Digital-Flexo-Cut User Manual English
Contents
1. luiuli eXc EEUU EPE m 16 15 misce ie IRR E E UT 17 15 1 Paper SIZE AGUS IMC see EE 17 15 2 MEd ANG mme C rt ate ect ct ee eae ete ee ee ee ee eee ee 17 159 SUCTION Drum and Paper Gdle ans 17 19 4 Compressed Air and Vacuum an a siae vase ata uie tae voee Lata i sta soe Ma I ui eta AR 18 16 Technical opeciealons or the Feeder a sich oii i n i i e ea n 18 17 IroubleShoolngessa as 18 18 ordening unting Platas nee 19 DECLARA HONOF CONFORM een 20 19 alossar aes idee ee 21 20 Ammenadmehtldex esbavtpsu tuc tsbeubbavivev iuc arcu coe over seule selves bre icu trou bre uence loan rcu sehe 21 Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 2 1 Safety Precautions 1 Please read this instruction and the Wink ABC cylinder carefully and completely before operating the machine Attention deviating from the ABC the DFC has a gap clearance of 0 8 mm 2 Please make sure the mains voltage is suitable and the outlet has a proper earth connection 3 Use an exclusive outlet as overloading may cause fire or an electric shock 4 Do not unplug the plug or unplug the power cord from the outlet with a wet hand this can cause an elec tric shock or injury 5 Repairs have to be carried out by trained Nagel technicians only 6 Disconnect the machine from the mains while servicing it 7 Use original Nagel consumables and spare parts only 8 Lay the cables in a w2. 14 kg 17 Trouble Shooting Problem Cause Remedy Paper is not being fed Not enough air supply under the paper Open air jets 4 or close air jets outside of the pile paper pile Position of vacuum drum 5 and paper Search for the position of the vacuum drum 5 gate 7 has not been adjusted precisely to to the paper gate 7 refer to point 15 3 Use the paper screw 9 Paper pile is too heavy Reduce the paper pile put less paper into the feeder Paper piles up after the Side guides 1 have been adjusted too Readjust the side guides 1 paper gate before narrow or are not parallel entering the folding rollers Double sheets Paper gate 7 has not been adjusted Adjust the paper gate 7 to 2 sheets of paper correctly refer to point 15 3 Front edge of sheets are Paper gate 7 is in wrong position for this Readjust the position of the paper gate 7 in being marked by the particular paper moving it back or forth Use set screw 9 paper gate Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 18 18 Ordering Cutting Plates To order a cutting plate the following specifications are necessary e The gap clearance of 0 8 mm distance between the cylinders e The thickness of the paper The specification g m won t be enough because it doesn t necessarily tell anything about the thickness However this information is important for creasing stamping and kiss cutting e The direction of t
3. Digital Flexo Cut User Manual English Index 1 Sale P IOCIS ea 02 222 9 2 9 2 2 229 9 224 22 9 2490 924 206 3 D ROP E O aE 0 0 4 0 990000 0490403 0 0 221 4 3 U jescnpHonsipd SbecillCdliOLiS 2 294 594 95299999500954 92 598250952 9 099 25 999 0 92 2 50402 4 d S ePi 5 Or FOS OO E 0920 0 09 9 02 8 0 20 00020 9 0 8 099 9 99 0 7 Or OTOS o 7 7 JMounting a New Cuming late srid 8 8 Register Adjustment in Longitudinal Direction esses 8 9 Correcting the Lateral Offset sessssssssssssssesssseenenen nennen nennen nnn nn sna nnne arn n annes nnns nennen 9 10 Correcting the Angular Offset ccccccccsecceseeeeeeeeeseeeeseeeeseeeeseeeeseeeesaeeesaeessaeeesaeessaeessaeesseesseeessaess 9 11 Possible Sources Of Failures cccccccccsececeeceseeeeseeeeseneeseeeeseneeseaeeseueeseaeeseneeseaeeseneeseeeeseneeseneesenes 10 12 Further Options of Adjustment on the Display cccccccccceeeceeeeeeeeeeeeeeeeeeeesseeeeeeeeeseeesaeesaeeeeaaees 11 12 1 BASIC OSG S e a EE DERE ETT 11 12 2 spar UII IC Ra A RR TULIT OT 12 13 SENICE MOS Van E ger eee ee ett er tere ee er era kept eet Se 13 13 1 PALS OCW ICCUVICMUs csr A A MEAE 13 132 Second ServiceMenu nr 14 1 98 o PASENIE MENU Eee 15 14 Operating Instructions Feeder cccecccceecccececeececeeeeceeeecececeuceseuceseuceseueeseeeseueeseueeseueeseueeseneesaes 16 14 1 S AISLE VIN SIUC TORIA TET 16 14 2 Bede EIE 16 14 3
4. ay that no dangers arise 9 Install the machine in a dry room on levelled and solid ground And within easy reach 10 Block the breaks after putting the machines in place 11 Safety precautions like covers or switches must not be removed or bypassed 12 Always replace fuses with the same type and rating 13 Users with long hair need to keep safe distance to turning parts 14 Close lids that they don t fall 15 Don t open lid during operation this could cause paper jams 16 Connect the machines with the provided screws It is not allowed that they can be disconnected w o tools 17 Allow at least 20 seconds to pass between attempts to switch on the unit otherwise the software may be damaged 18 When changing plug connections always switch off the machines 19 Work careful at the leaf springs They consist of thin sheet metal and could cause injury through incau tious contact 20 Do not place receptacles containing liquids on any surface 21 Do not under any circumstances adjust the paper gate or other parts when the machine is switched on Attention Important for startup If the DFC is connected to left turning three phase current the pump will generate an uncomfortable noise This condition is harmful to the pump Therefore power off the machine immediately and swap two of the three phases Attention Important for operation Please do not over tighten the tensioning bolts which apply the cutting pressure T
5. e written down because after the update the value will be zero again Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 13 13 2 Second Service Menu lactsingle v l actAuta T A A A V Noodstop V Safetyinput QO A Start otart RegFwd RegBwd Torn Reg i Mj A e O9 v Stop TactSingle TactAuto Noodstop v Torn Rea Here the several sensors and the buttons of the user panel can be checked An active sensor button causes a check mark on the display as shown above ProductSenso The reflex lightbar which detects the front edge of the sheet before reaching the paper stop TactSingle Single sheet button Uitlegsensor Sensor of the optional delivery wheel 3955066 RegBwd Rotate right button TactAuto continious feed switch Dubbelsheet Doublesheet sensor not implemented RegFwd Rotate left button Noodstop Emergency Stop button Safetyinput not implemented Homingsensor Sensor Home position of the cutting cylinder Start Start button Stop Stop button Torn Reg Jog Reg Setup or produce turning switch Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 14 13 3 Third Service Menu In this menu you can enter settings for various machine components and choose the display language Vacuumvalve 230 Volt at valve attached to pump Delivery 230 Volt AC at extern jack for optional d
6. elivery wheel 3955066 Vacuumpump 230 Volt at pump Feeder 230 Volt at motor of feeder Paper stop 230 Volt at solenoid of the paper stop Uitlegeband 24 Volt DC at extern Jack for convey 3955061 Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 15 14 Operating Instructions Feeder 14 1 Safety Instructions For safety reasons always first unplug the main plug before undertaking any repair or maintenance work 14 2 Description OOnNOOaRWND 14 3 Paper guides L and R Back stop adjustment screw for paper infeed 6 2 3 1 Air jets Vacuum drum Adjustment screw for suction slot Paper gate Height adjustment screw for paper gate Set screw for gate position Installation By hooking the feeder to the catching bolts the necessary connection to the drive is accomplished Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 16 15 Feeder Adjustments 15 1 Paper Size Adjustment After the lateral paper guides 1 have been adjusted to the size of the paper being processed the back stop 2 has to be placed at the end of the paper pile This avoids the paper moving backwards because of the air blow To achieve a maximum sheet separation all air jets 4 outside the paper stack have to be closed thus ensuring optimal air pressure under the stack 15 2 Infeed Angle The paper infeed angle to the folding rollers can be adjusted by the adjustment screw 3 15 3 Suction Dru
7. en LF and LL then move the lateral guiding along the guiding block to your desired position Fasten LL again For fine adjustment fasten LF loosen LL and use ML to move the lateral guiding in the desired direction Fasten LL again An angular deviation can be corrected by the thumb wheel as shown in the pictures above Please notice that the paper stop is always orthogonal to these cylinders If very thin and flexible paper is used rather the cutting plate should be repositioned Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 9 Attention Inprecisions in this place can also result from the used balls and their weight Here are two examples following Light papers heavy balls By using too heavy balls for light papers the paper sheet might be pulled with too much force against the lateral guiding and a bulge appears between the balls and the lateral guiding If the distance between the ball bar and the lateral guiding ist too big a similar effect apears Heavy papers light balls By using too light balls for heavy papers it might happen that the paper sheet isn t pulled to the lateral guiding In this case the paper sheet isn t aligned properly and runs random between the rotation cylinders Production Turn rotary switch JOG REG to REG Now the cylinder turns to the home position a check mark behind the array Start Homing should appear Otherwise touch the array Start Homing so that the cyl
8. etic plates Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 6 5 Start Up Turn on the machine at the main switch to the left of the control panel The emergency stop button must not be actuated at this time You will see the main menu Main menu le HI gt Register Irt Actual Po gis Fadhustment 0 00 mtm 84 20 mm EL LL D bal TA herci Pr ication Standh E Cl Press the button Start Homing The magnetic cutting cylinder moves to its reference position zero position you will see a check mark once the process has been successfully completed Important In case of using paper size bigger than A4 the gt A4 button must be activated otherwise the paper won t be ejected completely 6 Controls Upper controls from left to right Start button Rotation left button Rotation right button rotary switch Setup or Production Lower controls from left to right Stop button Single sheet feed button rotary switch Continuous feed on off Emergency stop Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 7 7 Mounting a New Cutting Plate Rotary switch Setup or Production on the upper right to Jog Use the Rotation left or Rotation right button to adjust the magnetic cylinder until both stop pins are at the top Place the cutting plate onto the middle of the cylinder pay attention to the marking in the centre of the pla
9. his will shorten the lifetime of the plain rollers see WINK The ABC of cutting tools Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 3 2 Proper Use Proper use consists in die cutting kiss cutting and perforating paper cardboard labels and foils The maxi mum thickness must be observed it is determined by the gap between the cylinders and by the plate thickness 3 Description and Specifications Production speed Up to 2000 cutting strokes h Maximum format 500 mm x 350 mm L x W Minimum format 90 mm x 160 mm L x W Cutting cylinder perimeter 20 inches 508 mm Cutting plate thickness max 0 80 mm for die cutting this equals the gap clearance between the cylinders Power connection 3 x 400 volts 16 A Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 4 4 Accessories Convey 3955061 Fan wheel 3955066 Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 5 Installation of the Optional fan wheel 3955066 Fasten plate 3955048 for the cover to the front plate of the DFC using 2 DIN 912 M6x12 screws Remove two screws see above and use them to mount the delivery wheel in holes 3 and 5 Connect the power cable for the motor and the encoder Fit the table assembly 3955036 at the cross bar Fit the cover TBD assembly at the DFC Fit the feeder as shown The stripping angles 3955065 are fastened to the table with the glued on magn
10. inder turns into home position Turn rotary switch continious feed to the right Push Start 11 Possible Sources of Failures Cutting Creasing Perforating Contour jumps Belt speed too fast residence time Timer Stopper to short balls too light By using thin waved material e g because of humidity it may happen that the leading edge goes up the paper stop In this case the material can be processed anyway if a simple deflector e g a stripe out of paperboard is beeing attached Paper jam The sheet stays stuck in the cutting creasing perforating contour and is beeing deflected upwards in stead of beeing moved out straight Stripes or plates out of natural rubber 3955081 should be attached along the cutting creasing perforating contour The elastic material pushs the paper sheet away from the cutting plate on the cylinder and enables an uncomplicated transport Cutting Creasing Perforating Contour is in delay The paper sheet swims in the gap between the cylinders By attaching a stripe out of natural rubber 3955081 at the perimeter of one of the two cylinders the sheet will be transported in a secure way see picture below plexiglas deflector paper stop Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 10 12 Further Options of Adjustment on the Display You can navigate to the next screen or to the previous screen by means of the Arrow right and Arrow left butt
11. m and Paper Gate Gate 7 must be positioned as shown in illustrations 1 and 2 depending upon the thickness of the paper being processed The ideal position can be determined by trial and error e Picture 1 for thicker papers e Picture 2 for thinner papers This procedure might require 2 3 trials until the best gate 7 position is found There is no basic rule be cause every paper feeds differently The suction slot A must always be adjusted to the position of the gate 7 by adjustment screw 6 After positioning the gate 7 has to be set to leave a gap of approx 2 sheets to the suction drum with the adjust ment screw 8 The position of the suction slot A can be adjusted on the run with adjustment screw 6 m0 Picture 1 Picture 2 Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 17 15 4 Compressed Air and Vacuum On most vacuum pumps the volume of air can be adjusted by means of valves provided for this purpose If less vacuum is required for very light papers a reduction can be achieved by adjusting the air supply on the pump directly Normally the air supply on the vacuum pump is set to the maximum 16 Technical Specifications of the Feeder 90 x 120 mm standard Maximum size 235 201 A3 350 x 500 mm standard 245 201 A2 450 x 650 mm standard Friction by the drive shaft of the folding machine Dimensions 235 201 A3 387 x 700 mm 245 201 A2 487 x 700 mm 245 201 A2
12. ments of EEC directives der EU Richtlinien _ auquel se r f re cette des directives de la commt nne 89 336 EEC and amendments und Anderungen et amendements 89 392 EEC and amendments und Anderungen et amendements 73 23 EEC and amendments und Anderungen et amendements by applying the following harmonized standards unter Anwendung der folgenden harmonisierten Normen en appliquant les normes harmonis es suivantes EN 60204 1 06 93 prEN 1010 10 99 EN 60950 08 92 A1 A2 A3 A4 All EN 55022 09 98 Klasse B class B classe B EN 55024 09 98 EN 61000 3 2 04 95 A1 A2 A14 EN 61000 3 3 01 95 Year of affixing the CE marking Jahr der Anbringung der CE Kennzeichnung L an de l application de la marque CE 2008 otuttgart October 02 2008 Place and Date Ort und Datum Managing Director Lieu et date Gesch ftsf hrer Gerant 19 Glossary Abbreviations BG assembly Baugruppe ELR Electron Load Relais GND Ground H x W x D Height x Width x Depth IR Infra red RH Relative humidity 20 Ammendment Index Rev 1 0 Rev 1 3 Service Screens Trouble shooting DFC Instructions Feeder Rev 1 4 Ordering Information Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 21 Ernst Nagel GmbH D 70565 Stuttgart Germany Inland 0711 78078 11 Export 49 711 78078 21 Telefax 49 711 78078 10 www ernstnagel com
13. ons of the touch panel 12 1 Basic Settings Heat rH irit ew standby 2 Counter on off The continuous feeding mode will not work while the counter is deactivated Sheets per Pack Number of Packs Rotations per Pack Reset Counter Hesets the counter to zero Arrow left Takes the operator back to the main menu Arrow right Takes the operator to fine tuning menu Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 11 12 2 Fine Tuning Machine speed AL 2 ation St 3T ii Ji v TSS Control Ch Triggertime Configures the time span of the opening of the vacuum valve at the suction drum of the feeder If this time span ist too short the paper sheets will stay lying in the feeder For working with big sheets the time span should be a bit longer If there is an appearance of doubled sheets the time span should be chosen shorter Timer Stopper paper stop Waiting period during recognition of the front edge of the sheet and the sinking of the paper stop see also p 8 Chapter 10 If the period is adjusted too short the sheet might vibrate or doesn t lie properly at the paper stop by the time On the other hand the sheet might be damaged by the bevel belt if the chosen period is too long Executiontime Runtime of the optional convey 3955061 Deliveryspeed Time period of 1 8 Turn of the optional delivery wheel in of the maximum speed Diecuttingspeed o
14. peed of the cutting cylinder It might be adjusted to a fast speed Beltspeed Speed of feeder and bevel belt It might be increased if using heavy stock Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 12 13 Service Mode Bt Re Input Actual Pos eet pv Steradiustrnent 0 00 mm 94 20 mm E I m Dubbel sheet check See pplication Stand CTS E a atob 0k To go to service mode touch the Nagel symbol on the main menu Then enter the password 4711 Press Enter to return to the main menu Then press Nagel again to go to the first service menu 13 1 First Service Menu ili HAU mm mustment hah LUO mm ENS EN E ten adjustmoer it dew lu mm jir punt Litlegbar id 250 00 mm 4 unter total t E Homingspeed Rotation speed of the cylinder during going into home position Jogspeed Rotation speed when turning the cylinder by buttons in JOG mode Machineregister 254 half of the cylinders perimeter don t change Registeradjustment high The value the register is altered by pushing the buttons for more than a second during production Registeradjustment low fine like Registeradjustment high accept the value is 0 1 mm Beginpunt Uitlegeband The distance the cutting cylinder turns in mm until the convey 3955061 begins to run Counter total Read only Important Before the software is getting an update the value has to b
15. ransport because the cutting plate has to be shortened in perimetric direction e The position of the hold points at partial cutting e Position orientation and reference of the drawing e g topview or bottom view referenced to paper or cutting plate e The perimeter is 508 mm the maximum lenghth of the cutting plate is 504 mm because of the stop pins which shouldn t be covered by the plate e The maximum breadth is 360 mm The drawing must be true to scale Following scalable file types may be used PDF Al EPS DWG DXF More precisely informations are available from the specific manufacturer of the cutting plates direction of transport printed surface transport AR a direction of A stamp e g for folded boxes is beeing done from the backside This means that in this case the material lies face down perforated measure direction of e g 120 transport of the mm paper the cutting is done onto cut printed sur face topview onto printed surface scale 1 1 A4 format hold points Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 19 DECLARATION OF CONFORMITY KONFORMITATSERKLARUNG DECLARATION DE CONFORMITE We Wir Nous declare under our sole responsibility that the product erklaren in allei erantwortung dass das Produkt d clarons sou eule responsabilit que le produit Nagel DFC to which this decla is in conformity with the es equire
16. te Draw in the plate with the Rotation left button Set the rotary switch Setup or Production on the upper right back to Reg The DFC cutter moves back to reference position Adjust the lateral stops of the feeder so that the sheet to be fed is centred Adjust the lateral stop of the oblique belt oet the rotary switch Continuous feed on off on the lower right to zero Press the Start button on the upper left The blower is started and the belts are set in motion Adjust the blast air so that the sheets in the stack are well separated Press the button Single sheet feed to feed a sheet into the machine Press the Stop button on the lower left 8 Register Adjustment in Longitudinal Direction Measure the offset in longitudinal direction with a ruler Press the Enter button on the display to the right of the Reset Register button You will see an input box in which you can enter the measured value Repeat these steps if necessary Should the cutting contour be moved into the opposite direction of the direction of transport a negativ value must be entered Ernst Nagel GmbH 9965197 User Manual IA DFC doc Rev 1 4 3 9 09 Pg 8 9 Correcting the Lateral Offset Names of the items Locking screw of the lateral guide LL Micro adjusting screw of the lateral guiding ML Guiding block Locking screw for fine adjustment LF Ball cage out of plastic material To correct a larger deviation loos
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