Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød, Denmark Phone: +45 45 81 23 00 Internet: www.gm.dk e-mail: gm@gm.dk Fax: +45 45 81 99 56 OPERATING INSTRUCTIONS FOR PMS LARGE Unwinding machine Rev 18 23/06/2015
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3 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: PMS Large Unwind 500mm Model number: LUW500V5 Serial number / production year: 115107 /2015 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 EN 12100 Safety of machinery -- Safety-related parts of control systems Safety of machinery Person authorised to compile and hold the technical documentation: Lennart W. Petersen Managing Director Uffe Nielsen (Mr.) Grafisk Maskinfabrik A/S 01/06-2015 Birkerød Uffe Nielsen Date Signature
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5 EU Declaration of Conformity... 3 General... 6 Safety instructions... 7 Safety instructions for operator... 8 Misuse of the PMS LARGE... 9 Emergency stop/interrupting the print process... 9 Electrical safety remarks... 10 Shutting down the PMS LARGE... 11 Moving the PMS LARGE... 11 Unpacking... 12 Rust prevention:... 12 Installing the machine:... 13 Levelling the machine:... 13 Adjusting web tension- against the press:... 13 Connecting power and air to the machine... 14 End of roll and Estop... 14 Web path for PMS LARGE unwind unit... 15 Debug/Setup Screen... 17 Running the PMS LARGE machine:... 18 Start:... 18 Stop:... 18 Loading of roll... 19 Unloading of roll... 20 Troubleshooting... 21 Adjusting dancer potentiometer... 21 Dancer arm stuck in top position... 21 Specifications... 22 Enviroment... 22 Unit... 22 Disposal instructions... 22 Electrical Parts for PMS LARGE... 23 Mechanical Parts for PMS LARGE... 26 Layout... 28 Spare parts list... 29
6 General The PMS LARGE is an unwinding station for a Xeikon press. It supports a wide range of materials and has operator friendly "lift from floor" forks for the paper rolls. It features an integrated processor and touch screen that connected with a Xeikon press makes a complete print system. Options include different spindles, web guides, and nip for loose loop unwinding. The machine will synchronize to the speed from the press with a dancer arm/tension control that also gives the possibility to adjust the web tension between the press and the PMS LARGE.
7 Safety instructions This chapter describes the safety guidelines that must be observed under all circumstances when installing, commissioning, operating and maintaining the PMS LARGE unwinder. 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 hazardous electricity. 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.
8 Safety instructions for operator Caution: To operate the PMS LARGE the operator needs to understand all the functions of the controls for safe and proper use of the machine. The operator of the PMS LARGE must have the necessary training for this. Caution: The PMS LARGE should only be operated within its scope. (As an unwinder for a Digital press) Caution: Using materials not within the scope of the machine could cause risk of damaging the machine. Caution: Keep fingers, hair, loose jewels away from the moving objects! Caution: Stand clear of the machine while lifting / lowering the roll. Wear protective shoes when working with heavy rolls. Caution: Side covers are only to be opened up by trained electrician. The equipment s side covers have been mounted with bolts to prevent the operator from opening the cabinet. The area protected by the side covers does not require operator access for routine cleaning, setting or maintenance operations. The cabinet is only to be removed by a qualified service engineer or electrician, in case of complete overhaul, major repairs or dismantling. Refer servicing to qualified personnel
9 Misuse of the PMS LARGE The following actions or situations are considered as a misuse of the PMS LARGE and are 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. Use as a rewinder Modifications mechanical or electrical to the unit Emergency stop/interrupting the print process A mushroom-type emergency stop button is provided near the PMS LARGE control panel to bring the PMS LARGE in an emergency stop state. The PMS LARGE main switch is also intended as emergency stop switch and main disconnection device. In case of emergency, or when the machine is not responding, switch the main switch to the OFF position. This shuts down the power to the PMS LARGE. When the PMS LARGE is in running mode, do not under any circumstance: Leave the PMS LARGE unattended. Remove fixed covers or other parts of the protective enclosure. Refer servicing to qualified personnel.
10 Electrical safety remarks The cover of the PMS LARGE is only to be removed by a trained service engineer or electrician. Risk of electric shock. Caution: To prevent fire or electrical shock hazard, do not expose this product to rain or moisture. Caution: The PMS LARGE 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: Never try to solve a problem by putting your fingers or a tool into a running machine. Caution: When the machine is stopped: Use gloves to protect your fingers from sharp objects when performing maintenance in the vicinity of the sharp edges. When inspecting, cleaning or pulling web through the machine etc., mind your head. The PMS LARGE 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. Do not allow anything to rest on a power cord. Do not locate the PMS LARGE where persons may walk on the power cord. If necessary, make sure to provide adequate protection for the power cord. To disconnect a plugged-in power cord, pull it out by the plug. Never pull the cord itself. Never push objects of any kind into the PMS LARGE 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. Never spill liquid of any kind on the PMS LARGE. Should any liquid or solid object fall into the cabinet, turn the power off and have the PMS LARGE checked by qualified service personnel before resuming operations. Lightning: For added protection of the PMS LARGE 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 PMS LARGE due to AC power line surges. Do not remove or replace any fuses. Refer servicing to qualified personnel.
11 Shutting down the PMS LARGE The main power can be disconnected by means of the mains switch (main disconnection device). However, certain parts remain powered even with the mains switch in the OFF position. For this purpose, it is better to fully power down the PMS LARGE by switching the external disconnect device (if present) to the OFF position. Moving the PMS LARGE The unit is heavy. Wear protective shoes when moving the unit. Caution: The PMS LARGE is only to be moved by qualified service personnel. Lift the unit from the back or front - not from the sides (see red arrows below). The unit has and odd point of gravity. Be careful when unloading.
12 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. When lifting the unit down from the pallet, - please lift from front and back. See red arrows below. Never lift the machine in the rollers, as this may damage the machine. Rust prevention: For transportation purposes the machine has been protected in a sealed bag. This bag should only be removed when the unit is to be installed. Do not remove the bag and store the unit in a moist or cold environment for a long time. If the unit is to be transported actions must be taken to avoid rust (seal packing or other method).
13 Installing the machine: Before starting operation make sure to follow all steps in this section. After this has been completed make sure the web path is correct (see diagram in the manual) Levelling the machine: To secure an even unwind it is very important that the machine is levelled correctly by adjusting the feet on the machine. Levelling the machine It is also important that the machine is placed so that the web is centred 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. Adjusting web tension- against the press: Tension against press After positioning the PMS LARGE in front of the press the web tension must be adjusted. Please turn the air manometer until you have a web tension of appx 1 kg (10N) (1 bar) Too high web tension may damage the press. Too low web tension will cause the web to drift.
14 Connecting power and air to the machine The machine is to be connected by a local electrician. Max. fuse in front of the machine is 13A. Voltage is 200-240V, single phase. Use an RCCB that breaks at a leakage current of 300mA. Do not connect the unwinder via a standard 30mA residual current circuit breaker (RCCB), as the internal filters of the frequency inverters in the unwinder will cause a disconnection of the circuit breaker. The air connection is a standard 8mm fitting located on the front lower side of the unit. Please fit a water/oil separator if the air is contaminated. End of roll and Estop To install the End of roll and Estop signals please remove the cover (on the side where the power and air is connected). Be careful as the cover is heavy. Please see the diagrams on the machines for wire connections. Please note that the Xeikon cable is normally supplied with the machine and already connected inside.
15 Web path for PMS LARGE unwind unit Before operations make sure the unit is webbed up correctly. Please see the above web-up diagram for the PMS LARGE unwind unit.
16 Stop Screen Roll down / up Unwind direction Clamps on/off Stop at low unwind diameter Power off Hold down 5 sec Nip on/off (Only in Loose loop unwind mode) Debug/Setup menu Important: Expand the air spindle with compressed air and lock the air chucks on the spindle before pressing start. The End of roll warning signal can be adjusted by pressing the TOOL icon under the power off button. The roll can only go down if the air chucks on the roll are disengaged (open) Run screen Start machine Roll diameter Distance Reset distance Stop machine
17 Debug/Setup Screen By pressing the tool icon on the main menu the debug/setup menu above is displayed. This menu shows all sensors and potentiometers in the machine. It is very useful for debugging. The tool menu has two low unwind settings for the End of roll warning. Please see the red arrows above. There two different diameters can be setup - example 90mm (3") and 160mm (6"). This will cause the unit to WARN the Xeikon press when the roll is approaching minimum diameter. Loose loop unwind mode requires an optional output nip and IR sensor to be installed on the unit. This unwind mode will ensure that the web is always kept slack towards the press. When loose loop unwind mode is enabled, control for the output nip will appear on the main screen. If this option is not installed, enabling this mode will have no effect on the unit other than the nip symbol appearing on the main screen. If the output nip is installed but you wish the unit to run as a regular PMS LARGE, i.e. with tension towards the press, the Loose loop unwind mode should be disabled and the web should bypass the nip.
18 Running the PMS LARGE machine: Start: 1. Enable power to the machine 2. Mount a roll on the spindle. 3. Fill the spindle with air and lock the air chocks. Make sure to fill with 5 bar or roll will slide. 4. Pull the paper through the machine and through the press. 5. Select spindle direction. 6. Check that the low unwind diameter is set correctly (tool menu) 7. Push the start button. 8. The machine will now slowly tighten the web and is ready for use. The machine has an automatic End of roll stop signal to the press when the roll is almost empty. When running in Loose loop unwind mode using clear material, it is recommended to fasten regular label material or paper to the end of the machine and having it rest on top of the clear material. This is to ensure the IR sensor gets a proper reading so the machine feeds the web smoothly to the press. Stop: 1. Push the Stop button. 2. The web tension will go down and the unit will no longer feed web to the press. Always stop the press before stopping the unwinder. Remember to turn the machine completely off, when not in use.
19 Loading of roll CAUTION : Roll and axel/spindel may be heavy. Pay attention to lifting position. 1. Put spindle into roll core - equal distance free on each side 2. Inflate spindle with the air gun 3. Open the chucks on the arms 4. Move the roll into position of the chucks. 5. Start lifting up. (press up on the touch screen) 6. Lock the chucks by pressing the flanges towards the roll (see picture on the next page)
20 Unloading of roll CAUTION : Roll and axel/spindel may be heavy. Pay attention to lifting position. 1. To unload the chucks must be moved AWAY from the roll - if not the roll can't be lowered. It is only possible to move the chucks back when the two red dots on the chucks are aligned and the black safety pin on the lower side of the chuck is pressed. Stand clear of the roll. See picture below. 2. Start lowering by pressing the touch screen 3. Deflate the spindel and take it out of the roll. 4. If the chuck is "jammed" bar/wrench can be inserted between the roll and chuck to ease it out. Do not use exessive force. As a start the chuck is heavy to operate. After a while it will losen more up making it more easy to lock and un-lock the roll. Close up picture of spindel and chuck. To release the chuck align the two red dots. Then press the black knob and move the chuck ring in the direction of the red arrow. To close the chuck simply move the ring back towards the spindel. No alignement or knob pressing is needed to close.
21 Troubleshooting The unit has few moving parts and sensors. There is one key position sensor that is set from factory. This sensor (potentiometer) determins the position of the dancer arm. If this part needs to be replaced a qualified electrician or trained engineer is required. The position of the dancer arm can be seen in the debug menu. It is easy to verify correct operation the dancer arm position should read between 30 and 50 in the display at low position and climb upwards when the dancer arm is moved. The number must never «roll over» and start from zero again. Adjusting dancer potentiometer It is crucial that the potentiometer connected to the dancer arm is adjusted correctly. Remove the cover of the machine to perform the adjustment. Correct adjustment: in lower position the readout in the tools/debug menu for dancer pot must be between 30 and 50. Loosen screw and turn gear wheel to adjust. Dancer arm stuck in top position If the dancer arm I the unit is forced into the top position it may get stuck in this position. To release it turn off the unit on the side switch. Disconnect the air. Lower the arm carefully by forcing it down. Be careful that the arm does not slip and fall down quickly. This error can happen for a number of reasons 1. Loss of power to the unit 2. Problem with the signals between the Xeikon and the unit (ready) 3. Activation of the E-stop 4. Faulty adjustment of the dancer arm potentiometer
22 Specifications Enviroment Temperature: between 15 C and 40 C Relative humidity: * 15 C: between 15% and 80% * 30 C: between 25% and 55% Unit Max. web width: Max speed: Web tension: Noise level Max. roll size: Substrate support Power supply for the unit: Air supply: Weight: Roller size 570mm. Recommended max web width 520mm. 25m/min 5N-20N adjustable in machine 64dB (1 meters distance) Ø1500mm / 750kg. 40-350gsm paper and film. 200 240VAC 13A 50/60Hz and PE RCCB that breaks at a leakage current of 300mA. 5 6 bar (72-87 psi) > 20 L/min (5 gal/min) 650 kg Dimension: L: 1585mm (2065 mm with roll) + 320 mm with nip option W: 1415mm, H: 1275mm Disposal instructions If the unit is to be scrapped it must be taken to a machine disposal station. The unit contains hydraulic fluid that must be tapped before scrapping.
Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød, Denmark Phone: +45 45 81 23 00 Internet: www.gm.dk e-mail: gm@gm.dk Fax: +45 45 81 99 56 23 Electrical Parts for PMS LARGE Main board Part no.: -PDC* Emergency stop board Part no.: PESTOPV3* UNIEMS Part no.: -XEIKON02 CPU board Part no.: -PAVR* Frequency inverter 0,75kW Part no.: -FRE006 Frequency inverter 0,37kW Part no.: -FRE004 Relay 2 pole 24V Part no.: -RELÆ052 Double magnetic valve Part no.: -PNE0247 Single magnetic valve Part no.: -PNE0246 Main contactor Part no.: -RELÆ063 24V power supply Part no.: -PW020
Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød, Denmark Phone: +45 45 81 23 00 Internet: www.gm.dk e-mail: gm@gm.dk Fax: +45 45 81 99 56 24 Touch screen 5,7 Part no.: -KLCD038 Potmeter board Part no.: PPOTv2 Potmeter Part no.: -POT0007 Emergency stop Part no.: -SWNOTK and -SWNOTP Push button Part no.: -SWABW120 Fan Part no.: -BLÆ01 Gear wheel Part no.: -TRH0018 Encoder Part no.:.enc11 Gear belt Part no.: -TAR0169 Cylinder Part no.: -PNE0307 Hydraulic pump station Part no.: -HYD0176 Gear wheel Part no.: -TRH0121 Unwind motor Part no.: - MOT0210
Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød, Denmark Phone: +45 45 81 23 00 Internet: www.gm.dk e-mail: gm@gm.dk Fax: +45 45 81 99 56 25 Tacho sensors (PNP) Part no.: -FØL0049 Arm top sensor (NPN) Part no.: -FØL0046 Roll lock sensors (NPN) Part no.: -FØL0046 Arm bottom sensor (PNP) Part no.: -FØL0049
Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød, Denmark Phone: +45 45 81 23 00 Internet: www.gm.dk e-mail: gm@gm.dk Fax: +45 45 81 99 56 26 Mechanical Parts for PMS LARGE
Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød, Denmark Phone: +45 45 81 23 00 Internet: www.gm.dk e-mail: gm@gm.dk Fax: +45 45 81 99 56 27
Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød, Denmark Phone: +45 45 81 23 00 Internet: www.gm.dk e-mail: gm@gm.dk Fax: +45 45 81 99 56 28 Layout
Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød, Denmark Phone: +45 45 81 23 00 Internet: www.gm.dk e-mail: gm@gm.dk Fax: +45 45 81 99 56 29 Spare parts list Description GM part no. Xeikon SAP no. Page no. Clamp PNE0005 155267 27 CPU board PAVR* 155268 23 Cylinder, dancer arm PNE0307 155269 24 Drive belt, Nip TAR0176 155270 27 Emergency stop SWNOTK & SWNOTP 155271 24 Emergency stop board PESTOPV3* 155272 23 Encoder.ENC11 155273 24 Fan BLÆ01 155274 24 Frequency inverter 0,37kW FRE004 155275 23 Frequency inverter 0,75kW FRE006 155276 23 Hydraulic pump HYD0176 155277 24 Magnetic valve, double PNE0247 155278 23 Magnetic valve, single PNE0246 155279 23 Main contactor RELÆ063 155280 23 Mainboard PDC* 155281 23 Motor, Nip MOT0234 155282 27 Motor, unwind MOT0210 155283 24 Pneumatic cylinder, Nip PNE0126 & PNE0127 155284 27 Potmeter POT0007 155285 24 Potmeter board PPOTv2 155286 24 Power button SWABW120 155287 24 Power supply 24V PW020 155288 23 Relay 2 pole 24V RELÆ052 155289 23 Roller bearing KUG0038 155290 26 Rubber roller, Nip /VAL001C 155291 27 Sensor NPN FØL0046 155292 25 Sensor PNP FØL0049 155293 25 Touch screen KLCD038 24 UNIEMS XEIKON02 23