range is 80 .. 200 mm (3.1 .. 7.9").

The 'Automatic stop at label preset' feature makes the converting unit stop when the label counter reaches

or exceeds the preset value. The maximum value is 999999.

Note: When running in-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 'Automatic varnish roller' feature lifts the varnish roller when the web is not moving, and engages it

as soon as the web is moving again.

The 'Automatic laminate roller' feature lifts the laminate roller when the web is not moving, and engages

it as soon as the web is moving again.

The 'Nips and spindles off' feature may be useful when threading the machine. It lets the main motor run,

but turns off all spindles and nips.


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If the spot varnish option is installed in the machine, it can be activated with the 'Use spot varnish'

checkbox. In addition, the exact size of the spot varnish cylinder must be keyed in, either in "teeth", or in

mm (or inches). The two radio buttons select which unit is used. If the cylinder is a regular cylinder,

divisible in teeth, use the 'Spot varnish cylinder teeth'. The range is 80 .. 152 z.

The cylinder could also be a little bit larger than the exact z value (up to 1 z larger in circumference). In

this case, use the 'Spot varnish cylinder size'. The range is 254.0 .. 482.6 mm (10.000 .. 19.000").

If the 'Automatic slow run' feature is on, the varnish roller will lift from the web, and turn slowly, in order

to keep the varnish in motion, when the web is not moving. However, all safety covers on the varnish

station must be closed. Otherwise the varnish rollers will stop.

The '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-cut. Low range (box unchecked) is normally used for die-cut and stripped webs.

The range setting for each rewinder can be seen on the main screen. A blue 'L' means low range, and a

red 'H' means high range.

The 'Use tension roller' feature can be used only if the tension roller option is installed. It ensures a

nearly-constant web tension on the laminating foil. This can be necessary in cases where the laminated

material is cut out in sheets immediately after processing in the converter. In some cases, the end product

will bend one way or the other if there is the difference between web tension between the web and the

foil is significant.

The tension readout is on the main screen, next to the laminate spindle symbol. The readout shows only

the downward force on the tension roller, not the actual web tension. If the tension roller is not installed,

the readout will always show 0 N.


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5.2. Die-cut parameters

This converting unit is equipped with a die-cutting station, which can run in several modes. Correct setup

is crucial to the operation of the die-cutting station. Remember to change the plate in the die cut station

before entering new parameters. The die cut covers can be opned from the side and a new plate inserted.

First set the correct die-cut mode:

No die-cutting: The die-cut station is not used, and the die-cut cylinder cannot be engaged. However, the

cylinder will still 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 die-cutting with a die-cut cylinder between 12" and 25". The cylinder

must be made specially for digital die-cutting.

Then enter the relevant information. If 'No die-cutting' is selected, no further information is necessary.

'Blank labels': The die-cutting station cuts, but doesn't use printed marks. It is meant to be used only on a

non-printed web.

'Number of labels on cutting plate': This is for the label counter. Every time the die-cut station has made a

full rotation in register, the label counter is increased with this number.


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Analog mode:

If analog mode is selected, the operator must enter the size of the die-cutting cylinder. The unit is "teeth"

(Z). One tooth is 1/8 inch. This figure is entered in 'Die-cutting teeth'.

Digital mode:

The die-cut station must know a few details about the cutting plate and the print, in order to operate

correctly. The first value is 'Plate size', which is the size of the cutting plate – or more accurately – the

precise distance between the printed marks. The range of possible plates is calculated like this:

The minimum plate size is 30% of the cylinder size. Thus, shortest plate that will work on a 25" cylinder

is 190.5 mm, or 7.5".

The maximum plate size is the full cylinder size minus 4.5". Thus, the longest plate that will work on a

25" cylinder is 520.7 mm, or 20.5".

NOTE! Be carefull with other platesizes.

The machine can handle platesizes 50.0~558.8 mm.

'Cutting plate margin' is the next value. It is the distance from the leading edge of the plate, to the first

point that will actually cut the web.

The 'Distortion factor' is used when the plate to be used is not made for the used cylinder. If a plate is

originally 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 to a value less than 1. This

makes the die-cut station move in a slightly different pattern, stretching the label shapes on the web.

Great care should be taken when this value is altered. Since the die-cut plate will not run at the same

speed as the web, a considerable amount of force is necessary to make the correct die-cut shape. Some

jobs are easy to distort, and others are nearly impossible. Microlabels and small circular labels cannot be

expected to run well with a plate not made for the used cylinder.

Calculation of the distortion factor is a bit too complicated, but can be done by using a spreadsheet

supplied by the manufacturer. Below is a small table, showing the theoretical distortion for plates made

for different cylinders, used on five other cylinders.

The distortion factor can also be used for adjusting the gap between labels, if the gap is a little bit off,

even though the die-cut plate is manufactured for the used cylinder. The behaviour is be caused by

stretched web, thick web curving around rollers, and other mechanical factors. In this case, the distortion

factor should not be set lower than 0.9930 (heavy stress on paper and tools).

NOTE! Call support or write to GM Tech, and we will provide to your specific machine

the distortion factor.


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Running:

When the start button is pressed, this screen appears:

Most parts of the screen are exactly as when the machine is not running, but some things have changed.

The red button is the stop button. When this button is pressed, the machine will decelerate and stop. The

value above the stop button is the measured web speed.

'Measured print length' is the distance between two marks, measured by the die-cut station while running.

'Die-cut deviation' is the measured die-cut register fault. When the die-cut station is running, and

synchronizing with the printed marks, the deviation from the expected cutting position is measured and

displayed.

'Spot varnish 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-cut position on the web. The single arrows move the offset in

steps of 0.05 mm (approx. 0.002"). The double arrows move in steps of 1 mm (0.39"). If a double arrow

is held pressed, the steps will increase to 2mm after a while, and then to 5mm. In relation to the print, the

cutting lines will move in the direction the arrows are pointing 'Spot varnish offset' is used for moving the

varnish position on the web. The single arrows move the offset in steps of 0.05 mm (approx. 0.002").


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The double arrows move in steps of 1 mm (0.39"). If a double arrow is held pressed, the steps will

increase to 2mm after a while, and then to 5mm. In relation to the print, the varnish position will move in

the direction the arrows are pointing. The offset can also be adjusted on a knob mounted on the varnish

station.

The 'Clear blind' button is for syncronizing the die-cut station with the printed web, using a specific

registry mark. When the machine is die-cutting, the mark reader will "go blind" after reading the first

printed mark, and will continue being blind for 90% of the die-cut plate size. E.g. with a 12" plate, the

mark reader will be blind for 10.8" after reading the first mark. When 'Clear blind' is pressed, the die-cut

station will forget all about the previous marks, and use the following mark as a registry mark.

5.3. Speed control

The web speed is mainly controlled by the speed potentiometer. However, the different modes and

possibilities give different speed limits.

When running offline, without the die-cut station, the speed limit is 70 m/min, and the speed is solely

controlled with the speed potentiometer. In analog mode, the speed is limited to approx. 72 m/min. In

digital die-cut mode, the speed limit depends on which job is running, but the absolute limit is 35 m/min.

The following tables show the approximate speed limits relating to different job setups.

When running inline, the speed is controlled partly with the speed potentiometer, and partly by the

dancer arm. Therefore, when running inline, the speed potentiometer must be turned up. Otherwise, the

web will not move. Usually, a setting of about 4-5 is adequate.


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Green graph = 12 inch cylinder

Violet graph = 15 inch cylinder

Blue graph = 20 inch cylinder

Orange graph = 25 inch cylinder

The diagram shows the mechanical max speed on the given die cylinder.

Be aware that the max speed is depending on motion controller software.


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5.4. Web tension and scale print adjustments

By pressing the “tool” symbol on the machine in “running” mode the web tension parameter can be

accessed.

Tool icon.

The tool button will open the web tension and scale 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 the gearing on the impression cylinder relative to the machine. This alters

the length of the print.

Die-cut scaling alters the die cutting length. Be careful with this function heavy scaling can damage the

tool or break the web.


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6. Unwinder as rewinder

The unwinder as rewinder feature is useful when none of the functions in the converting unit are

necessary. It enables operator to rewind the material from the press directly onto the spindle that is

normally used as the unwinder spindle. The unwinder as rewinder function is reached from the main

menu.

When the green start button is pressed, the screen will change, and the spindle will start turning, lifting

the dancer to a high position. When the press feeds paper, the dancer will drop, and the rotation speed of

the spindle will increase. The only option to set up is the direction of rotation.

When the stop button is pressed, the spindle will rotate slowly backwards, letting the dancer drop nearly

to the bottom before stopping.

Note: There is no measurement of the roll size. The operator must keep an eye on the roll in order to stop

the press before the roll gets too big.


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7. Alarms and messages

A number of alarms and messages can be shown in the panel in various situations. All alarms are

accompanied by a symbol, showing if it is merely an info message, a warning, or a serious error

(malfunction).

This symbol indicates that the text message is a non-critical piece of information to the operator.

A typical info message could be: 'Die-cut station is initializing. Please wait.'

This symbol indicates that the text message is a warning to the operator. It could mean that the

operator should pay attention to something, or that something prevents the converting unit from

running. A typical warning could be: 'Safety shield open.'

This symbol indicates that a more serious error has occurred, which will most certainly affect

machine operation. A typical error message could be: 'Safety shield opened during machine

operation.

General messages:

Safety shield open One or more safety covers are open, preventing the

converting unit from running.

Automatic nip is manually overridden The 'Automatic varnish and laminating rollers' feature is

enabled, but the state of one or both rollers has been changed

manually.

Nips and spindles are off The 'Nips and spindles off' feature is enabled.

Safety shield opened

during machine operation!

A safety 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 outer diameter of the unwinding roll is smaller than the

number specified in the parameter menu. Thus, the machine

has stopped.

Preset number of labels

has been reached

The machine has been set to stop at a certain preset, which

has now been reached. Reset the counter, or set a higher

preset value to continue.

Can't start remote unit.

Converting unit is not ready.

An attempt has been made to remote activate the Feed or

Print cycle on the digital press, but the converting unit is not

ready. Start the converting unit, and turn up the speed.

Varnish activated,

but UV lamp is not ready.

The varnish roller has been activated, but the UV lamp is not

on, or not yet ready, creating a risk of smearing varnish on

the rollers. It is OK to do so, is a different type of varnish-

drying equipment is in use, such as hot-air, IR etc. This

messages is accompanied by a short beep.

Touch panel communication trouble The internal communication to and from the touch panel has

been briefly interrupted, probably due to electrical noise. If

the problem persists, please contact the manufacturer.


28

Internal RS422 communication trouble The internal communication between different parts of the

converting unit has been interrupted or cut off. If the problem

persists, please contact the manufacturer.

Fatal problem!

Press the flashing symbol

to clear the alarm.

An unexpected error has occurred, which has caused the

machine to stop abruptly. In this situation, the message

display will switch between this text and the actual

explanatory message text, along with intermittent beeps. The

message and beeps will not disappear before the flashing

alarm symbol has been pressed.

Buffer dancer forced in top position This error indicates that the converter has been pulling to

much material out of the buffer causing the dancer arm to be

forced into the upper stop. Please check that the converter is

operating in buffer mode and not in inline or internal

unwinder mode. This is selected by pressing the unwinder

symbol on the touch screen

Buffer is empty. A information only on the state of the buffer. This will

prevent the converter from pulling more web.

Motion controller is not responding.

Contact manufacturer.

A communication problem between the internal PLC and the

motion controller. Restart

the machine to reset this

Motion controller is not ready The motion controller 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 position error. Indicates that the servos are unable to

move to there

correct positions. Check that all servos have power and there

are no

red error messages on the drives. Check that no shafts are

blocked.

Remote unit is not ready. Remote unit is not ready. The printing press has raised the

not ready signal. This stops the converting

line

UV lamp related messages:

UV power supply on The power supply for the UV lamp has been switched on.

After a few seconds, an attempt will be made to switch on

the lamp.

UV lamp starting The UV power supply attempts to turn on the lamp.

UV lamp is too warm to start. Cooling... The UV lamp is too hot, so it cannot turn on. A new attempt

to turn on the lamp will be made after two minutes.

This situation will also occur if the UV bulb is broken or

missing.

UV lamp warming up The UV lamp is warming up to reach its working

temperature.


29

UV lamp off. Cooling... The UV lamp has been switched off, but the cooling unit is

left running for five minutes.

UV power supply error An error has occurred in the UV power supply. In a moment,

the type of error will be reported.

UV error: Low voltage The supply voltage for the UV power supply is too low.

UV error: Lamp overheated or case open The UV lamp has become too hot, or the lamp casing has

been tampered with. Please check cooling unit and lamp

case.

UV error: Lamp short circuit fault The UV lamp has been short-circuited.

UV error: UV power supply overheated The UV power supply has become too hot. Please check the

cooling fan on the UV power supply.

UV error: UV power supply earth fault The earth connection for the UV power supply is faulty.

UV error: UV power supply phase fault One supply phase for the UV power supply is missing.

UV error: UV shutter trouble The mechanical shutter in the UV lamp is unable to open or

close completely.

UV lamp not connected The UV lamp has not been properly connected to the main

circuit board.

Die-cut related messages:

Shield open in die-cut station. A safety cover in the die-cut station is open.

Die-cut station is initializing.

Please wait.

The die-cut station is positioning cylinder and sleigh rollers,

according to the keyed-in values.

Die-cut safety shield opened

during machine operation!

Web may be damaged.

If a safety cover in the die-cut station is opened while the

machine is running, the die-cut station will stop abruptly, and

the web 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 have not been connected properly.

Web speed is too high.

Die-cut station can't keep up.

Reduce web speed.

Depending on the die-cutting job, there is an upper web

speed limit. This limit has been exceeded. Reduce web

speed.

Die-cut station failed.

Limit switch activated.

The die-cut sleigh has activated a limit switch, and has been

shut down. The web speed could be much too high, or the

controller for the die-cut sleigh is damaged.


Program error.


Internal error in the die-cut controller. Contact manufacturer.


Internal E-stop.


Internal error in the die-cut controller. Contact manufacturer.

Spot varnish related messages:

Shield open in varnish station. A safety cover in the spot varnish station is open.

Spot varnish station is initializing.

Please wait.

The spot varnish station is positioning varnish cylinder,

according to the keyed-in values.

Spot varnish station

failed to initialize.

Check that the gears are in position.

The spot varnish station has attempted to rotate the varnish

cylinder, but the gears have not been connected properly.


30

Spot varnish position error. The spot varnish station has been mechanically blocked,

disabled, or is by other means prevented from reaching its

correct position.

Spot varnish station failed.

Program error.


Internal error in the spot varnish controller. Contact

manufacturer.

Spot varnish station failed.

Internal E-stop.


Internal error in the spot varnish controller. Contact

manufacturer.


31

8. Language and units setup

On the startup screen (right after power-up), press the 'Setup' button, to get to this menu:

When more languages have been installed in the panel, these can be selected with the radio buttons in the

left part of the screen.

In the 'Units' menu, the measuring units can be selected. In 'Metric' mode, the speed is measured in

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 UV lamp has been on. This can be used for

predicting when the lamp needs replacement. When the lamp is replaced, reset the counter by pressing

the [0] button.

Press 'Accept' to save changes and exit, or 'Cancel' to exit without saving changes.

Note: The selected time is not affected by pressing the 'Cancel' button.

The 'Next' button will lead to the Special parameters menu.


32

9. Special parameters

The following menu is reached by pressing 'Next' on the language setup screen.

Nip roller sizes:

The machine uses 304.8 mm (12”) rollers with a diameter of 97.02. Altering the size of the nips will

change the overall tension in the machine.

Digital 1 – 2 & Analog 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 reader and the die-cut

cylinder, when the sledge is in its engage position.

NOTE!Factory default value is 111 mm. Analog and digital setting is normally the

same.

Press 'Accept' to save changes and exit, or 'Cancel' to exit without saving changes.

The 'Previous' button leads back to the language setup menu.


33

10. Registration accuracy

The registration accuracy is defined as the deviation in the first cutting line relative to the registration

mark. If there is deviations due to differences in gab size between the labels, it has to do with the

distortion setting or the dispro factor of the plate. To get the best possible results do the following:

1. Select the shortest possible plate. The ideal situation is one label row pr. rotation, if this is not

possible go for 2,3,4. The machine gains accuracy as the distance between registration marks

shortens. For optimal economy it is acceptable to use the longest possible repeat on the print

engine, but remember to put several registration marks in the repeat, a shorter plate 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 first cutting distance is entered correctly

4. Run with all nips down.

5. Secure that the die is correctly shimmed up (no lateral movement) and the inductive sensor

behind the die is correctly adjusted (2mm from die tooth wheel)

6. Secure that the mark reader focus distance is 9 mm

7. The repeat distance must never be less than the distance between the mark reader and the die (this

is only the case if the mark reader has been moved) om the first cut line. If this happens, machine

will die cut a labels based on the registration mark for the next label. This will reduce precision.

8. The space between register marks must never be less than 50mm

9. Do not die cut across print engine frames (Always align the register mark with the frame start)


34

11. Markreader SUNX LX series

Quick overview of the SUNX markreader.

To make the adjustment of Sunx LX Markreader, there must be a colored mark.

Press the blue button shortly and place a colored mark under the reader, and press the ON/SELECT

button shortly. The display shows 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 both markreaders.

Calibration is now done.

NOTE! To achieve the best possible reading with Sunx LX-100 the distance from the

reader to material presented surface must be at max. 9 mm. Furthermore the web have

to be as stable as possible. Be sure to webtension is set correctly, same as webguides.


35

12. Distortion and dispro factor

The dispro factor is defined as the percentage the die plate is shortened in order to have the correct length

when wrapped around the magnetic die. On figure 1 (right side) the distances D1 and D2 are the length of

the die plate measured from the top of the knife and the bottom of the plate. When flat, D1 is equal to D2.

When wrap around a cylinder D1 is longer than D2. This means that a plate measuring D2 when flat will

be longer when put on the cylinder. To have the correct repeat length the plate has to be shortened by a

certain percentage, the dispro factor.

If a plate does 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 also occur when the plates are made for the 25” die – in this case the manufacture of the die plate has

to change the dispro factor slightly. Some die plate manufactures uses an experience constant that gives

the best result for a specific series of machines. The theoretical value is calculated on figure 1 (left side)

The machine can do a compensation for this problem – the distortion setting in the die cut parameters

menu. Doing a compensation will force the paper faster or slower under the die. The heavy

compensation on plates with many labels may not be possible and will cause deviations in the register.

Figure 1. Dispro calculation.


36

A series of tests has been done on standard label material.

Tool: 25” Gerhard cylinder.

Plates: 304.8 mm plate distorted for a 25” (200Z) die. Three different dispro factors tested.

The gab size between the labels was 2.8 mm giving a distance of 304.8 mm – 2.8mm = 302 mm between

the first and last cutting line.

Dispro factor Length Difference in millimetres

Test plate A 99,5874 301,61 mm -0,39 Gab to big.

Test plate B 99,6504 301,81 mm -0,19 Gab to big.

Test plate C 99,71339 302,07 mm 0,07 Gab to small.

Ideal length (304.8mm - 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 curving around rollers),

and mechanical factors (plate manufacture tolerances / die cylinder mechanical tolerances).

Keep in mind that if the dispro factor is a bit off, the error will become large as the plate size increases.

Keep the plates small to minimize distortion problems and lower costs.

Example:

Difficult long die plate. 10 labels in the length direction. High demands on the print lenght, registration

and plate dispro factor.

.

Good die plate. Two labels, short length. Short distance between registration marks, no dispro factor

problems.


37

13. Varnish station – prevent dripping

1) Check the dimension of the print roller. It must be 97.2+(0.3)mm.

2) Remember to mount the lower station cover (metal plate).

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 roller.

If there is no need for varnish on the sides of the web the impression roller can be tooled down to prevent

varnish build-up.

Figur 2. Standard rubber roller with shamfered edge


38

14. Dust problems with V-knifes & damages to anvil roller.

This issue does only relate to machine with V-knifes. Rotary knife systems does not have dust problems.

The standard V-knife has an angel of 45, this can generate dust with some materials. If there is a

problem, we can deliver a knife with a 30 angel to fix this problem. This knife is sharper and have a

shorter life cycle. Remember to limit the air-pressure to a minimum (what is needed to just cut through

the paper).

15. Die 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 an adjustment.

Centering the die cut cylinder extends support bearings lifespan, but it also avoids crushing the inductive

sensor on the backside of the sprocket. Use an allen 2,5mm and gently turn clockwise the pointed screws

Untill there are some slight pressure in the allentool. Its easy to feel when die cut cylinder is not ingaged

in gear.

Pay special attention to the rear of the gear on the die cut cylinder, that the inductive sensor does not hit

the cylinder gear. There should be 1-2 mm gap.


39

16. Die cut bridge adjustment

To adjust the stroke of the die bridge follow this procedure

1. Dismount 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. Hold the bolt with the allan key and lock the nut.

5. All 4. set points must have the same distance.

6. Remount the bridge


40

17. General information for GM diecut station


41

18. Pneumatic air cylinders

The two air cylinders can disengage the magnetic die cylinder because the die is supported with springs

below the bearing houses. The stroke of the piston plate is 1.5mm, enough to stop die cutting, but not

enough to get the cog wheels out of grip. The 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 from the air cylinders is only to move the die up and down and has nothing to do with the

pressure you use for die cutting, this is adjusted with the pressure screws.

WARNING:

Secure that the pressure screws are not tighten before you engage the die, - it can damage

the die because of to much pressure.


42

Gap:

The “gap” is the distance between the surface of the die cylinder and the surface of the anvil cylinder.

The distance cannot be adjusted because the bearers on the cylinders control it. The gap on GM machines

is 0,48mm (label) or 0,76mm (postcards etc.)

Pressure adjusting:

When the die is engaged (down) adjust the pressure so high that you get a perfect die cut and not higher.

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 pressure should never exceed 20N/mm ( 283 bar on 500mm web width and 187 bar for 330mm web

width)

If you cannot get a perfect die cut it is properly not a correct die plate.

Do not try to fix it by increasing the pressure, - it will only damage the magnetic die cylinder, - get a

correct plate.

WARNING:

Never use tools to tighten the pressure screws!

Never tighten the pressure screws and then put down the die!


43

19. Varnish station

The UV-varnishing unit is used after the digital printing unit to varnish the web. The varnishing unit is

designed for the use of UV - curing ink/lacquer. Also water based priming is possible with hot air dryer

mounted. Before the varnish station is used: Please check that the dimension of the Print roller diameter

is correct. It must be 97.2+0.3mm.

19.1. Technical data

Web widthmax: 330 mm

Plate cylinder diameter 97.02mm

Print roller diameter (replaces plate cylinder when flood varnish is used) 97.2+0.3mm

Printing widthmax: 310 mm

Printing lengthmin: 9“

Printing lengthmax: 19”

Increments: 1/8”

UV-lamp, effectmax: 5000 W

Continuously variable between 300 W and 5000 W

1. Handle for mounting ductorblade.

2. Handle for mounting anilox roller.

3. Handle for mounting of ink roller.

2

3

1


44

The paper web is fed through the press on stationary rollers (impression rollers and turning rollers).

Above the web is 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 anilox roller is inked up by the inking roller in the ink tray.

Paper web

Impression cyllinder

Plate cylinder

Anilox roller

Inking roller

Ink tray


45

19.2. Anilox roller types

The amount of the ink to be transferred to the plate and paper web is determinate by the form and size of

the anilox roller's cells.

If a lot of ink is to be transferred to the paper web an anilox 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 rollers with a screen number between 60-240 lines per cm are used.

The selection of anilox roller depends on type of ink and colour density. As a general indication for

selection of anilox roller the following can be stated (as an indication only).


46

60 lines per cm. Used for full inking up/varnishing on highly absorbent paper qualities. This coarse

screen is best suited for special inking-up rollers.

70 - 80 lines per cm.

For full inking-up/varnishing with full solids on finer paper such as e.g. High Gloss

qualities.


For mixed printing, smaller printing surfaces and text, etc.


For screen and process printing (see below).

Lines per cm Cell depth

micron

Theoretical ink transfer

grms/m2

80 15 10

100 15 8

120 13 6,5

140 15 7

140 11 6

140 7 4,5

160 6 3,5

220 7 2

19.3. Mounting of the anilox roller

Pull out the inking roller by loosening the two mounting handles. Carefully slide out the inking roller.

Loosen the two handles for mounting of anilox roller and carefully slide in the anilox roller. Tighten the

handles and make sure the 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 ought to be handled with care. Especially the ceramic

covering at the end of the roller can be damaged by a stroke or a loss on the floor.

The surface must be cleaned after use, so that the roller can transfer an even and uniform layer of ink to

the plate cylinder. Dried-up ink or dirt in the cups of the surface will reduce the quantity of ink and

produce an uneven image.

19.4. Mounting of the ink roller

The roller is placed in the same way as the anilox roller and locked with the bearing housing. Levers for

the ink roller's pressure on the anilox roller must be disengaged (down) on insertion and removal. The ink

rollers must be stored suspended in the shaft ends so that the rubber covering will not be deformed.

NOTE! When the press is not in use fold down the levers, so that the ink roller's

rubber is not squeezed against the anilox roller.


47

19.5. Mounting of side blades and doctor blade

1. Knurled nut for blade adjustment.

2 .Fixing of side wipers.

3. Doctorblade with outward bevelling.

4.Sidewiper.

The doctor blade can be adjusted when there is ink on the anilox roller. Adjust the two knurled nuts so

that the doctor blade can just reach in and 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 the ink is wiped off evenly in the entire width. The levers are moved

up so the ink layer disappears and down until correct pressure is achieved. There will be ink stripes with a

film of ink between them below the doctor blade. The reverse angle blade doses the same quantity of ink

to the anilox roller at all speeds.

1

3

2

4


48

NOTE! The blade may not be set too hard as both doctor blade and anilox roller will be

exposed to unnecessary wear and tear.

NOTE! The blade may only be ON when there is ink on the roller. Ink reduces friction.

Impurities in the ink or dried ink residues can damage the doctor blade, giving lines in the

image and at worst scratches in the anilox roller.

NOTE! If the doctor blade is damaged wiping will be uneven.

NOTE! A scratch may damage an anilox roller.

A defect doctor blade can be replaced by releasing the five screws on the blade holder.

The blade is pulled out. A new one is inserted and clamped, parallel with the blade

holder, so that the bevelling faces outwards.

Adjust the side wipers as close to the anilox as possible. If there is a gap between the wiper and the

anilox, dripping will become a problem.

19.6. 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-pump is connected, use an overflow pipe in the ink tray drain

hole in order to drain excess ink/varnish.

NOTE! When UV varnish is used cover the station with a blanket when stopping the

daily production. This will prevent light access to the ink tray and unintentionally ink dry

up.

NOTE! When using water based inks the entire station must be cleaned after production.

19.7. Mounting of print cylinder

The plate is mounted on the aluminium plate cylinder with the proper tape (see flexo plate

documentation). Make sure that the plate cylinder gear wheel has the correct size (the gear increment is 8

teeth per inch).

After plate mounting slide the plate cylinder into the flexo unit. Lower the plate cylinder until the gear

wheels are in mesh. On start the automatic print throw-off/on will lower the plate roller further.


49

19.8. Adjustment of impression

With the hand wheels (1) the print head is lowered and raised. The hand wheels are also used for

adjustment of impression. The impression of the print head 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 cylinder. Then lower the print cylinder in the side without printing by

turning the knurled handle in this side CW. You might need to raise the cylinder in opposite side to avoid

excess pressure on the web.

1


50

19.9. Cross register

When the knurled handle (1) is turned; Clockwise - impression is shifted towards the operating side of

the press. Counter 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 print cylinder pressure bridge (2). without contacting

the local Field engineer or support from GM. Severe damage to personel and/or

machine can ocurre.

1

2


51

19.10. Triangle adjustment of the flexo unit (Coarse adjustment)

In order to obtain best possible varnish/print quality on the flexo unit an initial coarse adjustment is

necessary. Under normal conditions this should be performed once a month at least or every time after

cleaning the flexo unit.

Clean impression roller, varnish roller and surface of anilox roller. Activate (engage) the varnish roller in

the “main screen” (press the varnish roller in the touch screen so the symbol turns to yellow colour).

1. From the front-end of the flexo unit insert two liner paper between 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 have to make sure the distance is

exact on both sides.

With a slightly pull in each of the liner papers the should be some tension.

2. From the backside of the flexo unit insert two liner paper between anilox roller and plate cylinder.

Now adjust the anilox roller towards the plate cylinder. Do not adjust the plate cylinder .

Gently adjust the anilox towards the plate cylinder until it grips the liner paper. You have to be

sure it grips in both sides. Do not tighten the anilox too much against the plate cylinder.

With a slightly pull in each of the liner papers the should be some tension.


52

3. Finally check the first adjust and repeat the two steps until all measures are OK.

19.11. Troubleshooting

If the impression between plate and web is too weak the image is not imprinted evenly. This is seen as

holes in solids and type. Too little pressure between the anilox roller and the plate is seen as bare lines

across the web.

The most frequent reason for a poor impression is too high pressure between anilox roller and print roller

or between print roller and web.

Too strong pressure between the anilox roller and the plate is seen as a brim 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 choice of anilox roller determines how much ink the plate receives. If this coverage is heavy and the

pressure on the impression to high it will be seen as a rim of pressed out ink at the rear edge of solids.

The expression "kiss printing" is often used to describe how light the pressure should be between anilox

roller, plate and paper.

Light but adequate impression is best achieved with new plates carefully mounted without air bubbles

underneath. Correct ink viscosity (possibly checked with a Zahncup) is also an important prerequisite to

achieve printing "as soft as a kiss".


53

20. Spot varnish guide.

Introduction

The spot varnish function of the converting unit enables the system to put down print in register. This can

be used for various applications; spot varnish effects (only part of the web varnished), Cold foil (a glue is

printed in patterns to make silver/gold effects) and single color printing. The most common option is the

spot varnish effect where only a part of the web is varnished. The spot varnish only has one parameter –

the “Z” count –the number of teeth on the tooth wheel of the print cylinder. The Z unit is 1/8 of an inch or

3.175mm pr. Tooth. A 10” plate cylinder has a Z count of 10*8= 80Z and a plate size of 10”*25,4mm =

254mm.

Working principle

When equipped with a spot varnish option the print plate cylinder in the flexo graphic station is driven by

an independent motor. This means that the print plates cylinder can be synchronized with the web using a

print mark reader located next to the station. To make sure printing starts in the same position every time

a job is setup the system makes a “homing” when a new cylinder is loaded. The print plate cylinder is

“homed”by turning until a small hole in the tooth wheel passes a sensor located in the frame of the flexo

station. This hole is only once (at the startup of the job). The cylinder will make a quick rotation and find

the hole. When the system is synchronized it will start to look for a mark on the web. When found the

plate cylinder is moved into a position in reference to the mark. This position can be altered by turning

the “offset knob” on the side of the station or pressing the “offset” button on the touch screen. The offset

determines the distance between the printed mark on the web and the zero hole on the cylinder.

The print plate cylinder can be lifted up and down on the touch screen of the machine. This is done by

pressing the 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 cause web break). When the cylinder is up the cylinder can make a ½ rotation of the

cylinder. This is enables the system to go quickly in regis ter. Important: Due to the small corrections

possible in print mode the print must match the circumsphere of the cylinder with a tolerance of +/-

0.1mm. If the print is “out” of size the gab between the repeats will be incorrect and in bad cases the

machine will not be able to synchronize (the register will “slide” out ).

To determine if the system is “locked” on the print mark monitor the “deviation” field on the touch

screen. The deviation is a feedback from the register system that constantly tells the operator how far the

print is out. When “locked” on the target this field is normally jumping in the range +-0.3mm. If it is

close to 1 mm there is a risk that the system will “slide out” of register and the number will steady

increase or decline; example print is 1.1 mm out. Deviation values will be 1.1 – 1.2 – 1.3 – 1.4 constantly

sliding 0,1mm out because the machine is not able to correct the full amount needed to be in register with

a misprinted web.

The machine also provides the operator with a 2. Feedback – the “measured print length” on the touch

screen. This is a measurement of how much web has passed between two marks. It will give a very quick

indication if the plate size and the distance between the print marks are not equivalent.

If the system fails to synchronize the machine has an option to compensate. This is done from the run

screen (with RED start button) by pressing the tool icon on the touch screen. Here there is an option

called “spot scaling”. Spot scaling can force the cylinder to run quicker or slower relative to the web. This

will allow a misprinted web to work (be locked in register), but the price to pay is poor print quality. To

adjust the scaling press the + or – until the deviation number stabilizes around 0.


54

20.1. Step by step guide

To startup spot printing follow the steps below. Please see picture section in the back of this

guide when there are references to buttons or menus.

Enter the Z size of the plate cylinder in the parameters menu of the touch screen. Always use the

Z size, never enter in mm. The Z count is engraved into the tooth wheel of the plate cylinder.

Please note that the system has a “slow run” feature. This feature will allow the plate cylinder to

rotate at stand still to avoid dry out of water varnish. If UV varnish is used turn off this feature in

the parameters menu.

Mount the print plate on the plate cylinder. Make sure to use the correct tape and plate thickness

for specific cylinder. This most common tape thickness is 0.38mm. The standard plate size

thickness is 1.7mm. If tape and plate thickness does not match the circumsphere of the cylinder

will be wrong. This will lead to a gap between the rotations (where the plate is put together on the

print plate) and misprint (print will not fit the preprinted web).

Important: Make sure the cylinder is only “loosely” in grip with the tooth wheels. When the

cylinder is engaged later in the process air pressure will make the cylinder move further down.

Adjust the print station. Use the guide the main manual for the machine. This step is normally not

needed, but if the station is completely 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 and a correct distance between the cylinders has been set.

Remember that the anvil cylinder is the reference in the station

Turn on UV lamp. Start running the web slowly with the plate cylinder up. Adjust the mark

reader next to the flexo station. Make sure it reads one mark pr. Rotation of the plate cylinder.

Look at the RED light of the mark reader. Only one blink pr. rotation of the plate cylinder. Using

more marks may lead to problems synchronizing (the system may lock on to a wrong mark) and

is generally not recommended. Look at the deviation field for the spot varnish. When the field is

dropping below (plate cylinder synchronized) drop the cylinder down by pressing it.

Adjust print quality by turning the two adjusters on the top of the flexo station station. Look at the

sides – you must have an even print quality on each side of the print plate. There are typically

support lines on each side of the print plate.

Move the station into register across the web. This is done by turning the side adjustment block to

the left or right.

Move the station into register in the web direction. This is done by turning the offset knob on the

side of the station. Please note that the system will move slowly. This can also be done from the

touch screen.

Increase speed and monitor print quality. Fine adjustment of pressure on print plate cylinder may

be needed as speed increases.


55

20.2. Trouble shooting

Problem Fix

Print runs out of register Check print length. Check mark reader. Re-tune mark reader.

Do spot scaling

Print quality is poor Check tape and plate thickness. Check support lines on plate.

Re-adjust station

No varnish at startup Turn off slow run feature (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 mark pr. print plate length.


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20.1. Pictures

Main screen.

From here the "parameters menu" gives access to the key spot varnish parameter - the "Z" count or size

of the tooth wheel on the print plate cylinder. Please note that the print plate cylinder can be controlled by

pressing the it (top left - the green cylinder).


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20.2. The parameter screen

When using spot varnish the spot varnish cylinder teeth point must be entered and the "use spot varnish"

check 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 plate cylinder at stand still. This can be used to avoid

damage to full float coating rollers at stand still. It will leave a small blank mark at startup.


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20.3. The run screen

The run screen is displayed when the start button is pressed. The start button will change from green to

red when pressed. From the run screen the measured print length and spot varnish deviation can be 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 in the web

direction in reference to the print mark.

If scaling is needed - the tool icon on the top left scan be pressed. This will allow the operator to scale

(adjust the print speed) of the print plate cylinder. This is only an emergency option.


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20.4. Print 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 can be used to

get a "bad job" done.


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21. Lamination (Tips and tricks)

If you have fish-eye's in the laminate it is normally a sign of lack of adhesive in some points.

Tricks for for self-adhesive laminates

a) Make sure that the lamination roller is clean and flat. No dirt on sides. Run 3-4 bars pressure.

b) Increase pressure on center nip roller to 5 bars - then it works as a "2nd

lamination roller"

c) Check substrate after 24 hours. Does the fish-eye problem go away over time?

d) Run a clean substrate in the machine (not printed) and check if problem goes away.

e) An additional work-around is to change to a harder nip roller to /VAL001D, which is SH95 compared

to the normal /VAL001C, that is SH65.

Tricks for UV laminates

a) Make sure that the lamination roller is clean and flat. No dirt on sides. Run 3-4 bars pressure.

b) Check that 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 roller. If the varnish build up on the sides of lamination roller, then the lamination

roller will "grow big" on the side and fail.

d) Check that anilox volume is high enough - simpel test: run without doctor blade - this will put down

30cm3/m2 of glue - more than needed for all laminates

e) Check substrate compatibility. Simple test. Put down glue without lamination.

Rewind substrate. Run it again and this time putdown glue and lam. If this fix the problem, the substrate

is too open for lamination (must be primed)

f) Check for oil from the press. Turn off oily web and clean all press rollers. Run 1000 feet in press

before starting test. Test if lam works without the oily web turned on.

22. Operator Maintenance Chart

Unit Module Every Activity Tools Remarks

Converter All nips

and rollers

1 day Clean for

varnish and glue

Cloth, alcohol

Converter Anilox/ductor

doctor blade ink

tray

7 days Clean for

varnish/ink

Cloth, uv wash Replace doctor blade

if it’s damaged


61

Converter Flexo unit 1 day Inspect side scraper and doctor

blades.

The doctor blade holder must

NEVER touch the anilox (heavy

damage)

Allan key. Side scrapers must 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 Flexo unit 1

month

Check diameter on print roller.

New roller has Ø97.2. At Ø96.5

the unit stops working

Calibre Always keep a spare print

roller

Chiller Water level 1

month

Refill if necessary Tap water

Chiller Return filter 1

month

Clean if necessary

Converter All belts 1 year Tighten if necessary

check that belts are ok

Replace belt if it’s

damaged

Converter UV lamp (Bulb,

hoses)

1000 h Replace bulb

check that hoses are ok

Replace hoses if it’s

damaged


62

Unit Module Every Activity Tools Remarks

Converter Die cut 8

hours

Lube the

bearer rings

Thin oil,

SAE 20

Check the filth pads. Must be

soaked in oil. Keep a oil can

near the die

Converter Die cut 1

month

Grease the gearwheels and check the side

shims for wear / adjust the side bearings

(small side adjuster nut on the bearing

block)

Grease

(Grade:

NGLI 2 or

3).

Note some models have shims

and some adjustable side block,

not both systems in same unit.

Use the RL14 roll lift to take

the cylinder out if needed.

Converter Die cut 1/2

year

Grease all the bearings in the die cut

station. Side block and lower ball bearings.

The bearings must be 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 sharpness and pressure of the

CRUSH knifes.

Pressure must never be more than 1-2 bars.

Replace the knifes if the cut is bad. Never

increase the pressure to cut with dull knifes

Always keep spare blades

Converter Sledge

(under die

cut)

1

week

Inspect the 2 timing belts. Must be tight

and in good condition. Look for signs of

wear on the side support ball bearings .

Always keep spare timing belts

for the sledge unit (under die

cut)

Converter Sledge

(Under die

cut)

1

month

Grease sides very lightly (where the side

ball bearings touch the metal re-

inforcements on the side of the sledge)

Grease

NGLI 2

Too much grease will damage

the system. Only a small wipe

with a finger.


63

23. Dimensions


64

24. Spare parts and consumables

Stock number Description

DC-001Q

X-011H

Anilox roller for DC330: 324mm 80L 15cm3/m2 (for full flood varnish)

Anilox roller for DC500: 502mm 80L 15cm3/m2 (for full flood varnish)

Ask for alternatives.

DC-002P

X-008F

Print roller for DC330:

Ø97.2 / W=324mm, including gear wheel and rubber coating (blue type)

Print roller for DC500:

Ø97.2 / W=500mm, including gear wheel and rubber coating (blue type)


DC-003P

X-008M

Ductor / Pick-up roller for DC330: ø97.2 W=320 SH40

Ductor / Pick-up roller for DC500: ø97.2 W=502 SH40


DC-004(ABCDE) Doctor blades 5 pcs. DC330/500.

Ask for specific length.

DC-005 Strip roller Ø15mm complet with bracket

/VAL001C Nip roller sh. 65 ø50x300/350

UVD00100-405 XSYS/ Akzo Nobel UV Screen Varnish

FKA00137-407 XSYS /Akzo Nobel UV Cleaner

UV-Bulp Write GMPart for correct bulp at [email protected]

SLD008-FC Solardor UV Flexo Cold Foil Adhesive (Sun chemical)

LSKL1.2 Top Knife blade rotary system 62x40x1,2 mm

LSKU Lower knife blade rotary system

DC3-VK Air knife (entire knife with blade and air system)

DIE02 Knife blade for air knife D76,96X22X6.197 / 45 Grad


65

25. Specification

Consumption of power: 5kw UV system, 1kW cooling system, 8kW converter unit.

Supply voltage: 3x400V 32A /phase 50/60 Hz Residual current circuit breaker (RCCB)

>300mA

Compressed air: 4 - 6 bar, 10 l/min

Digital die size 12" to 28"

Analog die size 12" to 28"

Speed (digital) 32-55 m/min

(Mechanical maximum 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 between register marks 50mm

Varnish station

Web widthmax: 330/510 mm.

Printing widthmax: 310/500 mm.

Printing lengthmin: 9“ (minimum cylinder)

Printing lengthmax: 19” (maximum cylinder)

Increments: 1/8”

Rubber shore in varnish station: 40

Total machine weight: 1600 kg.


66

26. Cliché roller drawing

This Cliché cylinder is the standard for GM Converting Unit.

An optinal sleevesystem can be ordered. Call ur local GM sales office for further information.


67


68

Specification die cylinder

The gap is 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 machine to make sure that it was shipped with a standard die tool.


69

27. Installation guide

To secure that the installation and training can be carried out without problems and waste of time due to

missing materials or on site preparations for the installation it is very important that the following

preparations and items are ready before the arrival of the machine:

Unloading the machine:

- A fork lift with min. 1000 kg lifting capacity must be ready to get the craters down from the truck.

- Also the fork lift is needed to get the machine down from the craters

- A pallet jack is needed to move and align the machines.

Electric Power:

Power for the machines must be prepared.

- DCOAT and BUFFER 3P+N+PE 400V AC 50Hz 32A

- COOLING UNIT 3P+N+PE 400V AC 50Hz 16A

Air supply:

Min. 6 bar and 20L/min is needed, tube Ø8mm

Cooling Unit (water cooled lamp)

The cooling unit 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.

Cooling fan (air cooled lamp)

All new GM converting units delivered with air cooled lamps, are supplied with a ozon emitting bulp.

For the machine to run without an external exhaust system a ozon filter is needed. GM can supply this

ozon filter as an option if needed.

The lifespan for the bulp is aprox.1000 hrs.

Verify that the fan is operating in the correct direction.

If external exhaust is used the capacity must på 800 m3/h. There must be no more than 2m between the

fan and the UV lamp. The tube must not make any sharp turns. Tube diameter is 100mm.


70

Starting up the machine:

Test and training can not be carried out unless the following materials are available on site:

- Label material, min. 2000m with a web width of 330mm.

(It is not possible to run a web with a width less than 330mm as the standard print roller is

320mm)

- A printed test job must be prepared and ready, min. 1000m web.

- UV-varnish min. 10 (XSYS Print 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 manual for the machine for distortion information )

- Super gloss foil min. 500m is available (width 330mm).

(Pütz Folien GMBH XUC B11 330mm)

- A cliché and a job for spot varnish must be prepared if the machine has spot varnish

( Cliché 1,14mm or 1,7mm double-sided tape 0,38 mm or 0,55mm, Distortion typical. 9,93 for

12” cylinder)

Anilox 10cm3, Glue from X-Sys Cold foil UV-FOILBOND UVH00002, Kurz foil.


71

Finishing Installation Form

Company Name:

Name

Address

City, ZIP

Equipment:

Model

Serial Number

Machine Configuration

Inline/Offline

Spot Varnish Yes/no

Gap Master Yes/No

Corona Treater Yes/No

Special Options

Meters tested

In signing this document I agree that the above equipment has been installed and

training has been completed in accordance to the sales agreement. Follow up training as outlined in the sales agreement can be requested by the customer and

at the customer’s leisure but needs to be completed before the end of warranty.

The One year warranty starts the first day of the first month following the installation :

Warranty starts on (dd-mm-yyyy) : Warranty end on (dd-mm-yyyy) :


72

Signed and accepted by (Please sign and date):

Press Manufacturer Customer GM Representative

Name Name Name

Signature Signature Signature

Date Date Date


73

28. Actions to be performed

When the machine can be accepted because functionally the machine is working

OK, then the following fields can be used to make agreements on which smaller issues to solve afterwards.

By GM

By Press Manufacturer


74

29. Installation Tracker

29.1. 1. Mechanical Installation

Remarks regarding mechanical installation and calibration:

29.2.

29.3.

29.4.

29.5.

29.6. 2. Safety/Compliance

Check the following items and comment on any items that are not OK:

OK NOK

External disconnect device present and tested.

All protective covers properly mounted.

Operator manual on site.

All emergency buttons of the pre and post devices connected

to the engine.

All emergency buttons working properly

Interlocks installed and is the circuit working properly.

Remarks about safety/compliance:


75

3. Operation

The operational test consists of a print run. During this run a number of tests have

to be performed and a number of finishing specs have to be tested.

Test Media

Start Meter Counter

End Meter Counter

Total meter counter

1.

2.

Total Meter

Check the following items and comment on any items that are not OK:

OK NOK

Testing varnish station

Testing of the UV Lamp

Testing of the Lamination station

Testing of the Diecut station

Testing of the Rewinders

Remarks about Finishing line functions:

operating manual dc330/500 - converting made easy · gm · converting unit 9 3. touch panel the...

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