Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød Denmark Phone: Internet: Fax:

Transcription

1 GM REWINDER UNIT OPERATING MANUAL XRN Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød Denmark Phone: Internet: Fax:

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3 We Manufacturer: EU Declaration of Conformity Grafisk Maskinfabrik A/S Bregnerødvej 92 DK-3460 Birkerød Denmark Telephone: Fax: Herewith declare that the product Equipment: Rewinder 500mm, Single Model number: XRN5R2V5 Serial number / production year: / 2012 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 Safety of machinery. Electrical equipment of machinery. EN EN Safety of machinery -- Safety-related parts of control systems Safety of machinery Person authorised to compile and hold the technical documentation: Bjarke Nielsen Managing Director Randi Nielsen (Mrs.) Grafisk Maskinfabrik A/S 12/ Birkerød Date Randi Nielsen Signature 3

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5 EU Declaration of Conformity Introduction Unpacking: Safety instructions Safety instructions continued Protective enclosure/safety concept General electrical safety remarks Shutting down the XRN The control panel: The touch screen control panel: Main menu Service Menu Run menu Taper tension menu Running the XRN machine: Setup and adjutsment Moving the XRN Adjusting web tension against the press Adjusting dancer potentiometer Connecting power to the machine: Machine layout Specifications Compliance specifications Environment specifications

6 1. Introduction. The XRN is a multi-purpose module, which act as a stand-alone rewinder with inspection / splice table and optional length slitting possibilities. The machine will synchronize to the speed from the press with a dancer arm that also gives the possibility to adjust the web tension between the press and the XRN. After the dancer arm the web goes true a nip that controls the speed of the web. The rewind web tension can be adjusted on the control panel and will not affect the web tension against the press. 2. Unpacking: Prior to shipment the machine has been securely packed to withstand even rough handling during transportation. Should you nevertheless discover any transportation damages on arrival, please accept the arrival only subject to transport damages, immediately make a claim to the transportation company and contact us. Never lift the machine in the rollers, as this may damage the machine. RUST PREVENTION: For transportation purposes the machine has been protected with a rust prevention coating which can be easily removed by kerosene, turpentine or similar. 6

7 3. Safety instructions. This chapter describes the safety guidelines that must be observed under all circumstances when installing, commissioning, operating and maintaining the XRN REWINDER 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. 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. 7

8 4. Safety instructions continued. This section contains important information for your safety, and to protect operators and bystanders. Please read it carefully before operating the XRN. Caution! The operator of the XRN must have the necessary training to run the machine in a safe way. The purpose of this section is to provide you with guidelines concerning the use and safety of the XRN. Caution: The XRN should only be operated within its scope. Rewinding after a press and optional length slitting. Caution! Using materials not within the scope of the machine could cause risk of damaging the machine. Caution! Keep fingers, hair, clothe and loose jewelry away from ANY moving objects! Misuse of the XRN. The following actions or situations are considered as a misuse of the XRN and are not to be avoided at all times: Not using the materials found suitable by the manufacturer of the materials. Usage of consumables and/or usage parts and/or spare parts other than those specified. Safety notifications. Caution! To operate the XRN the operator needs to understand all the functions of the touch screen controller for safe and proper use of the machine. Never hit the touch screen. Do not press the buttons with sharp objects. 8

9 5. Protective enclosure/safety concept. Emergency stop/interrupting the print process A mushroom-type emergency stop button is provided near the XRN control panel to bring the XRN in an emergency stop state. The XRN main switch is also intended as emergency stop switch and main disconnection device. In case of emergency, or when the software is not responding, switch the main switch to the OFF position. This shuts down the power to the XRN. When the XRN is in running mode, do not under any circumstance: Leave the XRN unattended. Remove fixed covers or other parts of the protective enclosure. Covers that can only be opened by means of a tool protect service areas. Refer servicing to qualified personnel. Lean up against the machine in running mode. Have any loose tools etc. laying around. 6. General electrical safety remarks Caution! To prevent fire or electrical shock hazard, do not expose this product to rain or moisture. Caution! The XRN can generate static electricity depending on the environment and on the material (foil) run on the machine. The operator must be careful when touching the print medium rolls and be prepared for a discharge without being shocked. Persons sensitive to static electricity should not operate or come near the machine. Caution! When the machine is running: Do not open any of the XRN hinged protective covers. Never try to solve a problem by putting your fingers or a tool in a running machine. 9

10 Caution! When the machine is stopped: 1. Use a roll lifter to handle heavy rolls. 2. Use gloves to protect your fingers from sharp objects when performing maintenance in the vicinity of the sharp edges. 3. When inspecting, cleaning or pulling web through the machine etc., mind your head. 4. The XRN is a class 1 machine: Make sure it is properly grounded. The grounding pin/line (protective earthing) is a safety feature, and a secured connection is vital. A qualified service engineer should verify or repair the connection, whenever cabling or terminals are damaged. Do not circumvent this grounding system. 5. Do not allow anything to rest on a power cord. Do not locate the XRN where persons may walk on the power cord. If necessary, make sure to provide adequate protection for the power cord. 6. To disconnect a plugged-in power cord, pull it out by the plug. Never pull the cord itself. 7. Never push objects of any kind into the XRN through cabinet slots, as they may touch dangerous voltage points or short out parts that could result in a risk of fire or electric shock. 8. Never spill liquid of any kind on the XRN. Should any liquid or solid object fall into the cabinet, turn the power off and have the XRN checked by qualified service personnel before resuming operations. 9. Lightning: For added protection of the XRN during a lightning storm, or when it is left unattended and unused for long periods of time, disconnect the main power supply. This prevents damage to the XRN due to AC power line surges. 10. Do not remove or replace any fuses. Refer servicing to qualified personnel. 7. Shutting down the XRN The main power can be disconnected by means of the main switch (main disconnection device). However, certain parts remain powered even with the main switch in the OFF position. For this purpose, it is better to fully power down the XRN by switching the external disconnect device (if present) to the OFF position. 10

11 8. The control panel: Emergency stop Power On Max. speed Rewind tension To power on the machine press the Power button. With the Max. Speed button the maximum web speed can be adjusted. The setting will normally be 10% faster then the speed of the press. With the Rewind tension button the torque of the rewind shaft can be adjusted. The torque depends on the material and the max. diameter the roll need to have. Big diameters need high torque and small diameters low torque. In case of a dual rewind machine a second tension button is present. 9. The touch screen control panel: The following screen appears. Power on menu. Software version Pressing Next will open the Main menu Next screen 11

12 10. Main menu. Rewind state Nip Mandrel Knife Service menu Taper tension menu Start button Clamp Pressing the button Power off will shut down the machine; - press and hold until machine shuts down (approx. 5 s). Press Nip to engage/disengage nip. Press Mandrel to expand/deflate mandrel. Press Rewind state to change direction and enable/disable rewinder. (The second rewinder will not be present on a single rewind machine.) Pressing the Start button will start the machine and the touch screen will change to the Run menu. Press Knife to engage/disengage knife. (Will only be present on machines with this option.) Press Clamp to engage/disengage clamps. The machine cannot start with a clamp engaged. Press Taper tension to enter the taper tension setup menu. Press Service menu to enter the service menu page. 12

13 11. Service Menu. This menu shows a readout of various potentiometers and sensors. This can be used to make adjustments and/or to identify faulty components. Web break detection can be enabled/disabled in this menu. 12. Run menu. Return to main menu Reset distance Stop button The run menu shows the speed of the web and length of the current job. Clamps and mandrels can only be manipulated when the web speed is 0.0 m/min. Clamps will automatically disengage if the web starts moving. The nip will automatically engage when Start is pressed and cannot be disengaged while the machine is in Run mode, regardless of web speed. 13

14 13. Taper tension menu. Return to main menu In this menu taper tension can be enabled/disabled and the percentage of tension increase per mm diameter can be set. (to a max of 1.00 %) 14

15 14. Running the XRN machine: From the press draw the web true the XRN as shown on the drawing: XEIKON 1 Set the speed potentiometer to minimum speed (stop). 2 Turn on the machine and navigate to the main screen page in the touch screen. (see main menu -section) 3 Turn the speed potentiometer so that the nip starts moving and the dancer arm goes up and stops the machine. 4 Set the tension to the desired tension for the roll. 5 Set the speed potentiometer 10% higher than the press speed. 6 Start the press. All splicing is done on the splice table. A groove in the table is used as knife guiding to ensure a precise cut through the web. To secure the web two clamps are placed on each side of the splicing point to hold each half of the web. Now tape can be applied to the splice. 15

16 15. Setup and adjutsment. Leveling the machine: To secure nice rewind roll it is extremely important that the machine is leveled, adjust the legs on the machine. Levelling the machine It is also important that the machine is placed so that the web is centered on the rollers and that the machine is not angled compared to the web, - secure that the web tension is the same at both side of the web. 16. Moving the XRN Caution! The XRN Rewinder is only to be moved by qualified service personnel. 17. Adjusting web tension against the press. After positioning the XRN after the press the web tension must be adjusted. For a XEIKON digital press the web tension should be 10N, not higher. Adjust web tension. 16

17 The web tension range can be changed inside the XRN, by moving an air hose. If low tension is required, the air hose should be connected to the upper end of the air cylinder. If high tension is required, the air hose should be connected to the lower end of the air cylinder. High tension range Pressure (bar) Tension (N) XEIKON 18. Adjusting dancer potentiometer It is crucial that the potentiometer connected to the dancer arm is adjusted correctly. To adjust some allen keys is needed. Follow this procedure: 1 Remove web from the machine 2 Go to the service menu. 3 Adjust the potentiometer so that the Dancer arm readout in the service menu shows a value above 750 when the dancer arm is at the bottom and less than 150 at the top. (NB! If it is a dual rewind version it should only be less than 210 at the top). 4 Start the machine and check that the nip stops moving when the dancer is about 1 from the top. Nip motor stops 25mm (1 ) before top position Loosen screw and turn gear wheel to adjust. 17

18 19. Connecting power to the machine: The machine is to be connected by a local electrician. Max. fuse in front of the machine is 16A. Do not connect the rewinder via a standard 30mA residual current circuit breaker (RCCB), as the internal filters of the frequency inverters in the rewinder will cause a disconnection of the circuit breaker. Use an RCCB that breaks at a leakage current of 300mA. POWER CONNECTION V 50/60Hz P+N+PE Air fitting Ø=8mm 4-6Bar >20 l/min At installation use fittings to get tube and cable in the machine 18

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20 21. Specifications. Max. web width: Max speed: Substrate Paper thickness Web tension press-xrn330: Rewind torque: Max. roll size: Power supply for the unit: Air supply: 500mm (1 ft.) 30m/min (100ft/min) Paper and Silicone-backed paper (labels). Some heavy foils (PET). Thin foils (50-20micron) and thermal transfer will not work gsm (other gsm s may work) 5N-20N adjustable in machine 11Nm-32Nm adjustable on front panel. Ø=500mm (20 ) to 700mm (28 ) depending on web material. NB! Ø=400mm(16 ) for a dual rewind machine VAC 6A 50/60Hz and PE RCCB that breaks at a leakage current of 300mA. 5 6 bar (72-87 psi) >20L/min (5gal/min) Weight: 300Kg Dimension: L:1210mm (47.6 ) W:1020mm (40 ) H:156mm (61.4 ) 22. Compliance specifications. CE compliant to the applicable European Directives. 23. Environment specifications. Temperature: between 15 C and 30 C Relative humidity: * 15 C: between 15% and 80% * 30 C: between 25% and 55% 20

21 Touch screen Part no.: -KLCD022 Main contactor Part no.: -RELAE063 24V power supply Part no.: -PW017 CPU board Part no.: -PAVR* Main board Part no.: -PDC* Safety board Part no.: PESTOPV3* Inductiv sensor PNP Part no.: -FOEL0049 Frequency inverter 0,75kW SMD Part no.: -FRE018 Frequency inverter 0,75kW SMVector Part no.: -FRE020 Relay 4 pole 24V Part no.: -RELÆ054 Push button Part no.: -SWABW120 Emergency stop Part no.: -SWNOTK and -SWNOTP Potmeter Part no.: -POT0012 Inductive sensor PNP Part no.: -FOEL0049 Single magnetic valve w/ 1 cable Part no.: -PNE047 w/ 2 cables Part no.: -PNE046 Inductive sensor NPN Only on this Rewinder Part no.: -FOEL0046 Inductive sensor PNP Part no.: -FOEL0049 Potmeter Part no.: -POT0007 UNIEMS Part no.: -XEIKON02 GM REWINDER UNIT 21

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