Dynamic perforating unit. Spare Part Manual

Transcription

1 Dynamic perforating unit Spare Part Manual Another quality product from: Matti Technology AG Wilenstrasse 6 CH-8588 Zihlschlacht / Switzerland Main Number: +41 (71) Fax: +41 (71) info@mattitech.ch Web: v 1

2 Dynamic perforating unit is a trademark of Matti Technology AG, Switzerland Copyright by Matti Technology AG, Switzerland. All rights reserved. Under copyright laws, neither the documentation nor the software may be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without the prior written consent of Matti Technology AG, Switzerland, except in the manner described in the documentation. Matti Technology AG, Switzerland reserves the right, without notice, to alter or improve the design or specifications of the products described herein. No warranty or guarantee of any kind is expressed or implied by information contained herein v 2

3 Dear Customer Thank you for purchasing a Dynamic perforating unit high performance printing system. The Dynamic perforating unit provides the technology you need to print and dry at high speeds. With this system, your company will increase throughput and quality. The Dynamic perforating unit is one of many high-quality, innovative systems from Matti Technology AG, Switzerland. If you would like information on our other systems or require technical assistance or spare part replacement, please contact one of our field service or customer service specialists at: Matti Technology AG Wilenstrasse 6 CH-8588 Zihlschlacht / Switzerland Main Number: +41 (71) Service Number: +41 (71) Fax: +41 (71) info@mattitech.ch Web: Again, thank you and welcome to the growing family of Matti Technology AG customers. We appreciate your current and continued business. Sincerely, Dr. Dieter Woschitz President Pascal Fäh Vice President of Operations v 3

4 1 Table Of Contents Dynamic perforating unit Spare Part Manual Table Of Contents List Of Illustrations Forward Important Safety Information General Safety Information For The Owner Safety Information For The Operator Specific Security Advices Labels Safety Labels Dangerous Voltage Burn Hazard Danger Of Cuts From Moving Paper Danger Of Crushing Pinch Point Rollers Pinch Point From Moving Parts Danger Of Entanglement From Belt Drive Danger Of Entanglement From Rotating Gear Danger From Cutting Blade Danger Of Cutting To Fingers And Hands Text Warning Labels Running With Different Voltages And Frequencies Disconnect Main Switch Before Servicing This Switch Does Not Disconnect All Power From This Machine Inside The Dryer It May Be Very Hot Compressor Installed Behind Cover Mechanical Parts Drives Belts And Pulleys Anvil Cylinder Inch Magnetic Cylinder Linear Bearing And Interrupter Assembly Cam Follower Assembly Shim Table Motor Assembly Bridge Assembly Cam Wiper Mount Assembly Truck Assembly Idle Rollers Cue Mark Reader Web Break Gripper Unit Cover Covers Input End Covers Output End Top Cover Electrical Parts Overview Power / Transformer v 4

5 7.3 Circuit Breakers Terminal Rail Drives Control Panel Additional Electrical Parts Pneumatics Recommended Spare Part List RECOMMENDED LUBRICANTS List Of Illustrations Illustration 1: Dangerous Voltage...8 Illustration 2: Burn Hazard...8 Illustration 3: Danger Of Cuts From Moving Paper...9 Illustration 4: Danger Of Crushing...9 Illustration 5: Pinch Point Rollers...9 Illustration 6: Pinch Point From Moving Parts...10 Illustration 7: Danger Of Entanglement From Belt Drive...10 Illustration 8: Danger Of Entanglement From Rotating Gear...10 Illustration 9: Danger Of Cutting Blade...11 Illustration 10: Danger Of Cutting To Fingers And Hand / Angled Blade...11 Illustration 11: Running With Different Voltages And Frequencies...11 Illustration 12: Disconnect Main Switch Before Servicing...12 Illustration 13: This Switch Does Not Disconnect All Power From This Machine...12 Illustration 14: Inside The Dryer It May Be Very Hot...13 Illustration 15: Compressor Installed Behind Cover...13 Illustration 16: Drives Belts And Pulleys...14 Illustration 17: Anvil Cylinder Inch...15 Illustration 18: Magnetic Cylinder...16 Illustration 19: Linear Bearing And Interrupter Assembly...18 Illustration 20: Cam Follower Assembly...20 Illustration 21: Shim Table...21 Illustration 22: Motor Assembly...22 Illustration 23: Bridge Assembly...23 Illustration 24: Cam Wiper Mount Assembly...24 Illustration 25: Truck Assembly...25 Illustration 26: Idle Rollers...26 Illustration 27: Cue Mark Reader...27 Illustration 28: Web Break...29 Illustration 29: Gripper Unit...30 Illustration 30: Covers Input End...32 Illustration 31: Covers Output End...33 Illustration 32: Top Cover...34 Illustration 33: Electrical Overview...36 Illustration 34: Power / Transformer...37 Illustration 35: Circuit Breakers...38 Illustration 36: Terminal Rail...39 Illustration 37: Drives...40 Illustration 38: Control Panel...41 Illustration 39: Pneumatics v 5

6 2 Forward The purpose of this manual is to provide the necessary information to enable experienced personnel to safely install, operate and maintain the Versamark Dynamic perforating unit Printing System. It is assumed that all necessary tools, precision measuring devices and equipment for safely moving and installing this system will be available. Information and data is based on the latest product information available at the time of writing. The right is reserved to make changes at any time, in materials, specifications, models or to discontinue models. Note: In order to show clearly the details of this system some covers, shields, doors or guards have either been removed or are shown in an open position. All such protective devices must be installed in the closed position before operating the system. 2.1 Important Carefully read the instructions and safety precautions given in this manual. Do not attempt to install this system until you have thoroughly read and understood the data contained in this manual. At the time of writing, this manual was completely up-to-date. However, due to continued product development, some illustrations or descriptions contained herein may vary slightly to the system delivered to you. This merely implies that the system has been improved to better fulfil your requirements. If there are any questions, you are encouraged to contact our field service personnel for assistance at: Matti Technology AG Wilenstrasse 6 CH-8588 Zihlschlacht / Switzerland Main Number: +41 (71) Service Number: +41 (71) Fax: +41 (71) info@mattitech.ch Web: v 6

7 3 Safety Information 3.1 General The Dynamic perforating unit is designed for safe operation. Nevertheless, installation, maintenance and operation of the system can be dangerous for a careless operator or maintenance person. For your safety and the safety of others, please read the instructions of this INSTRUCTION MANUAL and follow these safety practices, which will help to prevent accident or injury. 3.2 Safety Information For The Owner The owner of the system must ensure that the system is only used in good operating condition which adheres to the safety regulations. Only trained and qualified personnel which are totally familiar with all the safety and mechanical instructions and devices should operate the system. Supervisors must ensure that they are familiar with all the chapters of operating and safety of the equipment. Furthermore they should be familiar with the general requirements of accident prevention and preservation of the environment. 3.3 Safety Information For The Operator The Operator of the equipment must read and understand the operating instructions, especially the paragraphs regarding safety. This is especially important for shift personal that might not be involved with this equipment on regular basis. The Operator must be familiar with the safety and accident prevention information, and should avoid any functions on the machine that are doubtful or in violation of the operating procedures. 3.4 Specific Security Advices Prior to any kind of repair, the MAIN SWITCH must to be turned off. The location of the main switch is to be secured with a padlock to prevent accidental switch on. Only original parts used in maintaining / repairing the machine will ensure correct functionality and protect warranties. Any changes to the system, including components requires prior written approval from the manufacturer v 7

8 4 Labels The following chapters explains the different labels used on the transport system. Chapter 4.1 Safety Labels on page 8 and chapter 4.2 Text Warning Labels on page 11 define the labels in general. All available safety labels are shown. 4.1 Safety Labels Dangerous Voltage Illustration 1: Dangerous Voltage Dangerous voltage. Contact may cause electric shock or burn. DANGER! Power terminals remain live up to 3 minutes after mains disconnection Burn Hazard Illustration 2: Burn Hazard Burn hazard, hot surface. Do not touch the surface of this component during equipment operation. Allow to cool down before servicing v 8

9 4.1.3 Danger Of Cuts From Moving Paper Illustration 3: Danger Of Cuts From Moving Paper Danger of cuts from moving paper. Keep body away form edge of moving paper Danger Of Crushing Illustration 4: Danger Of Crushing Danger of crushing from moving paper roll. Stand back from the lift arms and paper roll during operation Pinch Point Rollers Illustration 5: Pinch Point Rollers Pinch point danger from rollers. Keep hands and clothing away from rotating rollers v 9

10 4.1.6 Pinch Point From Moving Parts Illustration 6: Pinch Point From Moving Parts Danger from moving parts. Moving parts can crush and cut. Do not operate with guard removed. Follow lockout procedure before servicing. Disconnect main power before servicing Danger Of Entanglement From Belt Drive Illustration 7: Danger Of Entanglement From Belt Drive Danger of entanglement from belt drive. Shear hazard. Moving part can crush and cut. Keep hands and clothing clear. Do not operate with guard removed. Follow lockout procedure before servicing Danger Of Entanglement From Rotating Gear Illustration 8: Danger Of Entanglement From Rotating Gear Danger of rotating gear. Keep hands and clothing away from rotating gear. Danger of entanglement from gear. Moving part can crush and cut. Keep hand clear. Do not operate with guard removed. Follow lockout procedure before servicing v 10

11 4.1.9 Danger From Cutting Blade Illustration 9: Danger Of Cutting Blade Danger from cutting blade. Shear hazard. Moving part can crush and cut. Keep hands and clothing clear. Do not operate with guard removed. Follow lockout procedure before servicing Danger Of Cutting To Fingers And Hands Illustration 10: Danger Of Cutting To Fingers And Hand / Angled Blade Danger of cutting to fingers and hand. Moving parts can crush and cut. Do not operate with guard removed. Follow lockout procedure before servicing. 4.2 Text Warning Labels Running With Different Voltages And Frequencies Illustration 11: Running With Different Voltages And Frequencies v 11

12 4.2.2 Disconnect Main Switch Before Servicing Illustration 12: Disconnect Main Switch Before Servicing This Switch Does Not Disconnect All Power From This Machine Illustration 13: This Switch Does Not Disconnect All Power From This Machine v 12

13 4.2.4 Inside The Dryer It May Be Very Hot Illustration 14: Inside The Dryer It May Be Very Hot Compressor Installed Behind Cover Illustration 15: Compressor Installed Behind Cover v 13

14 5 Mechanical Parts When ordering spare parts, it is important to note the Serial Number of the unit to facilitate correct identification of parts, together with the Part No. of the component. The Serial Number is written on the type plate at the drive side of the machine. 5.1 Drives Belts And Pulleys Illustration 16: Drives Belts And Pulleys Position Description Part - # 1 Pulley HTD 8M Taperlock bore Belt gates MGT Pulley HTD-8M Taperlock bore Motor MOTOR FACE W21 DF90 FACE v 14

15 5.2 Anvil Cylinder Inch Illustration 17: Anvil Cylinder Inch Position Description Part - # inch ANVIL CYLINDER BEARING 7210BE (X2) ROLLER BEARING N210EC (X2) ANVIL BEARING RETAINER INNER OIL SEAL WRM ANVIL BEARING RETAINER OUTER ANVIL PULLEY SPACER ANVIL ENDCAP OP SIDE ANVIL BEARING CLAMP SPACER ANVIL ENDCAP DRIVE SIDE PULLEY HTD8M TAPERLOCK ENCODER (SICK 65536) ENCODER BAR ENCODER BAR SPACER v 15

16 5.3 Magnetic Cylinder Illustration 18: Magnetic Cylinder v 16

17 Position Description Part - # 1 MAGNETIC CYLINDER CAM (12 0.5MM LIFT) C 3 SLIDE BLOCK SLIDE BLOCK BEARING COVER MAG CYLINDER BEARING SPACER LOCK WASHER SKF MB LOCK NUT SKF KM MAG CYLINDER ENDCAP SENSOR DISC ENDCAP SENSOR LOCATING PIN INA BEARING 3008-B-2RSR-TVH SLIDE BLOCK ROLLER PLATE ROLLER BUNG CYLINDRICAL ROLLER RL 6X OILER PLATE INDUCTIVE SENSOR SHIELDED CABLE ROTATION SENSOR BRACKET DOWEL 6 DIA X v 17

18 5.4 Linear Bearing And Interrupter Assembly Illustration 19: Linear Bearing And Interrupter Assembly v 18

19 Position Description Part - # 1 RETAINING SLIDER RAIL SLIDER RAIL (1 ONLY-OPS INPUT SIDE) SOLENOID INTERUPTER BUFFER TYPE D BUFFER SCREW SOLENOID ROLLER BLOCK OILER PLATE LOCKING WASHER MB LOCKING NUT KM SUPPORT ROLLER SHAFT SUPPORT ROLLER NATV 12PPX CAM LIFT BLOCK BUFFER PLATE STAND-OFF BUFFER PLATE SOLENOID BACK PLATE SOLENOID TIE ELBOW MALE KQL23-M ROLLER BUNG CYLINDRICAL ROLLER RC 6X SOLENOID SPINDLE RING SOLENOID PLUG GREASE NIPPLE (NIP A1) v 19

20 5.5 Cam Follower Assembly Illustration 20: Cam Follower Assembly Position Description Part - # 1 Cam lift block Cam follower Support roller shaft Locking nut KM Locking washer MB Air fitting straight KQHO4-M5 Grub screw M4x Cam Follower Assembly v 20

21 5.6 Shim Table Illustration 21: Shim Table Position Description Thickness Part - # 1 Cam lift shim 0.1 mm Cam lift shim 0.15 mm Cam lift shim 0.2 mm Slider rail shim 0.1 mm Slider rail shim 0.15 mm Slider rail shim 0.2 mm Magnetic block shim 0.1 mm Magnetic block shim 0.15 mm Magnetic block shim 0.2 mm SHIM SET (6 OF EACH) v 21

22 5.7 Motor Assembly Illustration 22: Motor Assembly Position Description Part - # 1 Motor BSM 90-C Alpha gear head LP 090-M Motor mount Motor mount tie Bellows coupling Anti sag strip Gearbox ring Shoulder bolt M10 Ø 12 x v 22

23 5.8 Bridge Assembly Illustration 23: Bridge Assembly Position Description Part - # 1 BRIDGE BEAM BELLOWS BRIDGE SPACER TRUCK BEAM CAM OILER MOUNT ASSEMBLY BRIDGE TRUCK ASSEMBLY LHS BRIDGE TRUCK ASSEMBLY RHS M10 X 120 CAP HEAD BELLOWS CLIP Bridge Assembly v 23

24 5.9 Cam Wiper Mount Assembly Illustration 24: Cam Wiper Mount Assembly Position Description Part - # 1 Cam wiper mount Cap head bolt M5 x 35 long Felt wiper Cam oiler support spacer Nyloc nut M CAM WIPER MOUNT ASSEMBLY v 24

25 5.10 Truck Assembly Illustration 25: Truck Assembly Position Description Part - # 10 Nyloc nut M Grease nipple Cam roller Cam follow bolt Bridge truck right hand side Bridge truck left hand side Oiler support spacer Felt wiper Washer M Spring washer M Full nut M Cap head bolt M6 x 40 long Cam follower spacer BRIDGE TRUCK ASSEMBLY LHS BRIDGE TRUCK ASSEMBLY RHS v 25

26 5.11 Idle Rollers Illustration 26: Idle Rollers Position Description Part - # 1 Idle roller Idle roller shaft Bearing Z M10 x 12 shoulder bolt Circlip Idle roller complete v 26

27 5.12 Cue Mark Reader Illustration 27: Cue Mark Reader Position Description Part - # 1 Tension plate Side guide left hand side Side guide right hand side Guide clamp piece P2287P 3a Side guide shaft M6 locking screw E0469A Cue mark reader 5 (S65-PA-5-W09-PH contrast sensor) Cue mark reader cable Cue mark reader block Cue mark reader block clamp Indexing handle Adjusting screw v 27

28 Position Description Part - # 10 Thumb screw Spring plate R2317P 12 Adjuster block C6359A 13 Flange bearing E1087A 14 External circlip - 12mm Brush B0166A Brush bar Cue mark reader shaft Cue mark reader clamp spacer Loop sensor Hanger spring G1280C v 28

29 5.13 Web Break Illustration 28: Web Break Position Description Part - # 1 Web break detector sensor Detector bracket Web break sensor cable v 29

30 5.14 Gripper Unit Illustration 29: Gripper Unit Position Description Part - # 1 Pivot end cap Gripper cylinder pivot Gripper arm Spring M6 lock nut SKT set screw M6 x Dowel pin Gripper lever v 30

31 Position Description Part - # 9 Cylinder CM2E Gripper lever cylinder pivot Gripper slide bar Gripper shaft spacer Slide bar block Adjusting screw M6 x Gripper body Bearing Gripper shaft stop spacer External circlip - 25mm DU bush MB2530DU Gripper wheel Gripper unit assembly v 31

32 6 Cover When ordering spare parts, it is important to note the Serial Number of the machine to facilitate correct identification of parts, together with the Part No. of the component. The Serial Number is written on the type plate at the drive side of the machine. 6.1 Covers Input End Illustration 30: Covers Input End Position Description Part - # 1 Front door Front console side in Front console top Infill cover Slide strap SBB089 Accuride ball bearing slide Back enclosure top Back enclosure top stay Top cover cross beam side Back enclosure door Back enclosure side in v 32

33 6.2 Covers Output End Illustration 31: Covers Output End Position Description Part - # 1 Back enclosure side in Back enclosure door Back enclosure top stay Back enclosure top Top cover window 6mm a Top cover clamp button b Top cover button spacer Handle Infill cover Front console top Front console side out Front door Accuride ball bearing slide Levelling foot Castor Datacard E0233A v 33

34 6.3 Top Cover Illustration 32: Top Cover Position Description Part - # 1 Top cover front end Slider strap mount Top cover window Accuride ball bearing slide v 34

35 Position Description Part - # 5 Top cover cross beam side Slide strap Handle stand off Rencol T-Handle 3772F Top cover front end Stainless plug Top cover cross beam top Top cover frame washer Slide strap Safety switch ( ) Switch actuator ( ) Cover holding screw (B) Holding screw spacer Top cover button spacer Top cover clamp button Bolt M5 x v 35

36 7 Electrical Parts When ordering spare parts, it is important to note the Serial Number of the machine to facilitate correct identification of parts, together with the Part No. of the component. The Serial Number is written on the type plate at the drive side of the machine. 7.1 Overview Illustration 33: Electrical Overview Position Description Part - # 1 240V fan Motor cooling casing V Power supply unit E100 control unit Solid state relay v 36

37 7.2 Power / Transformer Illustration 34: Power / Transformer Position Description Part - # 1 Transformer 230V - 35V Transformer 230V - 18V Capacitor 4700pF 200V Capacitor holder Bridge rectifier v 37

38 7.3 Circuit Breakers Illustration 35: Circuit Breakers Position Description Part - # 1 FUSE HOLDER FUSE 30A MCB 20A MCB 6A MCB 4A CONTACTOR C1 (32A) v 38

39 7.4 Terminal Rail Illustration 36: Terminal Rail Position Description Part - # 1 SAFETY TIMER RELAY INTERFACE REALY LATCH MODULE FREQUENCY/VOLTAGE MODULE 5 FUSE HOLDER v 39

40 7.5 Drives Illustration 37: Drives Position Description Part - # 1 SERVO DRIVE 1 (MOTIFLEX E100) a ANVIL VECTOR DRIVE b VECTOR DRIVE CONTROL PANEL BALDOR POWER RESISTOR EMC FILTER M CAT 5e PATCH LEAD v 40

41 7.6 Control Panel Illustration 38: Control Panel Position Description Part - # 1 Display 5.6 touch screen (HMI) Emergency stop body Emergency stop head Emergency stop legend Additional Electrical Parts Position Description Part - # 1 ISOLATOR SWITCH 63A 3 POLE SCHAFFNER EMC FILTER v 41

42 8 Pneumatics Illustration 39: Pneumatics Position Description Part - # 1 5 port valve SY3130-5LOZ-C6-Q Lead wire E0435A 2 E to P regulator Filter E0403A Black polyurethane hose E0402A v 42

43 9 Recommended Spare Part List Description Part number Quantity Motor Bearing 7210BE Roller bearing N7210BE Oil seal WRM Hengstler encoder Cam Lock washer SKF MB Lock washer SKF KM Magnetic cylinder end cap INA bearing 3008-B-2RSR-TVH Slide block roller plate Cylindrical roller RL6X Inductive sensor Inductive sensor cable Retaining slider rail Slider rail Solenoid Interrupter Buffer type D Locking washer MB Locking nut KM Support roller shaft Support roller NATV 12PPX Cylindrical roller RC 6X Motor BSM 90-C Alpha gear head LP 090-M Bellows coupling Bellows Felt wiper Cam roller Cam follower bolt Bearing Z Cue mark reader (S65-PA-5-W09-PH contrast sensor) Brush B0166A 2 Web break detector sensor Cylinder CM2E DU bush MB2530DU Gripper wheel Accuride ball bearing slide Levelling foot Castor data card E0233A 4 Safety switch V fan V Power-supply unit E100 Control unit Solid state relay Watchdog timer v 43

44 Description Part number Quantity Contactor 32A Opto-isolator V-35V Transformer V-18V Transformer Capacitor 4700 pf 200V Bridge rectifier MOTIFLEX E100 Servo drive Resolver card Anvil vector drive Display 5.6 touch screen (HMI) Emergency stop body port valve E0434A 1 E to P regulator Filter E0403A v 44

45 10 RECOMMENDED LUBRICANTS Lubricant Type Oil Standard engine oil Bearing grease based grease such as Castrol LMX Gear grease Open gear grease such as Mobile OGL v 45