VT3000™ instruction manual english

VT3000™ instruction manual english
VT3000™
Instruction Manual
Another quality product from:
Matti Technology AG
Wilenstrasse 6
CH-8588 Zihlschlacht / Switzerland
Main Number: +41 (71) 422 31 92
Fax: +41 (71) 422 31 44
E-Mail: [email protected]
Web: www.mattitech.ch
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VT3000™ is a trademark of Kodak Versamark Inc.
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.
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Dear Customer
Thank you for purchasing a VT3000™ high performance printing system. The VT3000™
provides the Technology you need to print and dry at high speeds. With this system, your
company will increase throughput and quality.
The VT3000™ is one of many high-quality, innovative systems available 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) 422 31 92
Service Number: +41 (71) 422 31 58
Fax: +41 (71) 422 31 44
E-Mail: [email protected]
Web: www.mattitech.ch
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
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Pascal Fäh
Vice President of Operations
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1
Table of Contents
VT3000™ Instruction Manual
1 Table of Contents
1.1
List of Illustrations
1.2
List of Tables
2 Forward
2.1
Important
2.2
Compliance statements
2.2.1. FCC Compliance Statement
2.2.2. European EMI Compliance Statement
2.3
Inspection of Shipped Parts
3 Specification sheet
3.1
General
4 Safety information
4.1
General
4.2
Safety Information for the Owner
4.3
Safety Information for the Operator
4.4
Specific Security Advices
4.5
Guarding
4.6
Machine handling and lifting
4.6.1. Print unit
4.7
Mechanical Safety
4.8
Electrical Safety
4.9
Fire Safety
4.10
High Temperature
5 Labels
5.1
Safety Labels
5.1.1. Dangerous voltage
5.1.2. Burn hazard
5.1.3. Danger of cuts from moving paper
5.1.4. Danger of crushing
5.1.5. Pinch pint rollers
5.1.6. Pinch point from moving parts
5.1.7. Danger of entanglement from belt drive
5.1.8. Danger of entanglement from rotating gear
5.1.9. Danger of cutting blade
5.1.10.
Danger of cutting of fingers or hand
5.2
Text warning Labels
5.2.1. Running with different voltages and frequencies
5.2.2. Disconnect main switch before servicing
5.2.3. This switch does not disconnect all power of this machine
5.2.4. Inside the dryer it is may be very hot
5.2.5. Compressor installed under the cover
5.3
Position of safety labels
5.3.1. Danger of cuts from moving paper
5.3.2. Burn hazard
5.3.3. Pinch point rollers
5.3.4. This switch does not disconnect all power of this machine
5.3.5. Running with different voltages and frequencies
5.3.6. Disconnect main switch before servicing
6 Site preparation / Installation instruction
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6.1
Electrical requirement
6.2
Fire Precautions
6.3
Mechanical / Physical
6.3.1. Heat distribution
6.4
Pad loads of the different unites
6.4.1. Pad weight VT3000-3 Head Print module XV.3R
6.4.2. Pad weight VT3000-3 Head Print module XV.3R with Infeed
6.4.3. Pad weight VT3000-3 Head Print module XV.3R with Outfeed
6.4.4. Pad weight VT3000-3 Head Print module XV.PU3
6.4.5. Pad weight VT3000-3 Head Print module XV.PU3 with Infeed
6.4.6. Pad weight VT3000-3 Head Print module XV.PU3 with Outfeed
6.4.7. Pad weight VT3000-5 Head Print module XV.PU5
6.4.8. Pad weight VT3000-5 Head Print module XV.PU5T with Infeed
6.4.9. Pad weight VT3000-5 Head Print module XV.PU5T with Outfeed
6.5
Dimensions of packaged units
6.5.1. 5 Head print unit with infeed and outfeed
6.5.2. 5 Head print unit
6.5.3. Infeed and outfeed for 5 Head print unit
6.5.4. 3 Head print unit
6.5.5. 3 Head print unit with infeed or outfeed
6.5.6. 3 Head print unit with infeed and outfeed
6.5.7. 3 Head print unit with dryer
6.5.8. 3 Head print unit with dryer and infeed or outfeed
6.5.9. 3 Head print unit with dryer, infeed and outfeed
7 Introduction
7.1
Infeed
7.1.1. Web Guide (optional)
7.2
Print Unit
7.2.1. Head Mounting
7.2.2. Dryer
7.2.3. Turnbar
7.2.4. Kodak Versamark Tach and Cue
7.3
Outfeed
7.4
Power Control Cabinets
7.4.1. Infeed/outfeed Control Cabinet
7.4.2. Dryer control Cabinet
8 Mechanical Installation
8.1
Tools Required
8.2
Install 5 Head Print Unit
8.3
Install 3 head unit
8.4
Install Infeed or Outfeed
8.5
Install additional units
8.6
Installing dryer assembly
9 Electrical Installation
9.1
Tools Required
9.2
Power connection points
9.3
Connecting Power to Power Control Cabinet
9.4
Using 400V support
9.5
Using 400V support
9.6
Transformer connection using 400V support
9.7
Transformer connection using 480V support
9.8
Schematic for 5 head module dryer
9.9
Schematic for 3 head module dryer
9.10
Connecting communication between Cabinets
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9.11
Interface
9.12
Kodak Versamark IPDS Controller
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Operation
10.1
Transport System Configuration
10.1.1.
Legend for Transport System Configuration
10.1.2.
1-up (narrow) configurations
10.1.2.1 1/4 Narrow
10.1.2.2 4/1 Narrow
10.1.2.3 4/4 Narrow
10.1.2.4 4/4 Narrow on 4/1 Wide configuration
10.1.3.
2-up (wide) configurations
10.1.3.1 1/1 Wide
10.1.3.2 2/1 Wide
10.1.3.3 2/2 Wide
10.1.3.4 1/3 Wide
10.1.3.5 3/1 Wide
10.1.3.6 1/4 Wide
10.1.3.7 4/1 Wide
10.1.3.8 4/2 Wide
10.1.3.9 4/4 Wide
10.2
Operating Buttons
10.2.1.
Emergency Stop Button
10.2.2.
Jog Button
10.2.3.
Reset Machine Button
10.2.4.
Counter Reset Button
10.3
Side guides and nip roller adjustment
10.3.1.
Side guides
10.3.2.
Nip roller
10.4
Cue mark sensor support
10.5
Print Head
10.5.1.
Head Adjustment
10.5.1.1 Height Adjustment
10.5.1.2 Skew Adjustment
10.5.1.3 Side Adjustment
10.6
Operation web Guide (optional)
10.6.1.
Position of the web guide
10.6.2.
Adjustment of the web guide
10.6.2.1 Display sensor signal
10.7
Turn bar
10.8
Dryer
10.8.1.
Pass the paper through the dryer and print unit
10.8.2.
How to open the Dryer
10.8.3.
How to close the Dryer
10.8.4.
How to close the Dryer (Serial number 24741 and higher)
10.8.5.
IR-Sensor
10.8.6.
Quartz Infrared Halogen Lamps
10.8.7.
Lubrication of the bearings of the dryer
10.8.8.
How to change the dryer lamp
10.9
Reset Line Hole Counter
10.10
Sensitivity adjustment of the amplifier for two line hole sensors
10.10.1. Reset of Sensor
10.10.2. Setting Functions in SET Mode
10.10.3. Power tune
10.10.4. Teaching with and without a work piece
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10.11
Kodak Versamark Encoder/Tach Support
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Electrical cabinet
11.1
Drive control exhaust air fan
11.1.1.1 Settings driver (Commander SE) 14501
11.1.1.2 Setting of the values:
11.2
PLC Battery
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Maintenance
12.1
General
12.2
Every Month
12.3
Every 3 month
12.4
Every 1 year
12.5
Every 2 year
12.6
Spare parts
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Trouble shooting
13.1
Printing Problem
13.2
Electrical Control Problem
13.3
Machine Running Problem
13.4
Paper Processing Problem
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Interface Type 1
14.1
Signals used on the Type 1 Interface
14.2
Power Requirements Type 1 Interface
14.3
Interface 15 pin for Unwind and Rewind Units
14.3.1.
Connector (socket)
14.4
Interface 37 Pin Connector
14.4.1.
Connector (Socket)
15
Paper Handling and Storage
15.1
Paper
15.2
Handling
15.3
Storage
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1.1 List of Illustrations
Illustration 1: Dryer main switch
Illustration 2: Drive main switch
Illustration 3: Emergency stop
Illustration 4: Function of the Emergency Circuit
Illustration 5: Lift the print unit
Illustration 6: Dangerous voltage
Illustration 7: Burn hazard
Illustration 8: Danger form cut of moving paper
Illustration 9: Danger of crushing
Illustration 10: Pinch point rollers
Illustration 11: Danger from moving parts
Illustration 12: Danger of entanglement from belt drive
Illustration 13: Danger of rotating gear
Illustration 14: Danger of cutting blade
Illustration 15: Danger of cutting of fingers or hand / angled blade
Illustration 16: Running with different voltages and frequencies
Illustration 17: Disconnect main switch before servicing
Illustration 18: This switch does not disconnect all power of this machine
Illustration 19: Inside the dryer it is may be very hot
Illustration 20: Compressor installed under the cover
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Illustration 21: Danger of cuts from moving paper
Illustration 22: Burn hazard on dryer
Illustration 23: “Burn hazard” and “Inside the dryer” on dryer outlet
Illustration 24: Pinch point rollers at infeed and outfeed
Illustration 25: This switch does not disconnect all power of this machine
Illustration 26: Running with different voltages and frequencies inside electric panel and on
connector box
Illustration 27: Disconnect main switch before servicing outside electric panel
Illustration 28: Head mounting
Illustration 29: Mounting holes
Illustration 30: Leveling feet
Illustration 31: Backside print unit
Illustration 32: Dryer exhaust connection
Illustration 33: Power connecting points
Illustration 34: wire blocks
Illustration 35: wire blocks for second dryer
Illustration 36: Schematic for 5 head module dryer
Illustration 37: Schematic for 3 head module dryer
Illustration 38: Interface on electrical cabinet drive side
Illustration 39: IPDS controller
Illustration 40: Run with 1 over 4 narrow; with web guide module
Illustration 41: Run with 4 over 1 narrow; with web guide module
Illustration 42: Run with 4 over 4 narrow; with web guide
Illustration 43: Run with 4 over 4 narrow; on a 4 over 1 wide configuration with web guide
Illustration 44: Run with 1 over 1 wide; with web guide module
Illustration 45: Run with 2 over 1 wide; with web guide module
Illustration 46: Run with 2 over 2 wide; with web guide module
Illustration 47: Run with 1 over 3 wide; with web guide module
Illustration 48: Run with 3 over 1 wide; with web guide module
Illustration 49: Run with 1 over 4 wide; with web guide module
Illustration 50: Run with 4 over 1 wide; with web guide
Illustration 51: Run with 4 over 2 wide; with web guide
Illustration 52: Run with 4 over 4 wide; with two web guide
Illustration 53: Operating Buttons
Illustration 54: Swan neck assembly adjustment
Illustration 55: Swan neck assembly and nip roller
Illustration 56: Cue mark sensor support
Illustration 57: 9” Head high adjustment
Illustration 58: 9” Head side adjustment
Illustration 59: Position of the web guide
Illustration 60: Controller web guide
Illustration 61: Display sensor signal
Illustration 62: Turn bar and air turbine
Illustration 63: Web path dryer and print unit
Illustration 64: Front view dryer unit
Illustration 65: Front view dryer unit for open
Illustration 66: Dryer inside
Illustration 67: Front side dryer unit IR-sensor
Illustration 68: Lubricator device back and front side dryer
Illustration 69: Line hole counter sensor
Illustration 70: Kodak Versamark Encoder/Tach Support
Illustration 71: Infeed/outfeed electrical cabinet
Illustration 72: Dryer electrical cabinet
Illustration 73: Driver exhaust vent
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Illustration 74: Location battery PLC dryer control cabinet
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Illustration 75: PLC battery location in main control cabinet
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Illustration 76: web break sensors Illustration 77: Control cabinet air filter
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Illustration 78: air ventilator servo-drives Illustration 79: dryer and all the parts inside
96
Illustration 80: air inlet of the dryer fresh air Illustration 81: air inlet of the turn bar turbine 96
Illustration 82: Dryer bearing operator side Illustration 83: Drum dryer bearing gear side 97
Illustration 84: spindle for the fine adjust Illustration 85: Glider rail and housing
97
Illustration 86: turn bar tubes Illustration 87: gas strut on the top cover
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Illustration 88: PLC battery
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Illustration 89: Paper handling
104
Illustration 90: Paper storage
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1.2 List of Tables
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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® VT3000™ 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) 422 31 92
Service Number: +41 (71) 422 31 58
Fax: +41 (71) 422 31 44
E-Mail: [email protected]
Web: www.mattitech.ch
For more information about other modules used with this transport please refer to the
following manuals:
-
ReelRunnar Unwind Unit Manual
ReelRunnar Rewind Unit Manual
StarCut Manual
FanFolder Manual
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2.2 Compliance statements
2.2.1.
FCC Compliance Statement
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential area is
likely to cause harmful interference, in which case the user will be required to correct the
interference at the users own expense.
2.2.2.
European EMI Compliance Statement
This equipment generates, uses, and can radiate radio frequency energy. When this
equipment is not installed in accordance with instructions in the installation chapter and is not
used in accordance with the instructions in the operator safety information, the radio
frequency energy may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference, in which case the user,
at the user’s own expense, will be required to take whatever measures may be required to
correct the interference.
2.3 Inspection of Shipped Parts
Please inspect all packaged materials carefully so that small parts are not inadvertently
thrown away. Report any shortage or damage to Matti Technology AG and the carrier.
All equipment is shipped on one or more pallets, and should contain all or some of the
following parts:
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5 Head Print unit with dryer and turnbar
Infeed
Outfeed
3 Head module with dryer
3 head module without dryer
Unwind unit
Rewind unit
Sheeter
FanFolder
Perforating unit
Selective perforating unit
Line hole punch unit
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3
Specification sheet
3.1 General
Name / Type
Operating speed
Basic configurations
Modularity
Duplex capability
Weight of material
Min. web width
Max. web width
Tach roller
Cue mark sensor
Print register
Turn bar
Web tension adjustable
High performance drum dryer
Sensors
Dimension print unit 4 to 5 heads
Weight print unit
Dimension 3 head unit
Weight 3 head unit with dryer
Weight 3 head unit without dryer
Dimension infeed/outfeed
Weight infeed
Weight outfeed
Floor load
Spacing between units
Power control cabinet
Power input for each dryer
Power input for infeed/outfeed
Leakage current protection
Interface
Noise level
Ambient temperature and
Relative humidity, transport:
Relative humidity, operating:
Agency compliance
Max. crating height
MTBF
Painting
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DataRunnar™ VT3000™
5 - 150 m/min ( 16 - 500 ft/m)
Roll to Roll; Roll to Sheet; Roll to Fold
up to 16 print heads
1-Up and 2-Up
coated and uncoated; 55 - 160 gr/m2
200 mm (8“)
520 mm (20.5“)
situated directly at the print head
closest to the print head
80% are ≤ ± 1 dot (both direction)
included with own air supply;
horizontally integrated for better operability
between infeed and outfeed nip
Closed loop control with ≤ ± 3%
Drum diameter 400 mm; 32 kW
Drying temperature between 40 - 130ºC (104 - 266°F)
Reads paper surface temperature
Usually runs with 70ºC (182°F)
“web width” and “web break”
2000 x 1410 x 1420 mm (79” x 52” x 56”)
approx. 1’000kg (2200 lb)
1000 x 1410 x 1420 mm (39” x 52” x 56”)
approx. 520kg (1150 lb)
approx. 400kg (880 lb)
300 x 1340 x 1425 mm (12” x 52” x 56”)
approx. 180 kg (400 lb)
approx. 100 kg (220 Lb)
≤ 450 kg per pad (≤ 1000 lb per pad)
760 mm (30”)
integrated
3x400V (3 phase, neutral, ground); 50Hz; 63 A
3x480V (3 phase, ground); 60Hz; 63 A
3x400V (3 phase, ground); 50Hz; 16 A
3x480V (3 phase, ground); 60Hz; 16 A
300 mA
IPDS
78 dB (A)
60-85°F(15-29ºC) @ 10-90% RH
60-104°F(15-40ºC) @ 10-60% RH
60-85°F(15-29ºC) @ 30-60% RH
CE; UL; CSA
≤ 1.6m (≤ 63”) to fit into a normal aircraft
6 month; does not include Kodak equipment
Kodak Versamark Grey (RAL 7024)
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Safety information
4.1 General
The VT3000 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.
4.2 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.
4.3 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.
4.4 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.
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4.5 Guarding
Main Switch:
The main switches for the transport system and dryer are located on the control cabinets.
These switches turn the systems on and off.
WARNING
This switch does not disconnect all power of
this machine. Make sure all power switching
off before servicing!
Illustration 1: Dryer main switch
Drive main switch
Illustration 2: Drive main switch
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External Emergency Stop:
The external emergency switch shuts down the system in case of emergency.
Illustration 3: Emergency stop
Function of the Emergency Circuit:
Illustration 4: Function of the Emergency Circuit
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4.6 Machine handling and lifting
The following illustrations show how the unit can be lifted by a fork lift or a pallet truck.
4.6.1.
Print unit
Illustration 5: Lift the print unit
ATTENTION!
Never lift the print unit by the Kodak
Versamark support.
ATTENTION!
Move the print unit only with a forklift or a
pallet truck
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4.7 Mechanical Safety
Wear safety shoes and safety glasses at all times.
Remove or secure items that could be caught, fall into, or become entangled in the
mechanisms, including jewellery, loose clothing, and long hair.
Keep all equipment covers closed when operating the printer.
After a fast stop or emergency stop, make sure all error conditions are corrected before trying
to restart the machine.
In the event of leaks or breaks at pressure relief valves, automatic pressure regulators, limit
sensors, and other automatic safety features, turn off all compressed air to the system.
The air expandable shafts require the same action if a leak or break occurs.
Watch your feet when loading, unloading and handling the paper roll.
Do not touch any moving parts.
Do not remove any cover of the unit.
If any unsafe situation is possible or recognized, stop the machine immediately and switch it
off. Do not run the machine again until the situation is safe.
4.8 Electrical Safety
There is danger of an electrical shock when servicing the transport, dryer or control cabinet.
Even when the circuit breaker of the control cabinet is in the OFF position, there is live HIGH
VOLTAGE (up to 480V) present at the power entry of the circuit breaker.
WARNING!
ALWAYS disconnect the external power
prior to servicing the system.
NEVER operate the system with the doors of
the control cabinet or transport open.
DANGER!
Power terminals remain live up to
3 minutes after mains disconnection.
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4.9 Fire Safety
When operated using the maximum recommended drum dryer set-point temperature of 265°F
(130°C), there is no fire hazard from operating the system unless the flash point of the web or
coatings are below 265°F (130°C).
CAUTION!
If drying on a web consisting of material or
coatings with flash point below the set-point
drum dryer temperature, jams or stoppages
in the transport may cause a FIRE HAZARD.
In these instances, NEVER operate the
system unless an operator is present.
In these instances, NEVER operate the
system without a FIRE EXTINGUISHER in the
immediate area.
4.10
High Temperature
During operation, the aluminum drum dryer can become very hot. Contact with the drum dryer
may cause severe BURNS.
WARNING!
NEVER place hands on the drum dryer.
Wait 15 min for it to cool down
or use heat resistant gloves.
The maximum allowable drum dryer set-point temperature is 265°F (130°C). If a power
controller of feedback circuit malfunctions, a safety circuit automatically turns off the system
when any zone exceeds 480°F (250°C).
The excess temperature circuit will allow the dryer to restart when the temperature drops
below 480°F (250°C).
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5
Labels
The following chapters explains the different labels used on the transport system.
5.1 Safety Labels
5.1.1.
Dangerous voltage
Illustration 6: Dangerous voltage
Dangerous voltage. Contact may cause electric shock or burn.
DANGER! Power terminals remain live up to 3 minutes after mains disconnection.
5.1.2.
Burn hazard
Illustration 7: Burn hazard
Burn hazard, hot surface. Do not touch the surface of this component during equipment
operation. Allow to cool down before servicing.
5.1.3.
Danger of cuts from moving paper
Illustration 8: Danger form cut of moving paper
Danger of cuts from moving paper. Keep body away form edge of moving paper.
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5.1.4.
Danger of crushing
Illustration 9: Danger of crushing
Danger of crushing from moving paper roll. Stand back from the lift arms and paper roll during
operation.
5.1.5.
Pinch pint rollers
Illustration 10: Pinch point rollers
Pinch point danger from rollers. Keep hands and clothing away from rotating rollers.
5.1.6.
Pinch point from moving parts
Illustration 11: Danger 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.
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5.1.7.
Danger of entanglement from belt drive
Illustration 12: Danger of entanglement from belt drive
Danger of entanglement from belt drive. Shear hazard. Moving part can crush and cut. Keep
hand clear. Do not operate with guard removed. Follow lockout procedure before servicing.
5.1.8.
Danger of entanglement from rotating gear
Illustration 13: Danger of 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.
5.1.9.
Danger of cutting blade
Illustration 14: Danger of cutting blade
Danger of cutting blade. Shear hazard. Moving part can crush and cut. Keep hand clear. Do
not operate with guard removed. Follow lockout procedure before servicing.
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5.1.10. Danger of cutting of fingers or hand
Illustration 15: Danger of cutting of fingers or hand / angled blade
Danger of cutting of fingers or hand. Moving parts can crush and cut. Do not operate with
guard removed. Follow lockout procedure before servicing.
5.2 Text warning Labels
5.2.1.
Running with different voltages and frequencies
Illustration 16: Running with different voltages and frequencies
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5.2.2.
Disconnect main switch before servicing
Illustration 17: Disconnect main switch before servicing
5.2.3.
This switch does not disconnect all power of this machine
Illustration 18: This switch does not disconnect all power of this machine
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5.2.4.
Inside the dryer it is may be very hot
Illustration 19: Inside the dryer it is may be very hot
5.2.5.
Compressor installed under the cover
Illustration 20: Compressor installed under the cover
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5.3 Position of safety labels
5.3.1.
Danger of cuts from moving paper
Illustration 21: Danger of cuts from moving paper
5.3.2.
Burn hazard
Illustration 22: Burn hazard on dryer
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Illustration 23: “Burn hazard” and “Inside the dryer” on dryer outlet
5.3.3.
Pinch point rollers
Illustration 24: Pinch point rollers at infeed and outfeed
5.3.4.
This switch does not disconnect all power of this machine
Illustration 25: This switch does not disconnect all power of this machine
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5.3.5.
Running with different voltages and frequencies
Illustration 26: Running with different voltages and frequencies inside electric panel and on
connector box
5.3.6.
Disconnect main switch before servicing
Illustration 27: Disconnect main switch before servicing outside electric panel
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6
Site preparation / Installation instruction
6.1 Electrical requirement
Power input for each dryer
Power input for infeed/outfeed
3x400V ± 10 % (3 phase, neutral, ground)
50/60Hz ± 0.5 %; 63 A
short circuit capacity of Breaker/Fuses 10 kA
3x480V ± 10 % (3 phase, ground)
50/60Hz ± 0.5 %; 63 A
short circuit capacity of Breaker/Fuses 10 kA
3x400V ± 10 % (3 phase, ground)
50/60Hz ± 0.5 %; 16 A
short circuit capacity of Breaker/Fuses 10 kA
3x480V ± 10 % (3 phase, ground)
50/60Hz ± 0.5 %; 16 A
short circuit capacity of Breaker/Fuses 10 kA
Note: power for Kodak Versamark data and print station not included
6.2 Fire Precautions
Fire extinguisher near the machine; CO2-type
6.3 Mechanical / Physical
Working space front side
Working space back side
Spacing between units
1500 mm (59”)
2000 mm (79”)
760 mm (30”)
Note: space for Kodak Versamark data station and print station not included
Floor loading capacity
Floor loading per pad
Ambient temperature and relative Humidity
transport
operating
best for printing
Exhaust air
Exhaust air duct diameter
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≤ 450 kg (≤ 1000 lb.)
15 – 29°C (60 – 85°F) @ 10 – 90 % RH
15 – 40°C (60 – 104°F) @ 10 – 90 % RH
15 – 29°C (60 – 85°F) @ 30 – 60 % RH
18 – 23°C (64 – 73°F) @ 50 % RH
max. 1000 m3/h (35000 cu.ft. /h)
∅ 160 mm (6¼ “)
28
6.3.1.
Heat distribution
inkjet paper
normal paper
inkjet paper
normal paper
@ 100 m/min (325 fpm)
@ 100 m/min (325 fpm)
@ 150 m/min (500 fpm)
@ 150 m/min (500 fpm)
10kWh (34’121 BTU) @ 1000 m3/h
12kWh (40’945 BTU) @ 1000 m3/h
16kWh (54’594 BTU) @ 1000 m3/h
19kWh (64’830 BTU) @ 1000 m3/h
This is the data if the exhaust air is blown into the same room.
If the air is blown out of the room, then the value can be reduced by 25%.
Important: The length of the exhaust duct should be no longer then 6-8 meters otherwise an
additional ventilator is needed which should suck from the end of the complete duct.
Duct diameter needs to be minimum of 160mm (6 ¼”).
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6.4 Pad loads of the different unites
6.4.1.
Pad weight VT3000-3 Head Print module XV.3R
1
2
4
80
912
832
740
XV.3R
(3 Head print unit no dryer)
3
738
182
1000mm
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Tot. Weight:
350kg
771.6lbs
Pad 1:
Pad 2:
Pad 3:
Pad 4:
70kg
150kg
40kg
90kg
154.3 lbs
330.7 lbs
88.2 lbs
198.5 lbs
6.4.2.
Pad weight VT3000-3 Head Print module XV.3R with Infeed
1
2
80
350
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738
182
1000mm
31
832
912
Infeed unit
4
740
XV.3R
(3 Head Print unit with Infeed, no dryer)
Tot. Weight:
500kg
1102.3 lbs
Pad 1:
Pad 2:
Pad 3:
Pad 4:
150kg
150kg
40kg
160kg
330.7 lbs
330.7 lbs
88.2 lbs
352.8 lbs
6.4.3.
Pad weight VT3000-3 Head Print module XV.3R with Outfeed
1
2
XV.3R
(3 Head Print unit with outfeed, no dryer)
Outfeed unit
740
832
912
4
80
3
738
182
400
1000mm
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Tot. Weight:
500kg
1102.3 lbs
Pad 1:
Pad 2:
Pad 3:
Pad 4:
70kg
220kg
120kg
90kg
154.3 lbs
485.0 lbs
264.6 lbs
198.4 lbs
6.4.4.
Pad weight VT3000-3 Head Print module XV.PU3
1
2
4
80
912
832
740
XV.PU3
(3 Head Print unit with dryer)
3
738
182
1000mm
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Tot. Weight:
470kg
1036.2 lbs
Pad 1:
Pad 2:
Pad 3:
Pad 4:
80kg
180kg
100kg
110kg
176.4 lbs
396.8 lbs
220.5 lbs
242.5 lbs
6.4.5.
Pad weight VT3000-3 Head Print module XV.PU3 with Infeed
1
2
80
350
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738
182
1000mm
34
832
912
Infeed unit
4
740
XV.PU3
(3 Head Print unit with dryer and Infeed)
Tot. Weight:
620kg
1366.9 lbs
Pad 1:
Pad 2:
Pad 3:
Pad 4:
160kg
180kg
100kg
180kg
352.7 lbs
396.8 lbs
220.5 lbs
396.8 lbs
6.4.6.
Pad weight VT3000-3 Head Print module XV.PU3 with Outfeed
1
2
XV.PU3
(3 Head Print unit with dryer and Outfeed)
Outfeed unit
740
832
912
4
80
3
738
182
400
1000mm
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Tot. Weight:
620kg
1366.9 lbs
Pad 1:
Pad 2:
Pad 3:
Pad 4:
80kg
250kg
180kg
110kg
176.4 lbs
551.2 lbs
396.8 lbs
242.5 lbs
6.4.7.
Pad weight VT3000-5 Head Print module XV.PU5
1
2
4
124
832
740
XV.PU5
(5 Head Print unit with dryer)
3
1694
182
2000mm
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Tot. Weight:
630kg
1388.9 lbs
Pad 1:
Pad 2:
Pad 3:
Pad 4:
140kg
180kg
160kg
150kg
308.6 lbs
396.8 lbs
352.7 lbs
330.7 lbs
6.4.8.
Pad weight VT3000-5 Head Print module XV.PU5T with Infeed
1
2
124
350
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832
912
Infeed unit
4
740
XV.PU5T
(5 Head Print unit with dryer, turnbar and
infeed)
3
1694
182
2000mm
37
Tot. Weight:
810kg
1785.7 lbs
Pad 1:
Pad 2:
Pad 3:
Pad 4:
230kg
180kg
160kg
240kg
507.1 lbs
396.8 lbs
352.7 lbs
529.1 lbs
6.4.9.
Pad weight VT3000-5 Head Print module XV.PU5T with Outfeed
1
2
XV.PU5T
(5 Head Print unit with dryer, turnbar and
Outfeed)
Outfeed unit
740
832
912
4
124
3
1694
182
400
2000mm
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Tot. Weight:
830kg
1785.7 lbs
Pad 1:
Pad 2:
Pad 3:
Pad 4:
160kg
260kg
240kg
170kg
352.7 lbs
573.2 lbs
529.1 lbs
374.8 lbs
6.5 Dimensions of packaged units
For shipping the 5 head module the infeed and outfeed are mounted normally.
When a 5 head module is shipped together with a 3 head module infeed and outfeed are
mounted on the 3 head module.
6.5.1.
5 Head print unit with infeed and outfeed
Weight: 1700kg (3750 pound)
292 cm (9.6 ft)
165 cm
(5.4 ft)
160 cm
(5.3 ft)
6.5.2.
5 Head print unit
Weight: 1200kg (2650 pound)
230 cm (7.6 ft)
165 cm
(5.4 ft)
160 cm
(5.3 ft)
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6.5.3.
Infeed and outfeed for 5 Head print unit
Weight: 380kg (840 pound)
120 cm (3.9 ft)
155 cm
(5.1 ft)
160 cm
(5.3 ft)
6.5.4.
3 Head print unit
Weight: 400kg (880 pound)
120 cm (3.9 ft)
155 cm
(5.1 ft)
160 cm
(5.3 ft)
6.5.5.
3 Head print unit with infeed or outfeed
Weight: 600kg (1320 pound)
160 cm (5.2 ft)
155 cm
(5.1 ft)
160 cm
(5.3 ft)
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6.5.6.
3 Head print unit with infeed and outfeed
Weight: 740kg (1630 pound)
160 cm (5.2 ft)
155 cm
(5.1 ft)
160 cm
(5.3 ft)
6.5.7.
3 Head print unit with dryer
Weight: 520kg (1150 pound)
120 cm (3.9 ft)
155 cm
(5.1 ft)
160 cm
(5.3 ft)
6.5.8.
3 Head print unit with dryer and infeed or outfeed
Weight: 900kg (2000 pound)
160 cm (5.2 ft)
155 cm
(5.1 ft)
160 cm
(5.3 ft)
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6.5.9.
3 Head print unit with dryer, infeed and outfeed
Weight: 900kg (1990 pound)
200 cm (6.6 ft)
155 cm
(5.1 ft)
160 cm
(5.3 ft)
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7
Introduction
The VT3000 system is specifically designed to print with ink-jet on various substrates while
minimizing power consumption and exhaust. On many types of stock, the material does not
absorb the water-based ink being applied. Instead, it remains on the surface in a liquid state
and is easily smeared if touched.
To dry water-based inks on coatings, the moisture must be removed from the surface of the
web without overheating the paper. Conduction and convection heating are combined in the
dryer unit to do this. The conduction heating excites the moisture, causing it to evaporate.
The convection heating also aids in the drying process by rapidly removing the moisture from
the drying area.
The system’s closed loop temperature control maintains a constant temperature across the
web. This constant temperature eliminates the potential for any overheating of the paper,
including areas that have been pre-printed with a heavy dark ink coverage.
7.1 Infeed
The Infeed consists of a servo controlled drive roller with spring loaded nip to ensure a perfect
web tension and print register.
7.1.1.
Web Guide (optional)
The web guide system is a microprocessor-controlled web guiding system. This guiding
system may be used for:
• Web edge guiding (right or left)
• Centre line guiding
• Guiding on continuous or interrupted printed lines
• Guiding on continuous or interrupted printed edges
7.2 Print Unit
The print unit consists of a chassis to support head mounts for Kodak Versamark 9” print
heads, a high performance drum dryer, turnbar and mounting for Kodak Versamark tach and
cue.
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7.2.1.
Head Mounting
Individual high precision head mount to support Kodak Versamark 9” print heads; mounts are
manually adjustable. The head mounts provide for a perfect stitching and registering.
Illustration 28: Head mounting
7.2.2.
Dryer
The dryer consists of two main components; the air chamber, which provides the conduction
heating and the drum dryer itself.
The high efficiency air chamber surrounds the drum dryer and removes moisture from the
paper. The air chamber has slides that allow for easy webbing and dryer maintenance.
Infrared lamps mounted inside the low inertia aluminium drum provide the conduction heating
for the drying process. The force to rotate the drum dryer is provided by the moving web.
A closed-loop temperature control system regulates the power dissipated by the aluminium
drum dryer. Output from an infrared temperature measurement device is fed back into the
closed-loop controller. This provides tight temperature control and prevents damage to the
web due to overheating.
7.2.3.
Turnbar
Turn bars consists of special bars with air holes to provide a frictionless paper path through
the turn bar. An integrated air turbine supplies enough air to ensure easy single or double
sideed production.
7.2.4.
Kodak Versamark Tach and Cue
For the information about Kodak Versamark Tach and Cue please see chapter 10.11 Kodak
Versamark Encoder/Tach Support.
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7.3 Outfeed
The outfeed consists of a servo controlled drive roller with spring loaded nip to ensure a
perfect web tension and print register.
7.4 Power Control Cabinets
The power distribution cabinets contain the main circuit breaker for incoming power and the
circuit breaker for each power device. They also contain the process control units for the
dryer and the transport system.
The VT3000 connects to a 480V, three phase, 50/60Hz or a 400V, three phase and neutral,
50/60Hz service (for more details please see schematic and type plate).
The control cabinet is located on the paper infeed side of the unit. The power supply has to
be connected to this cabinet.
WARNING!
Switch OFF the Main switch before opening
the control cabinet.
7.4.1.
Infeed/outfeed Control Cabinet
The main control cabinet is located on infeed side of the print unit. It consists of control - and
power- components for the infeed and outfeed.
Power supply has to be connected into this cabinet.
7.4.2.
Dryer control Cabinet
The dryer control cabinet is located on drive side or under the outfeed and consists of control
components for the drum dryer, for example PLC, Temperature controller, circuit breakers
etc.
Power supply has to be connected into this cabinet.
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8
Mechanical Installation
For the mechanical installation follow this sequence:
-
Install 5 Head Print Unit
Install 3 head unit
Install Infeed or Outfeed
Install additional equipment
8.1 Tools Required
-
Knife
Torx bit for a hand drill or Torx screw driver
Good quality spirit level
Open end wrenches 6 – 24 (mm scale)
Allen key set 1 – 12 (mm scale)
Fork lift or Pallet truck; minimum load capacity 2000kg (4400 pound)
Illustration 29: Mounting holes
Illustration 30: Leveling feet
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8.2 Install 5 Head Print Unit
-
-
Unpack the print unit
Put the print unit on the palette truck
(for details see: Machine handling and lifting on Page 16)
Position the print unit in the designated place
(for details see: 6.3 Working space on Page 28)
Level the print unit in both directions.
To level the unit use the leveling feet with the counter locking nut. Check with the spirit
level.
After mounting all units re-level the machine again. Make sure the weight is equal on
all leveling feet. Check the level again after 2-3 days.
Go to step 8.3 Install 3 head unit on Page 47
8.3 Install 3 head unit
-
Unpack the unit.
Put the unit on the palette truck.
Lift the feet so they do not touch the floor after mounting the unit together with the 5
head print unit.
Position the unit in the designated place.
Put the 3 head print unit and the 5 head print unit together.
Attach the 3 head print unit with four M12 screws
(see also Illustration 29: Mounting holes on Page 46)
The 4 mounting screws are strong enough to support the unit during installation. Make
sure to level the unit at the end of installation with all feet. Make sure the weight is
equal on all leveling feet.
8.4 Install Infeed or Outfeed
-
Unpack the unit
Put the unit on the palette truck
Position the unit in the designated place
Attach the infeed and/or outfeed units with the two M12 screws.
8.5 Install additional units
-
Follow the steps on 8.3 Install 3 head unit on page 47 for installing more modules.
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8.6 Installing dryer assembly
Install a flexible tube for the exhaust air.
For the diameter see: 6.3 Site preparation Mechanical / Physical on Page 28
The position of the output (A) of the exhaust air is on the back of the print unit as shown in the
following picture.
We recommend connecting a tube from the exhaust air to the outside of the building. This
prevents overheating of the room and additional load on your air conditioning unit. The air
needs to be exhausted by an additional ventilator.
A
Illustration 31: Backside print unit
Illustration 32: Dryer exhaust connection
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9
Electrical Installation
9.1 Tools Required
-
Wire prep tool (optional)
Screwdriver set 1 – 5
9.2 Power connection points
The power connection points are:
-
The infeed/outfeed electrical cabinet is installed near the paper inlet of the machine.
On the 5 head module the electrical cabinet for the dryer is on the drive side of the unit.
When an additional 3 head module with dryer is installed the electrical cabinet is
installed at the paper outlet of the machine.
For power requirements please see chapter: 6.1 Electrical requirement on page 28
Illustration 33: Power connecting points
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9.3 Connecting Power to Power Control Cabinet
Pass the Power supply cable through the cable support into the infeed control cabinet and the
dryer cabinet and connect the cables to the clamp bar.
To connect the main Power:
Check that there is no power on the cable
Connect the ground cable first, then the neutral (only 400 Volt), and then the three
phase to the terminal block.
Check rotation of phases.
Adjust the settings on the transformer.
Make sure all bridges are mounted when running 400 Volt.
ATTENTION!
See installation instructions and electrical
schematic before connecting to the power
supply.
This transport system supports different
voltages and frequencies.
Be sure that the correct settings are made
before you turn on the main switch.
WARNING!
Only trained people are allowed to do work
on high power wiring.
Please refer to national and local laws.
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9.4 Using 400V support
In case of using a 400V drop make sure that the following settings in the dryer cabinet are
made:
ATTENTION!
In case of using a 400V drop be sure that the
power supply includes three phase, neutral
and ground.
Otherwise the IR – lamps will be destroyed.
ATTENTION 400V:
Bridge the IR-Dryer lamps on the
wire block X1 or 2X6,
clamp X and Y and Z and N
When using 400V it’s necessary to add three bridges (Illustration 34: wire blocks) to the wire
blocks of the IR-lamps as shown in the following pictures.
Illustration 34: wire blocks
Illustration 35: wire blocks for second dryer
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9.5 Using 400V support
When running on 480V remove the bridges to the IR-Dryer lamps on the wire block X1 or
2X6, clamp X and Y and Z and N (Illustration 34: wire blocks).
9.6 Transformer connection using 400V support
When using with 400V it’s necessary to change the wiring on the transformer.
ATTENTION 400V:
Infeed electrical cabinet
Transformer configuration:
X1 clamp 9 and 10= 400V
Dryer electrical cabinet
Transformer configuration:
X1 clamp C and D= 400V
9.7 Transformer connection using 480V support
When using with 480V it’s necessary to change the wiring on the transformer.
ATTENTION 480V:
Infeed electrical cabinet
Transformer configuration:
X1 clamp 8 and 10= 480V
Dryer electrical cabinet
Transformer configuration:
X1 clamp C and F= 480V
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9.8 Schematic for 5 head module dryer
For more details please refer to the schematic supplied with the machine.
If there is no schematic supplied you can request a copy from Matti Technology AG after
providing the serial number of the electrical cabinet.
Illustration 36: Schematic for 5 head module dryer
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9.9 Schematic for 3 head module dryer
For more details please refer to the schematic supplied with the machine.
If there is no schematic supplied you can request a copy from Matti Technology AG after
providing the serial number of the electrical cabinet.
Illustration 37: Schematic for 3 head module dryer
9.10
Connecting communication between Cabinets
Connect the different cable on the cabinets to their designated socket.
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9.11
Interface
Illustration 38: Interface on electrical cabinet drive side
3X30 D-Sub 15 female
3X31 D-Sub 15 female
3X32 D-Sub 15 female
3X33 D-Sub 15 female
3X34 D-Sub 15 female
3X35 D-Sub 37 female
3X36 D-Sub 37 female
3X37 D-Sub 9 female
3X38 D-Sub 9 female
3X39 D-Sub 9 male
from/to web guide
from/to Unwind
from/to Rewind
master VT3000 Unit
slave VT3000 Unit
from/to selective perforating unit
from/to punch unit
Kodak Versamark Cue mark reader
Matti Hole reader
Kodak Versamark Controller
For additional information see chapter 14 Interface Type 1.
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9.12
Kodak Versamark IPDS Controller
The Kodak Versamark Data Controller provides AFP/IPDS compatibility by providing a direct
connection from a host mainframe computer or compatible server to a Kodak Versamark
Modular Printing System (MPS) or other systems integrating Versamark printing technology.
With the controller; data is received from the host, processed and output to the printer at a
speed up of to 500 feet per minute (2000 images per minute).
Designed specifically for the high speed, variable data requirements of data centers, the Data
Controller provides the functionality of an IPDS Printer; allowing both new and existing users
to take advantage of the cost-effective, ultra-high-speed printing capability of the VersaMark
printing systems. Other important features of the controller include support for spot and
highlight colors and automatic speed control to eliminate problems associated with
“clutching”.
Fully compatible with the family of Kodak Versamark products, the controller supports up to
12 page-wide (9”) print heads, with a basic resolution of 300 dpi, the capability to scale 240
dpi images to 300 dpi and configurations that include roll-to-fold, roll-to-roll and roll-to-sheet.
System functions are performed at a single point of control through a user-friendly enhanced
graphical touch screen where the operator initiates automatic print start, responds to status
messages and monitors the status of the print modules, transport and finishing equipment.
Illustration 39: IPDS controller
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10 Operation
The VT3000 Transport system is easy to operate and allows you to print any job with high
quality results.
This chapter describes the operation of the transport system and includes procedures that
may be occasionally necessary.
10.1
Transport System Configuration
10.1.1. Legend for Transport System Configuration
Tach Roller (used position)
Tach Roller (original position)
Big size idle roller (used position)
Idle Roller (used position)
Idle roller (unused in this configuration)
Idle roller to change (used position)
Idle roller to change (original position)
Cue Sensor position (used position)
Cue Sensor position (original position)
Web path (used)
Web path (unused in this configuration)
Turn Bar
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10.1.2. 1-up (narrow) configurations
10.1.2.1 1/4 Narrow
Illustration 40: Run with 1 over 4 narrow; with web guide module
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10.1.2.2 4/1 Narrow
Illustration 41: Run with 4 over 1 narrow; with web guide module
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10.1.2.3 4/4 Narrow
Illustration 42: Run with 4 over 4 narrow; with web guide
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10.1.2.4 4/4 Narrow on 4/1 Wide configuration
Illustration 43: Run with 4 over 4 narrow; on a 4 over 1 wide configuration with web guide
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10.1.3. 2-up (wide) configurations
10.1.3.1 1/1 Wide
Illustration 44: Run with 1 over 1 wide; with web guide module
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10.1.3.2 2/1 Wide
Illustration 45: Run with 2 over 1 wide; with web guide module
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10.1.3.3 2/2 Wide
Illustration 46: Run with 2 over 2 wide; with web guide module
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10.1.3.4 1/3 Wide
Illustration 47: Run with 1 over 3 wide; with web guide module
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10.1.3.5 3/1 Wide
Illustration 48: Run with 3 over 1 wide; with web guide module
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10.1.3.6 1/4 Wide
Illustration 49: Run with 1 over 4 wide; with web guide module
For the second side only one cue sensor must be used (after the turn bar or immediately before the tach roller).
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10.1.3.7 4/1 Wide
Illustration 50: Run with 4 over 1 wide; with web guide
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10.1.3.8 4/2 Wide
Illustration 51: Run with 4 over 2 wide; with web guide
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10.1.3.9 4/4 Wide
Illustration 52: Run with 4 over 4 wide; with two web guide
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10.2
Operating Buttons
With the machine connected to power, the main switches need to be switched on to power up
the machine.
The operating panel is placed on the operator side at the paper inlet end of the unit.
This panel contains 4 buttons. Those are from left top to right bottom:
1.
2.
3.
4.
Emergency Stop Button (red button on yellow ground)
Jog Button (yellow button on white ground)
Reset Machine Button (blue button, flashing while print unit in error condition)
Counter Reset Button (blue button)
Illustration 53: Operating Buttons
10.2.1. Emergency Stop Button
Press this button only in case of emergency. To reset the machine, turn the emergency
button clockwise, then press the “reset machine” button.
10.2.2. Jog Button
Press this button to jog the machine without printing (e.g. passing paper, web break).
10.2.3. Reset Machine Button
When the button is flashing, press this button to reset the error message. If the flashing does
not stop check the following possible errors and try to reset again.
The following errors can cause an emergency stop:
-
E-Stop button
Web break
Trip on infeed or outfeed driver
Dryer over temperature
Dryer air stream switch not active
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10.2.4. Counter Reset Button
When running pre-processed paper you need to indicate to the Kodak Versamark controller
where the first page starts. Move the paper till the light of the sensor is at the perforation
between the last hole of one page and the first hole of the next page. Then press the counter
reset button.
10.3
Side guides and nip roller adjustment
10.3.1. Side guides
Illustration 54: Swan neck assembly adjustment
The side guide plates need to be adjusted to guide the paper straight into the machine.
Please make sure that the paper goes as straight as possible into the machine. Otherwise the
paper may start to wrinkle.
To adjust the tension of the paper going into the machine the swan neck assembly can be
turned to achieve a smaller or bigger wrap around the two bars. To turn the swan neck
assembly pull the handle on the operator side and turn the assembly. Make sure the locking
pin of the handle goes into a notch.
When webbing paper by hand through the machine, it is recommended that the swan neck is
assembly is adjusted so that the paper has a straight through path.
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10.3.2. Nip roller
Illustration 55: Swan neck assembly and nip roller
To obtain a good grip on the motor driven roller it is important to close the cover. For running
different width paper, the nip roller has to be adjusted. It is important to move the nip roller to
a position of the paper where you can obtain an equal grip on the paper.
To change the position of the nip roller, slide them to the desired place.
10.4
Cue mark sensor support
2
3
1
Illustration 56: Cue mark sensor support
The cue mark sensor support consists of a bracket (1), an adjustment block with a knurled
screw (2) and a fine tune handle with scale (3).
For adjusting the angle between cue mark sensor and paper, the screws on the adjustment
block (2) can be loosened and the angle adjusted.
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10.5
Print Head
10.5.1. Head Adjustment
2
1
3
Illustration 57: 9” Head high adjustment
10.5.1.1 Height Adjustment
To adjust the head height, loosen the screws #1 and adjust with the screws #2 the distance
between head and paper to 1.9 - 2.1 mm (0.075” – 0.083”). By turning the screws #2
clockwise the gap between head and paper will increase.
After adjusting to the correct height, retighten screws #1.
10.5.1.2 Skew Adjustment
To adjust the skew, loosen on the operator side screw #1 and adjust the cue with screw #3.
By turning screw #3 clockwise the head will turn clockwise to the paper movement. In case
there is insufficient adjustment, you will need to loosen screw #1 on gear side. Make sure that
you tighten all screws after adjusting.
Illustration 58: 9” Head side adjustment
10.5.1.3 Side Adjustment
To move the head side ways, loosen the head support by lifting the black locking handle
toward the drive side of the VT3000. To position the head support move the handle to a notch
nearest the desired position and pull the locking handle back to the operator side. Ensure that
the bolt in the positioner is exactly above a notch. To fine adjust the head, turn the knurled
knob with scale. One scale line equals 0.05 mm (0.002”). By turning the knob clockwise the
head will move to the drive side.
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10.6
Operation web Guide (optional)
10.6.1. Position of the web guide
Servo-Technik GmbH
Illustration 59: Position of the web guide
10.6.2. Adjustment of the web guide
Illustration 60: Controller web guide
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10.6.2.1
Display sensor signal
Illustration 61: Display sensor signal
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For future details about the web guide unit please
refer to the BST web guide manual supplied with
the web guide module.
10.7
Turn bar
The turn bar consists of a pair of specially coated bars with air holes to provide a frictionless
paper path through the turn bar. An integrated air turbine supplies air to ensure an easy
single or double side production.
The air turbine is located on the drive side of the machine between the dryer cabinet and the
blue dryer exhaust ventilator.
If running narrow a web, it’s recommended to cover the unused holes with tape.
Illustration 62: Turn bar and air turbine
10.8
Dryer
The dryer consists of an aluminium heating drum to dry the paper, IR-lamps heat the drum,
one cooling ventilator to cool down the inner parts of the aluminium heating drum (lamps,
lamp-holder, and wiring), an exhaust ventilator to exhaust the hot air in the dryer-casing and
an IR temperature sensor. The principle of the dryer is indirect drying of the paper. The paper
temperature is measured by an IR-sensor. A controller, independent of the speed, provides a
stable paper temperature.
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10.8.1. Pass the paper through the dryer and print unit
Illustration 63: Web path dryer and print unit
Illustration 64: Front view dryer unit
1.
2.
3.
4.
Open the 2 screws (Illustration 64: Front view dryer unit).
Remove the two covers by the handles.
Pass the web through the dryer as shown on the Illustration 63: Web path dryer.
Remount the two side covers of the dryer unit and tighten the screws.
WARNING!
The dryer may be very hot. Please wait for 15
min. to cool down before opening the dryer
or use heat resistant gloves.
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10.8.2. How to open the Dryer
Illustration 65: Front view dryer unit for open
1. Disconnect the main power connector
2. Unlock the two black Screws
.
.
into the provided threaded hole just nearby.
3. Put the upper and lower Screw
4. Now turn both of them clockwise until you feel the front door becomes loose.
5. Pull the entire unit out by the two black Screws.
6.
7.
8.
9.
Both wire ends of the lamp are connected to a ceramic terminal block
.
Follow the specific wires and loosen them (two on each lamp).
Lift the clamps on both lamp ends with your fingers and carefully remove it.
Do not touch the glass when mounting a new lamp.
Illustration 66: Dryer inside
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10.8.3. How to close the Dryer
1
2
To close the system you must take the 3 handle screws (1) and screw them through the
operating holes (2) and drum plate (3) into the drum (4). Push the dryer slowly into the drum
and take care to align the slot and pin (5). This procedure is necessary for perfect parallelism
between the drum (4) and drum plate (3), which is important for a smooth turning of the drum.
Remove the special tools and screw the two black handles into the frame, plug in the dryer
connector and restart the printing procedure.
4
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1
5
80
10.8.4. How to close the Dryer (Serial number 24741 and higher)
The new system has pins of different sizes to fix the drum (4) with the drum plate (3).
To close the dryer align the corresponding pins and holes. There are four big pins and holes
(1) and one small pin and hole (2).
Push the dryer slowly into the drum and take care to align the pins and holes. This procedure
is necessary for perfect parallelism between the drum (4) and drum plate (3), which is
important for a smooth turning of the drum.
Plug in the dryer connector and restart the printing procedure.
3
1
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4
81
10.8.5. IR-Sensor
The moveable IR-Sensor is mounted in the upper area above the drum. Through the
opening (L) (Illustration 67: Front side dryer unit IR-sensor) is it possible to move the
sensor. The position of the sensor is important for real paper temperature controlled
drying.
If running 1-up duplex the IR-sensor must be above the first paper path.
IMPORTANT:
The Sensor must be above the paper path
of the drum!
L
K
Illustration 67: Front side dryer unit IR-sensor
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10.8.6. Quartz Infrared Halogen Lamps
Caution: To ensure maximum safety, we advise the following:
1. Disconnect power before removing or installing a lamp!!
2. Preferably do not touch quartz with bare hands. If grease
or chemical compounds have been deposited on quartz,
clean simply by wiping with a cloth moistened with
alcohol.
3. Prolonged looking at the lamp during operation may
result in damage to the eye.
4. Take care not to exceed permissible pinch temperature
indicated in technical notice.
5. Respect burning position to the lamp indicated in the
technical documentation.
6. Avoid over-voltage, this can affect lamp life.
7. Integrate lamp in equipment specifically designed for the
type and the rating of the lamp.
8. Use fuse in conformity with the type and rating of the
lamp.
9. Protect the lamp against shocks and vibrations even
when it is cold.
Non-observance of these precautions may lead to damage of
the lamp and equipment, and in an extreme case create an
unsafe situation.
The manufacturer cannot assume any liability for personal injury
or damage to equipment, which may result from improper use of
the lamp or from the use of improper equipment.
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10.8.7. Lubrication of the bearings of the dryer
Illustration 68: Lubricator device back and front side dryer
Behind the front plate you will find the bearing cover plate with grease nipple. To keep the
bearing in good condition, lubricate it frequently.
Recommendation: Lubricate once every 3-month at a 1- shift cycle.
Lubricate once every 1-month at a 2- or 3- shift.
Lubricant:
High temperature grease.
The drive side lubrication device is accessible through the turn bar or the outfeed side.
10.8.8. How to change the dryer lamp
Make sure the dryer unit is switched OFF before doing any maintenance on the dryer. The
electrical cabinet may be behind the dryer or below the outfeed.
1.
2.
3.
4.
Open the dryer as described in chapter 10.8.2 How to open the Dryer on page 79.
Check which lamps need to be replaced. Normally burnt out dryer lamps are black.
Disconnect the wires going from the lamp at the clamp terminal.
Remove the holder on one side of the dryer lamp. Now it should be possible to take
out the dryer lamp.
5. Shorten the wires on the new lamp and pull the wires in and connect them. Make sure
the protecting hose is in a place so that it can’t touch any moving parts.
6. Mount the lamp holder in place. The lamp needs to have some play so it can expand
when heating up.
7. Clean the lamp with some alcohol pads. Grease and dirt can shorten the life time of
the lamp.
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10.9
Reset Line Hole Counter
When running pre-processed paper you need to indicate to the Kodak Versamark controller
where the first page starts. After a web break, switching off/on the unit or similar cases it’s
necessary to reset the line hole counter. For to do so please follow this procedure:
1. It’s necessary that the paper is under production tension.
2. Move the paper so that the perf line is under the second sensor, the first punch hole of
the next page will be between the two sensors.
3. Connect the line hole counter sensor to X202.
4. Sheet length is set by the Kodak controller.
5. Press the counter reset button.
Illustration 69: Line hole counter sensor
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10.10
Sensitivity adjustment of the amplifier for two line
hole sensors
Description: The line hole system contains three components, two optical lenses with a fiber
optic cable and one amplifier with a cable and a 9 pin Sub-D connector.
10.10.1. Reset of Sensor
Before setting the line hole counter amplifier it’s recommended to reset the amplifier to make
sure no old settings are stored.
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10.10.2. Setting Functions in SET Mode
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88
After the adjustment change the mode selector to “RUN”.
These settings must be done twice, once for every sensor. To select the sensor, change the
sensor selector to “1” or “2”.
IMPORTANT: These steps need to be done with both sensor 1 and 2.
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10.10.3. Power tune
To do a power tune press and hold the MODE button for 3 seconds when in RUN mode.
10.10.4. Teaching with and without a work piece
This description shows step by step how to adjust the amplifier type E3X-MDA41.
The yellow highlighted values must be selected.
These settings must be done twice, once for each sensor. To select the sensor, change the
sensor selector to “1” or “2”.
This description is a general description. For more details please refer to the Omron manual.
IMPORTANT: These steps need to be done with sensor 1 and 2.
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10.11
Kodak Versamark Encoder/Tach Support
Illustration 70: Kodak Versamark Encoder/Tach Support
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11 Electrical cabinet
Illustration 71: Infeed/outfeed electrical cabinet
Illustration 72: Dryer electrical cabinet
For details about the electrical cabinet please see the electrical schematic.
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11.1
Drive control exhaust air fan
Illustration 73: Driver exhaust vent
11.1.1.1 Settings driver (Commander SE) 14501
Parameter-no.
01
02
03
04
05
06
07
08
09
10
11
12
13
14
38
40
Value
10
50
10
25
Pr
1.7
0
230
0.8
L2
20
30
40
50
1
2P
11.1.1.2 Setting of the values:
Please follow below Steps to set the drive:
Pull the connector 1 out
Push button M for 2 seconds and push the M again for a short time.
Now you see the setting numbers in the display which can be moved by pushing ¿
and À.
If you reached the right setting number push M and you change to the
right display.
Pushing ¿ and À changes the value.
Pushing several times on the M saves the changes.
After saving push the button M until „Fr“ or „ih" is shown on the left Display.
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-
11.2
Now push the red button 0 for 2 seconds.
Now the Commander SE is programmed.
Switch off the main switch.
Reconnect the connector.
Switch on the main switch.
In the first Step the Commander SE is making a „Autotune“ (see Display), after that
the frequency should change up to 50Hz „Fr 50.0“
After aprox. 1 – 1.5 min. the Commander SE should go into stop mode „Fr 0.0“
PLC Battery
Illustration 74: Location battery PLC dryer control cabinet
Illustration 75: PLC battery location in main control cabinet
Note:
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The PLC battery is necessary to save program/parameters when
switched off. The PLC will loose the program/parameters if the machine /
PLC are not in use for 2 years.
94
12 Maintenance
Before doing any maintenance switch off the machine and guard the main switch with a pad
lock. These Maintenance plan is based on a 40 hour week.
12.1
-
12.2
-
12.3
-
12.4
-
12.5
-
General
Always keep the machine as clean as possible.
Always look out for loose or worn parts and report them to a supervisor.
Never abuse or misuse the machine.
Every Month
The web break sensors have to be cleaned with some cloth.
The fresh air filter in control cabinet has to be cleaned or changed.
Every 3 month
The cooling fins on the servo-drives have to been cleaned.
The bearings of the drum dryer have to be lubricated.
The dryer and all the parts inside e.g. bulbs, cables, reflectors, etc. have to be
checked and cleaned.
The air inlet of the dryer fresh air ventilator has to be cleaned.
The air inlet of the turn bar turbine has to be cleaned.
Every 1 year
Oil the screw spindle for the fine adjustment on the head support.
Oil the Glider rail and housing.
Clean the turn bar tubes.
Check the gas strut on the top cover.
Every 2 year
The battery in the PLC has to be changed.
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Illustration 76: web break sensors
Illustration 77: Control cabinet air filter
Illustration 78: air ventilator servo-drives
Illustration 79: dryer and all the parts inside
Illustration 80: air inlet of the dryer fresh air
Illustration 81: air inlet of the turn bar turbine
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Illustration 82: Dryer bearing operator side
Illustration 83: Drum dryer bearing gear side
Illustration 84: spindle for the fine adjust
Illustration 85: Glider rail and housing
Illustration 86: turn bar tubes
Illustration 87: gas strut on the top cover
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Illustration 88: PLC battery
12.6
Spare parts
When ordering spare parts, it is important to note
the type number and serial number of the machine
together with the Part No. to facilitate correct
identification of parts.
The type number and the serial number are written
on the type plate at the drive side of the machine.
Please refer to the spare part / FRU manual for details.
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13 Trouble shooting
13.1
Printing Problem
For printing problems please refer to the print head manual from Kodak Versamark.
13.2
Electrical Control Problem
If electrical problems occur please check the following points:
-
13.3
All fuses are ok
All cables connected
Power supply OK (400 Volt / 480 Volt; for details see: chapter 9 Electrical Installation)
All main switches are turned ON
PLC fault; indicated with a red error light on the PLC
Communication between Kodak Versamark controller and machine OK
No red error light on Ethernet card
No drive fault
Machine Running Problem
If the machine will not run please check the following points:
-
13.4
All main switches are turned ON
Emergency stop button not released or reset
No drive fault
Nip rollers are in correct position
No web break
Paper Processing Problem
If paper running problems occur please check the following points:
-
Correct web path
Machine alignment
Side guiding ring adjusted to paper width
The web path is undisturbed
All rollers easily turn
Dryer temperature adjusted to correct temperature
No dryer lamps broken
Dryer main switch turned on
No dryer drive fault
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14 Interface Type 1
The following description shows the specification for the Type 1 Interface for digital printing
machines.
14.1
Signals used on the Type 1 Interface
Slave connected The Slave connected signal is received from the slave unit and shows the
master unit that a Slave is connected. As soon as the signal is on “high
level”, the contact (NO) has been closed and the Master knows that an
additional slave is connected or switched on otherwise the “Ready”, “Stop”
and “Jog from Slave” signals will be ignored from this slave.
Ready
The Ready signal is received from the slave unit and shows the master unit
that everything is ok with this slave unit. The ready signal has to be on “high
level”, the contact (NO) has to be closed.
As soon as the ready signal is on “low level”, the contact (NO) is open the
transport will do an E-Stop (Fast Stop).
The ready signal is used for signals like:
- Web break
- E-Stop
- Drive fault
- Paper jam
-…
Stop
The Stop signal is received from the slave unit and shows the master unit
that everything is ok with this slave unit. The Stop signal has to be on “high
level”, the contact (NO) has to be closed.
As soon as the Stop signal is on “low level”, the contact (NO) is open the
transport will do a Normal Stop.
The stop signal is used for signals like:
- End of Roll
- Full Roll
- Stacker full
- Pack splicer empty
-…
Jog from Slave
The Jog from Slave signal is received from the slave unit and tells the
master unit to start jogging. The jog signal has to be on “high level”, the
contact has to be closed.
The master unit starts jogging after the following timing sequence:
3s ON, 0.5s OFF, Xs ON. X is the time how long the transport will jog. After
stop jogging is a delay of 2s to restart jogging again without run the timing
sequence again. The operator has to do this timing sequence to make sure
he gives his attention on this jogging comment.
Jog to Slave
The Jog to Slave signal is sent to each slave unit and tells them to start
jogging. As soon as the contact (NO) will close the slave will start jogging (if
needed).
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Run to Slave
6ppi
14.2
The Run to Slave signal is sent to each slave unit and tells them to switch in
run mode (if needed).
The 6ppi Signal supports the Slave units with a Pulse train signal of 6 Pulse
per inch. The signal runs a 50% duty cycle and a Voltage from 10V at
VJ1000 and 5V at VT3000.
Power Requirements Type 1 Interface
The Type 1 Interface supplies the +24V and 0V (Ground) for the communication to the
Slaves.
The +24V Power drop is just for the communication. Do not use this power drop for anything
else.
14.3
Interface 15 pin for Unwind and Rewind Units
14.3.1. Connector (socket)
Connector on the printing unit 15 pin D-Sub connector female. The following description
shows the pin out for this connection:
PIN
Description
1
Ready
2
Stop
3
4
Spare
Spare
5
Jog form Slave
6
7
8
9
Jog to Slave
Jog to Slave
Run to Slave
Run to Slave
10
6ppi Speed signal
11
12
13
14
15
+24V
+24V
0V
0V
0V
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Detail information
As long as the unit is ready a free contact (NO) will be closed
and makes a connection between pin 1 and 11 or 12.
As soon as the Ready signal is lost the Transport will do an EStop (Signals like “E-Stop”, “Drive fault”, …)
As long as the unit is ready a free contact (NO) will be closed
and makes a connection between pin 2 and 11 or 12.
As soon as the Stop signal is lost the transport will do an
normal stop (Signals like “End of roll”, “Full roll”,…)
Connected to PLC for additional input if needed
Connected to PLC for additional input if needed
As soon as somebody push a Jog button on the Slave a free
contact on the slave unit will close to make a connection
between pin 5 and 11 or 12
As long as the transport will jog a contact (NO) between pin 6
and 7 will close
As long as the transport is in run mode (production) a contact
(NO) between pin 8 and 9 will be closed
Pulse train signal (50% duty cycle, Output signal 5-10VDC,
VJ1000 5V, VT3000 10V)
6 Pulse per inch
Power supply
Power supply
Power supply
Power supply
Power supply
101
14.4
Interface 37 Pin Connector
14.4.1. Connector (Socket)
Connector on the printing unit 37 pin D-Sub connector female. The following description
shows the pin out for this connection:
PIN
1
2
3
Description
Free
Free
Spare
4
Ready
5
6
7
Free
Free
Free
8
6ppi Speed signal
9
Slave connected
10
Stop
11
12
13
14
Free
Free
Free
Free
15
Jog from Slave
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Jog to Slave
Jog to Slave
Run to Slave
Run to Slave
Reserve
Reserve
+24V
+24V
Free
Free
Free
Free
+24V
+24V
+24V
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Additional input on Master unit if needed
As long as the unit is ready a free contact (NO) will be closed
and makes a connection between pin 4 and 22.
As soon as the Ready signal is lost the Transport will do an EStop (Signals like “E-Stop”, “Drive fault”, …)
Pulse train signal (50% duty cycle, Output signal 5-10VDC,
VJ1000 5V, VT3000 10V)
6 Pulse per inch
As soon as the slave is connected or switched on a free
contact (NO) will make a connection between pin 9 and 23.
As long as on this pin is no signal every other signal will be
ignored from this connector.
As long as the unit is ready a free contact (NO) will be closed
and makes a connection between pin 10 and 28.
As soon as the Stop signal is lost the transport will do an
normal stop (Signals like “End of roll”, “Full roll”,…)
As soon as somebody push a Jog button on the Slave a free
contact on the slave unit will close to make a connection
between pin 15 and 29.
As long as the transport will jog a contact (NO) between pin
16 and 17 will close
As long as the transport is in run mode (production) a contact
(NO) between pin 18 and 19 will be closed
Reserve for E-Stop contact for future use (NO)
Reserve for E-Stop contact for future use (NO)
Power supply
Power supply
Power supply
Power supply
Power supply
102
31
32
33
34
35
36
37
+24V
Free
Free
0V
0V
Free
Free
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Power supply
Power supply
Power supply
103
15 Paper Handling and Storage
15.1
Paper
There are many types and grades of paper available, e.g. bonds, carbonless, carbon coated,
laids and woven, etc. Each manufacturer has their own specification for their papers.
Between manufacturers you will find the paper varies, i.e. carbonless paper can have a
different gramage base stock, different thickness of coating, different grade of fibres or laids
and woven may vary with different percentages of cotton and paper fibre sizes etc. Always
consult your paper supplier for technical handling and processing information, most suppliers
will give you a handbook on their papers.
15.2
Handling
Illustration 89: Paper handling
Handling of paper stocks is just as critical as storage, as poor handling practices can also
damage paper stocks and consequently give rise to production problems.
Always handle packs and reels as little as possible to reduce the risk of damage.
Avoid bumping or dropping packs and reels of paper, particularly coated stocks which are
pressure sensitive.
Avoid rolling reels, especially over rough surfaces.
Don’t tilt, spin or swivel reels on their edges.
Always stock packs in a sensible manner. Box finished packs as soon as possible and avoid
over stacking packs.
The best way to handle reels when stripping off their protective wrappings is to keep them on
one end of a pallet base, using a pallet transporter or forklift truck. Alternatively, a cradle
trolley can be used, but make sure the frame is padded with a pressure absorbing material.
Care should always be exercised when moving reels from a vertical to horizontal position for
fitting press mandrels or airshafts etc. Ensure a pressure-absorbing pad of corrugated
material or foam rubber is placed under the edge on which the tilt occurs. This will avoid
crushing the edges of the web.
Always handle with care.
Note: Always consult paper manufacturers or suppliers for any specific paper handling
requirements.
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15.3
Storage
Paper should be stored in rooms suitable for paper storage. It should not be stored near
radiators, heater blowers, water pipes, fans, open windows, in direct sunlight, next to walls or
lying on the floor.
Climatic conditions should not be subject to large fluctuations. We recommend storing paper,
especially chemical coated stocks under the following conditions: 18° to 20° Celsius (64° to
68° Fahrenheit) at 45 to 55% RH. To avoid processing problems, the paper should be
wrapped if in pack form, until the stock is required for processing. If the stock is to be
processed further at a later date, always re-box and wrap.
The paper temperature should be the same as of the processing room. Temperature changes
are very significant in the cold months. Generally, paper should be stored under the above
conditions for at least 130 hours before use.
As paper absorbs moisture it expands; as it loses moisture it shrinks. This movement
expresses itself in one or more of the following ways: curl, waviness, or ‘tight’ edges to
sheets, slack or ‘long’ edge on reels.
The result of this can cause miss-feeding, poor delivery, web wander, miss-register, creasing,
etc.
Coated papers such as CB (coated back) CF, (coated front) and CFB (coated front and back)
are more sensitive to humidity and temperature changes than standard plain stocks.
As full control of atmospheric conditions is rare, it is desirable to adopt certain practical
procedures to inhibit the risk of any of the above faults developing.
Illustration 90: Paper storage
When storing paper the following points should be considered:
•
•
•
•
•
Always keep paper off the floor and away from heaters and walls.
Always make sure reels and packs are stacked correctly. See Illustration 90: Paper
storage.
Always try to keep control of temperature and humidity – this is critical.
Never turn heating off at night in cold or damp environmental conditions.
If you have large opening doors, fit a draught screen around the door to reduce the
effects of cold or damp air.
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