Aztech DieMaster DM-40 series User Manual

Rotary die cutting machine

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AZTECH CONVERTING SYSTEMS

212 W Lodge Drive

TEMPE, AZ 85283

PHONE (480) 951-8351

FAX (480) 998-5409

www.aztechconverting.com

Ver 1.3

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Page 1 AZTECH CONVERTING SYSTEMS 212 W Lodge Drive TEMPE, AZ 85283 PHONE (480) 951-8351 FAX (480) 998-5409 www.aztechconverting.com Ver 1.3...
Page 2: Table Of Contents
AZTECH CONVERTING SYSTEMS -40XX USER MANUAL TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION SECTION 2: MACHINE INSTALLATION SECTION 3: MACHINE SETUP 6-18 SECTION 4: MACHINE OPERATION 19-28 SECTION 5: MAINTENANCE SECTION 6: STATION DETAIL 30-52 SECTION 7: TROUBLESHOOTING SECTION 8: WARRANTIES AND SERVICE...
Page 3: Section 1: General Information
Section 1: General Information 1-1: Introduction The AZTECH DieMaster Rotary Die Cutting Machine is available in 13 inch (33.02 cm), 18 inch (45.72 cm) and 20 inch (50.8 cm) widths, with dual-spindle rewinds, and web speeds up to 500 feet/minute. The DieMaster is designed to be highly productive, versatile, and simple to operate and maintain.
Page 4 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL FRONT LAYOUT (DIE MASTER ONLY) Rev 1.3...
Page 5 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL SIDE LAYOUT (DIE MASTER ONLY) (13” Shown, 18” and 20” are similar)
Page 6: Section 2: Machine Installation
ELECTRICAL CONNECTIONS: Your DieMaster uses a power supply of 220 volts, 50 amps AC 3PH. Im- proper connections or mishandling may cause seri- ous personal injury. AZTECH highly recommends that electrical service be performed only by a qualified electrician. Electrical connection to the machine is performed...
Page 7 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL 90PSI INCOMING HP AIR PNEUMATIC CONNECTIONS: Although your machine has been thoroughly tested before shipment, connections on occasion may loosen during shipment. Visually inspect all pneumatic to assure that each is fitted securely. Connect airline to the pneumatic...
Page 8: Section 3: Machine Setup
AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Section 3: Machine Setup 3-1: Webbing the Machine Proper webbing of your DieMaster is vital to optimal machine performance. The proper way to thread your machine for various substrates is shown on the following page. Any improper webbing of the machine may cause tension problems that will impede operation.
Page 9 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Unwind Sections Cradle Mount Unwind Unwind Disc Brake...
Page 10 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Flexo Print Station Lamination Tower ACCESSORY MODULES Rev 1.3...
Page 11 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL DIE SECTIONS 13” - 18” DIE MASTER 20” DIE MASTER...
Page 12 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL DieMaster w/ UDB Web Path 13” Die Master Shown -UDB -Print Station -Lamination Tower -13” Die Section PRINT STATION Rev 1.3...
Page 13 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL OPTIONAL WEB PATHS SHOWN DASHED LAMINATION TOWER REWIND MODULE UNDERSCORE...
Page 14 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL 13” Die Master Shown -CMU -2x Print Stations -Lamination Tower -20” Die Section INFEED NIP SAMPLE 20” PRESS PRINT STATIONS Rev 1.3...
Page 15 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL OPTIONAL WEB PATHS SHOWN DASHED 20” DIE SECTIONS Lamination Tower...
Page 16 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL AUTOMATIC SERVO CENTER 3-2: Web Guide Setup The web guide is located in the center of the machine between the unwind and re- wind stations. After webbing the machine, set the web by doing the following: Setting the Web Guide: 1.
Page 17 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL 3-4: Splice Table Operation The splice table on your Sidewinder BSR is located just above the Unwind Station, just after the optional Inspection Tower. To operate the Splice Table, simply follow the following steps:...
Page 18 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL 3-5: ROTARY SHEAR SET-UP Step 1 Set lower blades for desired slit-widths and tighten set-screws, making sure upper blades are up and not in lock position. Step 2 Lower upper blade assembly by turning handle...
Page 19 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL LOOSEN SET SCREW HERE 3-6: Changing Rewind Spindle Your Die Master may be equipped with Convertech pneumatically inflatable modular rewind spin- dles. These spindles are easily removed by loosening the hex-screw at the machine side and pull- ing away from machine.
Page 20 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL LOOSEN SET SCREW HERE CMU EOR Sensor Mounting 3-7: End-of-Roll (EOR) Sensor Adjustment The unwind unit will come equipped with an end- of-roll sensor. When this sensor is switched on, the machine will not RUN if there is insufficient material on the unwind roll.
Page 21: Section 4: Machine Operation
AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Section 4: Machine Operation 4-1: Operator Control Layout 13”- 18” Standard model Die- Master START PB JOG PB STOP PB SPEED KNOB REWIND CONTROLS COUNTER CONTROL E-STOP 20” Standard model Die- Master...
Page 22 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL 4-1: Operator Control Layout TOUCH SCREEN START PB JOG PB STOP PB SPEED KNOB REWIND CONTROLS AIR CONTROLS E-STOP The Die-Master is also available with a PLC machine control with a touch-screen interface. The operation of the HMI interface is described in the next section.
Page 23 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL 4-2: PLC OPERATION THE MAIN MENU On power-up of the machine, the PLC will boot. This is analogous to a home PC booting. It can be expected to take a minute or two. When the PLC has finished booting, the MAIN MENU will be displayed.
Page 24 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL MAIN MENU Buttons to acess primary ma- RUN SCREEN chine functions are displayed on the MAIN MENU. Menú principal en Español Hauptmenu auf Deutsch Rev 1.3...
Page 25 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL RUN MENU Set Torque. Press Adjustor / Indicator to set manually Machine Running Status Increment by 1 and 10 Enabled/Disabled Indicator Distance Units Progress Bar Counter ON/OFF Count Sensor Selection Exit to Main Menu Prompt...
Page 26 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL The Batch Count increments every time the set count is COUNTER STATUS reached and the counter is on. DISPLAY The user is prompted to con- firm reset. The prompt clears in 5 seconds. The current count is displayed...
Page 27 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Press the box to change between Over and Underwind. DO NOT SWITCH WHILE RUNNING TORQUE COMPENSATION The Torque Compensation feature mimics the act of slowly increasing rewind torque by gradually turning up the knob while the roll grows. To set up the feature, enter the core diameter as the Start- ing Diameter.
Page 28 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Press to set the finish count. Press to set the slowdown point. IF THE SLOWDOWN POINT IS GREATER THAN THE SET COUNT, THE When in distance count, press MACHINE WILL NOT SLOW- to set the units.
Page 29 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL 4-3: Mounting Rotary Die(s) in Die Station Recapping the set-up procedures as outlined in Chapter 3, care- fully follow the web path diagram in 3.1-2, web the DieMaster, and adjust the web guide if needed (see diagram 3-2).
Page 30 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL 4-4: Using the Waste-Windup With die properly positioned, slide a core onto the waste-windup spindle, inflate using the switch and perform the following steps: 1) Jog the machine to briefly begin cutting and than stop.
Page 31: Section 5: Maintenance
AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Chapter 5: Maintenance The DieMaster Rotary Die Cutting Machine is rigidly constructed to provide your company many years of reliable productivity, however regular and periodic maintenance is required to keep it run- ning to its full potential and to avoid damage. To assure maximum performance and longevity, the...
Page 32: Section 6: Station Detail
AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Chapter 6: Station Detail UDB Main Assembly Rev 1.3...
Page 33 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL...
Page 34 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL UBD: Brake Assembly Rev 1.3...
Page 35 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL...
Page 36 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL UDB: Brake Assembly Rev 1.3...
Page 37 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Waste Windup Assembly...
Page 38 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Rotary Die Station: Support Roll Assembly Rev 1.3...
Page 39 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Rotary Die Station: Anvil Roll Assembly...
Page 40 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Rotary Die Station: Die Truck Assembly Rev 1.3...
Page 41 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Main Drive: Nip Roll Assembly...
Page 42 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Main Drive: Pace Roll Assembly Rev 1.3...
Page 43 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Slitting Station: Main Assembly...
Page 44 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Slitting Station: Rotary Shear Assembly Rev 1.3...
Page 45 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Press Controls, PLC OPTION...
Page 46 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Rev 1.3...
Page 47 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL...
Page 48 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Cradle Mount Unwind Controls Rev 1.3...
Page 49 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL...
Page 50 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Press Controls, STANDARD Rev 1.3...
Page 51 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Press Schematic, STANDARD...
Page 52 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Press Schematic, STANDARD Rev 1.3...
Page 53 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL...
Page 54 AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Press Schematic, STANDARD Rev 1.3...
Page 55: Section 7: Troubleshooting
AZTECH CONVERTING SYSTEMS DM-40XX USER MANUAL Section 7: Troubleshooting 7-1: Why doesn’t the machine turn on? First check to make sure that the main power switch on the back electrical panel is turned on. Then make sure that the emergency stop button on control panel is disengaged.
Page 56: Section 8: Warranties And Service
Section 8: Warranties and Service 8-1: Warranties & Provisions WARRANTIES: All equipment manufactured and sold by AZTECH Converting Systems (Seller) is warranted to be free of defective materials and workmanship under normal use and service for a period of one (1) year from the date of delivery to Buyer's premises. All commercial components not manufactured by Seller carry the original manufacturer's warranty.