Page 1 SealCup Express Pad Printer Program version 1.30.30...
Page 2: Imprint
Imprint Copyright The distribution or reproduction of this instruction manual as well as the utilisation and communication of its contents are prohibited unless expressly permitted. Any party violat- ing this provision will be liable to pay compensation. All rights are reserved for registered patents, design and utility models.
Page 3: Important Information
Important Information About this document • This documentation describes several models and options. For this reason, elements which are not available on the machine may be described. • The documentation is an integral part of the product and must be kept in close proxim- ity to the machine where it must be available to staff at all times.
Page 4 Important Information...
Page 5: Table Of Contents
Contents Imprint..........2 Important Information .
Page 6 Commissioning ........37 11.1 Connecting the voltage supply ........37 11.2 Connecting the foot switch (optional) .
Page 7 16.2 Cliché removal ..........72 16.2.1 Remove pad .
Page 8 Safety guard ........103 21.1 Safety guard –...
Page 9 26.5 Pad cleaning ..........129 26.6 Light curtain .
Page 10 31.2 Electrical connector..........161 31.3 Terminal assignment.
Page 11: Safety Instructions
Safety instructions This chapter gives you an overview of all the important safety aspects for optimum perso- nal protection as well as for safe, fault-free operation. Failure to observe the handling and safety instructions contained in this instruction manual can result in significant dangers. General instructions The prerequisite for safe working is the observation of all safety instructions and handling instructions indicated in this instruction manual.
Page 12: Staff Qualification
Staff qualification In this instruction manual, the following qualifications are stated for various areas of acti- vity: The machine may only be operated by trained persons. Only those who can be expected to perform their work in a reliable manner are authorised to be operating staff.
Page 13: Personal Protective Equipment
Personal protective equipment Personal protective equipment must be worn when working with the machine in order to minimise danger to health. • The necessary protective equipment must always be worn when working with the machine. • The personal protective equipment signs displayed in the work area must be obser- ved.
Page 14: Signage
Signage Depending upon the equipment, symbols and information signs may be located in the work space of the machine. They refer to the direct surroundings of the location where they are attached. WARNING Risk of injury due to missing or illegible signage. Over time, stickers and symbols may become soiled or become illegible by other means.
Page 15: Special Dangers
DANGER Risk of fire due to highly flammable liquids or gases. When working with inks, paints and thinners, there is a risk of fire due to flammable or explosive liquid or gaseous substances. • No fire or naked flames permitted in close proximity to inks and sol- vents.
Page 16 DANGER Risk of injuries posed by uncontrolled and unexpected movements. With pneumatic and/or hydraulic assemblies, uncontrolled movements and sudden discharges of media can lead to injuries. • Work on pneumatic and/or hydraulic equipment may only be perfor- med by specialist staff on unpressurised plants. •...
Page 17: Behaviour In The Event Of Danger And Accidents
Behaviour in the event of danger and accidents Safety instructions Preventive measures • Always be prepared for accidents or fire. • Ensure that first-aid equipment (first-aid kit, blankets, etc.) and fire extinguishers are kept close at hand. • Ensure that staff are familiar with first-aid, accident notification and rescue equip- ment.
Page 18 Safety instructions...
Page 19: Used Symbols
Used Symbols Safety instructions These instructions contain particularly important information and instructions. Non-observation of the information may lead to dangerous situations. There is a danger to life and limb of the staff or significant damage could be caused to machines and devices as well as their surroundings. DANGER This instruction warns against dangerous situations.
Page 20: Instructions
Instructions Instructions are not safety-relevant; they contain helpful information. INSTRUCTION There instructions contain information that enable an effective and econo- mical use of the machine or the device. • Quality information. • Information regarding special processes. • Background information regarding the described processes. Lists Instructions and handling sequences are described in the form of lists.
Page 21: Terminology
Terminology Some modules and machine functions are specified in the menu levels of the operating terminal and in this documentation with special technical terms. The following list provides an overview of the terminology used. Functions on the machine Action Meaning Workpiece pretreatment Pretreatment of the workpiece surface for better ink absorption and ink adhesion.
Page 22: Elements And Modules
Elements and modules Element Explanation Silicon pad to transfer the ink to the workpiece. Cliché Steel or plastic plate with recesses in the form of the print image. Cliché holder Bracket to accommodate the cliché. Ink cup Special ink container which moves on the cliché. Ink cup holder Bracket which positions the ink cup on the cliché.
Page 23: Technical Data
Technical Data Connection values Electrical connection Operating voltage: 230 V AC – 50/60 Hz Power consumption: approx. 0.5 kW Control voltage: 24 V DC Operating conditions Ideal printing results are achieved under the following conditions: Ambient conditions Temperature: 20°C 68°F Humidity: 50% –...
Page 24: Versions
Versions The following features of the machines are shown in the classification. = ink cup holder for MCI-type ink cups = ink cup holder for Express Liner-type ink cups = ink cup fixing lever on left-hand side of machine. = ink cup fixing lever on right-hand side of machine. Ink cup Classification Ink cup...
Page 25: Dimensioned Drawings
Dimensioned drawings 8.5.1 Version on left without pad cleaning All dimensions without brackets = millimeters All dimension in brackets = [inches] Cliché level Print level (workpiece surface) Technical Data...
Page 26: Version On Right Without Pad Cleaning
8.5.2 Version on right without pad cleaning All dimensions without brackets = millimeters All dimension in brackets = [inches] Cliché level Print level (workpiece surface) Technical Data...
Page 27: Version On Left With Pad Cleaning
8.5.3 Version on left with pad cleaning All dimensions without brackets = millimeters All dimension in brackets = [inches] Cliché level Print level (workpiece surface) Technical Data...
Page 28: Version On Right With Pad Cleaning
8.5.4 Version on right with pad cleaning All dimensions without brackets = millimeters All dimension in brackets = [inches] Cliché level Print level (workpiece surface) Technical Data...
Page 29: Mounting Schematic
Mounting schematic Pad position Socket holes To secure the machine on a machine table, an M8 screw must be used in each socket hole. Technical Data...
Page 30: Cliché Layout
Cliché layout Cliché size Print image position Print image size 100 x 215 max. 80 mm Ø or max. 56 x 56 mm All dimensions in mm. Technical Data...
Page 31: Transport And Installation
Transport and Installation Incoming goods inspection • The delivery must be checked immediately upon receipt in order to check for comple- teness and transport damage. A claim for any damage must be submitted as soon as it has been discovered. •...
Page 32: Installing The Machine
Installing the machine 9.3.1 Location WARNING Confined or unsuitable set-up areas or insufficiently large work- spaces can lead to dangerous situations. Safety equipment which is inaccessible or difficult to reach may mean that the machine cannot be switched off in sufficient time in the case of an emergency.
Page 33: Mounting The Machine
Mounting the machine The machine must be mounted on a stable base frame or machine table. The “mounting plan” stipulated in the “Technical Data” chapter must be referred to. Transport and Installation...
Page 34 Transport and Installation...
Page 35: Assembly Instructions
Assembly Instructions 10.1 Scope of application These assembly instructions must be observed when the machine has been delivered wit- hout a safety enclosure and safety equipment. All of the following conditions must be met in order for the incomplete machine to be pro- perly incorporated in the complete machine without compromising the safety and health of persons.
Page 36: Equipotential Bonding, Protective Earthing
10.6 Equipotential bonding, protective earthing Components installed on site must be equipped with equipotential bonding and integrated in the protective earthing circuit, if applicable. 10.7 Further safety measures Additionally installed workpiece processing assemblies can cause health hazards for the operator as a result of gases, fumes or radiation (e.g. ozone gas or UV light). In such cases, suitable measures must be taken in order to ensure that permissible emis- sion limits are not exceeded.
Page 37: Commissioning
Commissioning WARNING Improper handling of machines and devices can lead to serious injury. A faulty electrical or pneumatic connection on the machine can result in the machine behaving uncontrollably and may lead to unexpected move- ments. This poses a risk of injury. •...
Page 38: Connecting The Foot Switch (Optional)
11.2 Connecting the foot switch (optional) WARNING Incomplete safety equipment may pose risk of injury. Incomplete safety equipment may mean that machine movements are not safely shut off when the machine’s work area is entered. This can lead to serious injury or death. •...
Page 39: Pad Cleaning
Pad cleaning 12.1 Overview The machine can be optionally fitted with a pad cleaning system. This is available in two versions and can be set up on the left-hand side or right-hand side of the machine. Pad cleaning enables the removal of contamination and ink residues from the surface of the pad.
Page 40: Inserting The Cleaning Tape
12.2 Inserting the cleaning tape 12.2.1 Pad cleaning – left-hand version Fit a new roll of cleaning tape to the lower roll holder. In doing so, pay attention to the unrolling direction. Guide the cleaning tape under the deflection roller, out the other side, and then upwards.
Page 41: Pad Cleaning - Right-Hand Version
12.2.2 Pad cleaning – right-hand version Fit a new roll of cleaning tape to the lower roll holder. In doing so, pay attention to the unrolling direction. Guide the cleaning tape under the deflection roller, out the other side, and then upwards.
Page 42 Pad cleaning...
Page 43: Pad Assembly Screw Fastening
Pad Assembly Screw Fastening WARNING Danger when performing assembly work in the working area of the machine caused by unintentionally or carelessly triggered machine movements. Machine movements caused by unintentional machine functions or those triggered by a second person can lead to injuries. •...
Page 44: Pad Coupling Without Limit Stop
13.3 Pad coupling without limit stop Pad sliding coupling Pad coupling Pad base plate The pad base plate is equipped with an M6 insert The insert nut serves the purpose of fastening the pad on to the pad coupling. The pad coupling is equipped with various bore- holes.
Page 45: Pad Removal
13.3.1 Pad removal Unscrewing the pad coupling Unscrew the clamping screw belonging to the pad coupling. Pull out the pad coupling complete with the pad towards the front. Unscrewing the pad The pad is fastened to the pad coupling with a screw Loosen the screw and remove the pad.
Page 46: Pad Installation
13.3.2 Pad installation Pad sliding coupling Position pad coupling on to the pad base plate In the majority of cases, the fastening generally takes place via the centre borehole Screwing on the pad Insert the fastening screw (M6) into the bore- hole.
Page 47: Pad Position Setting
Inserting the pad coupling Push the pad coupling together with the assem- bled pad into the guide. Fixing the pad coupling Tighten the clamping screw on the pad coup- ling. 13.3.3 Pad position setting The pad position can be set with the pad sliding coupling. Left / right movement Unscrew clamping screws The pad can be moved to the left or right.
Page 48: Pad Coupling With Limit Stop
13.4 Pad coupling with limit stop Pad sliding coupling Pad coupling Pad base plate The pad base plate is equipped with an M6 insert The insert nut serves the purpose of fastening the pad on to the pad coupling. The pad coupling is equipped with various bore- holes.
Page 49: Pad Removal
13.4.1 Pad removal Unscrewing the pad coupling Unscrew the clamping screw belonging to the pad coupling. Pull out the pad coupling complete with the pad towards the front. Unscrewing the pad The pad is fastened to the pad coupling with a screw Loosen the screw and remove the pad.
Page 50: Pad Installation
13.4.2 Pad installation Pad sliding coupling Position pad coupling on to the pad base plate In the majority of cases, the fastening generally takes place via the centre borehole Screwing on the pad Insert the fastening screw (M6) into the bore- hole.
Page 51 Inserting the pad coupling Push the pad coupling together with the assem- bled pad into the guide until the limit stop is reached. Fixing the pad coupling Tighten the clamping screw on the pad coup- ling. Pad Assembly Screw Fastening...
Page 52: Pad Position Setting
13.4.3 Pad position setting The pad position can be set with the pad sliding coupling. Left / right movement Unscrew clamping screws The pad can be moved to the left or right. The line marks on the ruler indicate the posi- tion.
Page 53: Pad Assembly Magnetic Holder
Pad Assembly Magnetic Holder WARNING Assembly works carried out in the machine’s working space may pre- sent a danger due to machine movements caused unintentionally or due to lack of care. Machine movements caused by functions which are activated unintentio- nally or by a second person can lead to injury.
Page 54: Overview
SAFETY INSTRUCTION Malfunctions may be caused by magnetic fields. Magnets generate a wide-reaching and strong magnetic field. Amongst other things, they can damage televisions, notebooks, computer hard dri- ves, credit and debit cards, data carriers, mechanical clocks, hearing aids and speakers. •...
Page 55: Pad Coupling Without Limit Stop
14.4 Pad coupling without limit stop Pad sliding coupling Pad coupling Pad base plate The pad base plate is manufactured from a mag- netic sheet. The holes enable the precise positioning of the pad on the centering pins of the pad coupling. coupling fitted with...
Page 56: Pad Removal
14.4.1 Pad removal The pad base plate is held to the pad coupling through magnetic force. Pull the pad base plate and pad downwards from the pad coupling. Pad Assembly Magnetic Holder...
Page 57: Pad Installation
14.4.2 Pad installation Attach the pad with the pad base plate to the pad coupling from below. Ensure that the centering pins insert into the holes on the pad base plate. The pad base plate is held to the pad coupling through magnetic force.
Page 58: Pad Coupling With Limit Stop
14.5 Pad coupling with limit stop Pad sliding coupling Pad coupling Pad base plate The pad base plate is manufactured from a mag- netic sheet. The holes enable the precise positioning of the pad on the centering pins of the pad coupling. coupling fitted with...
Page 59: Pad Removal
14.5.1 Pad removal The pad base plate is held to the pad coupling through magnetic force. Pull the pad base plate and pad downwards from the pad coupling. Pad Assembly Magnetic Holder...
Page 60: Pad Installation
14.5.2 Pad installation Attach the pad with the pad base plate to the pad coupling from below. Ensure that the centering pins insert into the holes on the pad base plate. The pad base plate is held to the pad coupling through magnetic force.
Page 61: Pad Position Setting
14.5.3 Pad position setting The pad position can be set with the pad sliding coupling. Left / right movement Untighten clamping screws The pad can be moved to the left or right. The line mark on the ruler indicates the posi- tion.
Page 62 Pad Assembly Magnetic Holder...
Page 63: Cliché Assembly (Eu)
Cliché Assembly (EU) WARNING Assembly works carried out in the machine’s working space may present a danger due to machine movements caused unintentionally or due to lack of care. Machine movements caused by functions which are activated unintentio- nally or by a second person can lead to injury. •...
Page 64: Cliché Removal
15.2 Cliché removal 15.2.1 Remove pad The pad should be removed in order to pre- vent damage and to ensure better accessi- bility. Untighten the clamping screw on the pad coupling. Pull the pad forwards out of the pad coup- ling.
Page 65: Unfasten Ink Cup
15.2.3 Unfasten ink cup Pull out the lock pin from the ink cup fixing and pull the lever down. When you let go, stop the lock pin in the lower position. The ink cup holder raises and releases the ink cup. Cliché...
Page 66: Remove Cliché
15.2.4 Remove cliché Pull the cliché together with the ink cup forwards and out of the cliché holder. When dealing with plastic or thin steel cli- chés, the cliché is pulled out together with the base plate. See Chapter 17.1 "Cliché types" on page The cliché...
Page 67: Cliché Installation
15.3 Cliché installation To allow the cliché to be assembled, the pad should not yet be installed in the machine. See Chapter 15.2.1 "Remove pad" on page 15.3.1 Insert cliché Insert the cliché together with the ink cup in the cliché holder and push it to the back.
Page 68: Clamp Cliché
15.3.2 Clamp cliché Push the clamping block up and tighten the clamping screw Cliché Assembly (EU)
Page 69: Secure Ink Cup
15.3.3 Secure ink cup Pull out the lock pin from the ink cup fixing and push the lever up. When you let go, stop the lock pin in the upper position. The ink cup holder lowers and secures the ink cup. Cliché...
Page 70: Install Pad
15.3.4 Install pad Push the pad into the pad coupling. Tighten the clamping screw on the pad coupling. Cliché Assembly (EU)
Page 71: Cliché Assembly (Us)
Cliché Assembly (US) WARNING Assembly works carried out in the machine’s working space may present a danger due to machine movements caused unintentionally or due to lack of care. Machine movements caused by functions which are activated unintentio- nally or by a second person can lead to injury. •...
Page 72: Cliché Removal
16.2 Cliché removal 16.2.1 Remove pad The pad should be removed in order to pre- vent damage and to ensure better accessi- bility. Untighten the clamping screw on the pad coupling. Pull the pad forwards out of the pad coup- ling.
Page 73: Attach Setup Tool
16.2.3 Attach setup tool Push the setup tool with the base plate into the notch under the cliché in an open position (clamping lever forwards). Here, the clamping jack will push under- neath the ink cup. Pull the clamping lever backwards.
Page 74: Unfasten Ink Cup
16.2.4 Unfasten ink cup Pull out the lock pin from the ink cup fixing and push the lever forward by 90°. When you let go, stop the lock pin in the for- ward position. This raises the ink cup fixing and relea- ses the ink cup.
Page 75: Remove Cliché
16.2.5 Remove cliché Pull the setup tool together with the ink cup and cliché forwards out of the cliché holder. See Chapter 17.1 "Cliché types" on page The cliché holder is empty. Cliché Assembly (US)
Page 76: Cliché Installation
16.3 Cliché installation To allow the cliché to be assembled, the pad should not yet be installed in the machine. See Chapter 16.2.1 "Remove pad" on page 16.3.1 Insert cliché Insert the setup tool into the cliché hol- der together with the ink cup and the cliché and push it to the back.
Page 77: Secure Ink Cup
16.3.2 Secure ink cup Pull out the lock pin from the ink cup fixing and push the lever up. When you let go, stop the lock pin in the upper position. This lowers the ink cup fixing and secu- res the ink cup. The fixings must precisely grip the notches in the ink cup.
Page 78: Remove Setup Tool
16.3.3 Remove setup tool Push the clamping lever forwards. The clamping jack will swivel upwards and detach itself from the ink cup. Pull the setup tool from the machine in an open position (clamping lever forwards). Cliché Assembly (US)
Page 79: Clamp Cliché
16.3.4 Clamp cliché Push the clamping block up and tighten the clamping screw 16.3.5 Install pad Push the pad into the pad coupling. Tighten the clamping screw on the pad coupling. Cliché Assembly (US)
Page 80 Cliché Assembly (US)
Page 81: Cliché Replacement
Cliché Replacement 17.1 Cliché types Three different cliché types can be used. Polymer cliché (0.5 mm thick) Thin steel cliché (0.5 mm thick) Thick steel cliché (10 mm thick) Support plate (carrier plate for polymer and thin steel cliché) The support plate is equipped with two fixing pins upon which the clichés are held in place via their holes.
Page 82: Removing The Cliché
17.2.1 Removing the cliché The cliché is removed from the machine together with the support plate. Using the long hole, first lift the cliché from the fixing pin. Slightly lift the cliché whilst simultaneously swivelling it back and forth in order to detach the round hole from the other fixing pin.
Page 83: Mci Ink Cup
MCI ink cup 18.1 Safety instructions for handling ink cups A sharp blade edge can be found on the lower side of the ink cup. The blade edge is later positioned on the cliché and seals the ink cup towards the cliché. WARNING Injury caused by sharp edges.
Page 84: Safety Instructions For Handling Magnets
18.2 Safety instructions for handling magnets WARNING Crushing caused by strong pulling forces. Large magnets exhibit an extreme pull. Careless handling can result in fingers or skin being trapped between magnets. This can lead to crushing injuries and bruising on the affected points.
Page 85: Overview
18.3 Overview Pad printing machines can be equipped with ink cups of different sizes and designs. In the majority of cases, the principle structure of the ink cups is identical. Slight deviations from the illustrated images are possible. Assembly works are to be performed on a level and soft underlay (e.g. rubber mat) in order to ensure that the sensitive blade edge belonging to the doctor ring is not damaged.
Page 86: Seal Insertion
18.5.2 Seal insertion Move the doctor ring complete with the doctor blade edge downwards and onto a level, clean and stable polymer plate Caution Soiled or uneven underlays could damage the sensitive doctor blade edge. Insert seal into the recess of the doctor ring.
Page 87: Doctor Ring Ejection
18.5.4 Doctor ring ejection The designated tool must be used for the ejection of the doctor ring. A suitable ejection tool can be obtained from the machine manufacturer. Other tools such as screwdrivers or sharp-edged mandrels can damage the doctor ring or the seal.
Page 88: Magnetic Ring Insertion
18.6 Magnetic ring insertion The ink cup is pulled onto the cliché via the pull of the magnetic ring. The pull depends upon the distance between the magnetic ring and the cliché. The magnetic ring can be installed in three positions at different distances to the cliché. The magnetic ring is equipped with three- level supporting surfaces.
Page 89: Joining The Ink Cup And Cliché
18.7 Joining the ink cup and cliché CAUTION Crushing caused by strong pulling forces. The magnets in the ink cup causes a great pull of the cliché. Without implementing a careful joining process, the cliché and ink cup would col- lide with great force.
Page 90: Adding Ink
18.9 Adding ink The ink cup and cliché must already be joined together. See Chapter 18.7 "Joining the ink cup and cliché" on page 89 Open the ink cup cover. Fill the ink cup with ink until the magnetic ring is covered with ink.
Page 91: Express Liner Ink Cup
Express Liner Ink Cup 19.1 Safety instructions for handling ink cups A sharp ground blade edge can be found on the lower side of the ink cup. The blade edge is later positioned on the cliché and seals the ink cup against the cliché. WARNING Risk of injury through sharp edges.
Page 92: Overview
19.2 Overview Pad printers can be fitted with ink cups of different sizes and designs. In the majority of cases, the principle structure of the ink cups is identical. Slight deviations from the illustrated images are possible. Assembly works are to be performed on a level and soft underlay (e.g. rubber mat) in order to ensure that the sensitive blade edge of the doctor ring is not damaged.
Page 93: Doctor Ring Installation And Removal
19.5 Doctor ring installation and removal 19.5.1 Handling instructions Depending upon the design, the doctor ring is manufactured from carbide metal or ceramic. Cross-section The sharp ground blade edge can be found on the lower side. IMPORTANT INFORMATION Doctor rings must be handled with extreme care and may not be distorted or allowed to fall.
Page 94: Inserting The Doctor Ring
19.5.2 Inserting the doctor ring Position the ink container with the opening facing upwards. There is a radial groove located on the outer edge to accommodate the doctor ring. Place the doctor ring into the radial groove from above. In this case, the sharp ground blade edge will be located on the top.
Page 95: Removing The Doctor Ring
19.5.3 Removing the doctor ring Position the ink container with the opening facing upwards. The doctor ring is located on the top. Pull the flap of the ink container down- wards to release the ink container from the doctor ring. Hold the doctor ring near the flap and lift it out of the ink container’s radial groove.
Page 96: Ink Cup Assembly
19.6 Ink cup assembly The ink cup is assembled on the setup table. In order to correctly position the ink cup, the setup table is fitted with two pins During assembly the pins grip the lateral grooves in the ink cup frame. Insert the ink cup frame in the notch of the setup table...
Page 97 Place the ink container with the inserted doctor ring in the frame with the ope- ning on the top. The illustration shows the fully assembled ink cup in the setup table from the front. Fill the ink container with ink. Express Liner Ink Cup...
Page 98: Joining The Ink Cup And Cliché
19.7 Joining the ink cup and cliché The plastic or thin steel clichés are positioned together with the support plate. The setup table is fitted with several pins to allow the cliché to be positioned cor- rectly. Place the cliché between the pins on the setup table and push it to the left as far as the limit stop.
Page 99 The setup tool is used to fix the cliché and ink cup in position for assembly. Push the clamping lever of the setup tool forwards. Flip over the setup tool (clamping lever on bottom). Carefully place the setup tool on the cliché and ink cup from the front.
Page 100: Separating The Ink Cup And Cliché
19.8 Separating the ink cup and cliché The ink cup and cliché are removed from the machine together using the setup tool. See Chapter “Cliché assembly”. Insert the setup tool together with the ink cup and the cliché into the setup table from above.
Page 101: Setting Up The Print Image
Setting up the print image 20.1 Setting the pad 20.1.1 Horizontal pad position See Chapter 13 "Pad Assembly Screw Fastening" on page 43 14 "Pad Assembly Mag- netic Holder" on page 20.1.2 Vertical pad position For an optimum printing result, the pad should only deform on the cliché to such an extent that it can just absorb the print image.
Page 102: Setting The Workpiece
20.2 Setting the workpiece The position of the print image on the workpiece is set by adjusting the workpiece position. For this reason, the machine can be equipped with various adjustment options depending on the version. 20.2.1 Workpiece height The pad stroke to the workpiece is set via the workpiece height. For this, the workpiece holding fixture can be mounted on a height-adjustable angle table.
Page 103: Safety Guard
Safety guard The machine can be equipped with various safety guards. Depending on the safety guard in place, the operation and functions of the machine will differ. 21.1 Safety guard – light barrier Machine Safety guard Light barrier If there is a light barrier in place as a safety guard, the functions are triggered using the illuminated START button.
Page 104: Safety Guard - Two-Hand Operation
21.2 Safety guard – two-hand operation Machine Safety guard Two-hand operation If two-hand operation is in place as a safety guard, the functions are triggered using two- hand operation. The green two-hand operation symbol appears on the touchscreen of the operating panel when the machine is ready to start.
Page 105: Operating Elements
Operating Elements 22.1 Control Panel On the front of the machine, three buttons and the operating terminal are built into the machine housing. STOP button ON illuminated button START illuminated button SIMATIC HMI Operating terminal The operating terminal features a touch screen and several function keys.
Page 106: Operating Terminal
22.3 Operating Terminal = Touch screen = Function keys F1 to F4 22.3.1 Touch screen The touch screen shows the user interface of the different operation modes. The push but- tons can be used to select functions, set operating parameters and view diagnostic func- tions.
Page 107: Layout Of A Menu Window
22.4 Layout of a Menu Window The layout of all menu windows follows the same structure. Operation mode menu symbol. Number of the menu window. Name of the menu window. Initials for current selected language of user interface. Field for operating notifications and information. If no notification is displayed, the date and time will be shown.
Page 108: Symbols
22.6 Symbols 22.6.1 Operation modes Symbol Meaning Homing Carry out homing after switching on the machine or after an EMERGENCY STOP. Automatic Carry out entire print processes based on current settings. Manual Mode Move the machine axes and carry out individual functions in order to confi- gure and test machine functions.
Page 109: Activation / Deactivation
22.6.3 Activation / deactivation Activation and deactivation is a pre-selection. The function is not carried out immediately but is taken into consideration in subsequent actions. Symbol Meaning Activated The function is activated. The function is deactivated when the push button is pressed.
Page 110: Change Settings
22.6.6 Change settings Settings with a yellow push button background can be changed. Pressing the yellow push button opens the input dialog. Input dialog for numerical values The min and max permissible values for this setting are displayed above and below the input line.
Page 111: Menu Structure
22.7 Menu Structure There are three sections in the menu where the performance of individual machine func- tions can be set and tested. In the various sections the menu levels of a function always have the same designation. Manual Mode •...
Page 112: Menu Configuration
22.8 Menu Configuration Access to functions and settings can be individually configured. This allows access by unauthorized persons to be prevented. In the Admin Settings menu, all of the machine’s settings and all menu configuration options can be accessed. All machine functions and access rights are managed from there.
Page 113: Switching On The Machine
Switching on the machine 23.1 Mains switch ON Switch on mains switch on the mains supply module on the rear of the machine (position 1). max 250V~ 23.2 Control unit ON The following conditions must be met in order to switch on the control unit. •...
Page 114: Home Position
23.3 Home position AUTOMATIC MODE and certain functions in MANUAL MODE require the machine to be in the home position. Otherwise these functions cannot be carried out. A notification displays the status. 23.3.1 Automatic homing In MANUAL MODE, before certain functions are carried out a check is made to see whe- ther the machine is in the home position.
Page 115: Operation Mode
23.4 Operation mode After homing has been completed, the operation mode menu is displayed. push button to call up the AUTOMATIC operation mode. See Chapter 24 "Automatic" on page 117. push button to call up the MANUAL MODE operation mode. See Chapter 25 "Manual Mode"...
Page 116: Control Unit Off
23.5 Control unit OFF The control unit is switched off by pressing the STOP button. When the control unit is switched off, the ON illuminated button will go out. A notification displays the status. After the STOP button has been unlocked, the last menu window that was viewed will be displayed again.
Page 117: Automatic
Automatic This operation mode is selected from the “Operation mode” menu or using the F1 AUTOMATIC function key. In the AUTOMATIC operation mode, print cycles can be carried out with the chosen set- tings. 24.1 Displays Current dataset The name of the most recently loaded dataset is displayed. See Chapter 26.8.2 "Load dataset"...
Page 118: Starting A Print Cycle
24.2 Starting a print cycle The machine can be equipped with various safety guards. Depending on the safety guard in place, the operation and functions of the machine will differ. See also Chapter 21 "Safety guard" on page 103 24.2.1 With light barrier safety guard Press the Automatic push button.
Page 119: With Two-Hand Operation Safety Guard
START via light curtain The machine can be set in such a way that the start pulse for a print cycle is activated by interrupting a light curtain and then ending contact with it again. See Chapter 26.6 "Light curtain" on page 130.
Page 120: Starting A Pad Cleaning
24.3 Starting a pad cleaning Press the Pad cleaning push button. The push button for the selected function is displayed in green. The green START symbol is displayed when the machine is ready to start. The START illuminated button lights up when the machine is ready to start. Pressing the START illuminated button carries out a pad cleaning.
Page 121: Manual Mode
Manual Mode 25.1 Overview • This operation mode can be selected from the “Operation mode” menu. • The Manual Mode menu can be accessed without a password prompt. • In Manual Mode individual machine functions can be called up and carried out. This allows sub-functions of the machine to be tested and monitored.
Page 122: Printer
25.3 Printer The desired function can be selected via the push buttons. The push button for the selected function is displayed in green. Settings push button This calls up the settings for this function. See Chapter 26.3 "Printer" on page 128.
Page 123: Pad Cleaning
25.4 Pad cleaning The desired function can be selected via the push buttons. The push button for the selected function is displayed in green. Settings push button This calls up the settings for this function. See Chapter 26.5 "Pad cleaning" on page 129.
Page 124: Tape Feed
25.4.2 Tape feed Press the Tape feed push button. The push button for the selected function is displayed in green. The green START symbol is displayed when the machine is ready to start. The START illuminated button lights up when the machine is ready to start. Pressing the START illuminated button activates a tape feed.
Page 125: Pad Blower
25.5 Pad blower Press push button 0 or I. The pad blower is immediately turned on or off when the push buttons are pressed. Settings push button This calls up the settings for this function. See Chapter 25.5 "Pad blower" on page 125.
Page 126 Manual Mode...
Page 127: Settings
Settings 26.1 Overview • This operation mode can be selected from the “Operation mode” menu. • The Settings menu is protected with a password prompt. • The designation of the menu levels for the Settings is identical to the designation of the menu levels in Manual Mode.
Page 128: Printer
26.3 Printer Print speed The speed of the machine during the print cycle in automatic mode. Print speed reduced The machine can operate at a reduced speed for part of the print cycle. For example, this allows the ink to be released more slowly for the pad on the workpiece. By pressing the push button , the reduced speed can be activated or deactivated.
Page 129: Pad Cleaning
26.5 Pad cleaning Cleaning time The push button activates or deactivates the pad cleaning before the print cycle. The push button activates or deactivates the pad cleaning after the print cycle. Only one of the two cleaning times can be activated. Cleaning interval After the set number of print cycles, a pad cleaning is performed.
Page 130: Light Curtain
26.6 Light curtain This menu only appears when the light barrier function is activated. See Chapter 27.11 "Safety guard" on page 148. START via light curtain If the machine is being operated in a safety enclosure with a light curtain, the start pulse for a print cycle can be activated in AUTOMATIC operation mode by interrupting the light curtain insertion area and then ending contact with it again.
Page 131: Pad Safety
26.7.1 Pad safety By pressing the push button the Pad safety signal can be activated or deactivated at an automation interface input. The characteristics of the signal are described in Chapter 31 "Automation Interface" on page 161. If the function is activated, the pad safety signal is analyzed. If the function is deactivated, the pad safety signal is ignored.
Page 132: Pad Blower
26.7.2 Pad blower By pressing the push button the signal for the Pad blower can be activated or deacti- vated at an automation interface output. The characteristics of the signal are described in Chapter 31 "Automation Interface" on page 161. The numeric values can be used to set the positions, from , between which the signal should be emitted.
Page 133: Cycle Signal
26.7.4 Cycle signal By pressing the push button , the Cycle signal can be activated or deactivated at an automation interface output. The characteristics of the signal are described in Chapter 31 "Automation Interface" on page 161. The cycle signal is emitted dependent on a print cycle. If several print pulses are perfor- med in a print cycle, the output signal is based on the entire print cycle.
Page 134: Automatic Auxiliary Signal
26.7.5 Automatic auxiliary signal By pressing the push button the Automatic auxiliary signal can be activated or deac- tivated at an automation interface input. The characteristics of the signal are described in Chapter 31 "Automation Interface" on page 161. 26.7.6 Sensors cleaning tape The signals of the cleaning tape sensors can be emitted at the Cleaning tape notification output of the automation interface.
Page 135: Datasets
26.8 Datasets The number and name of the most recently loaded dataset are displayed in field The menu settings can be saved for use at a later date. Here, all current settings and menu configurations are saved as a complete dataset is one disk space. See Chapter 26.8.4 "Save dataset"...
Page 136: Load Dataset
26.8.2 Load dataset The list of datasets can be scrolled through using the push buttons scroll up / down 21 disk spaces (1 to 21) can be chosen from. The selected disk space is displayed in the row marked with an arrow Pressing the push button Load loads the selected dataset.
Page 137: Save Dataset
26.8.4 Save dataset The list of datasets can be scrolled through using the push buttons scroll up / down 20 disk spaces (1 to 20) can be chosen from. The selected disk space is displayed in the row marked with an arrow Pressing the Save push button saves the dataset in the selected disk space.
Page 138: Foot Switch
26.9 Foot switch This menu only appears when the light barrier function is activated. See Chapter 27.11 "Safety guard" on page 148. One of the displayed functions can be activated for the foot switch. If no function is activated, the foot switch will do nothing when pressed. Pressing the foot switch in AUTOMATIC operation mode activates a print cycle.
Page 139: Admin Settings
Admin Settings 27.1 Overview • This operation mode can be selected from the “Operation mode” menu. • The Admin Settings menu is protected with a password prompt. • The designation of the menu levels for Admin Settings is identical to the designation of the menu levels in Manual Mode and the Settings menu.
Page 140: Printer
27.3 Printer Adjustable settings see Chapter 26.3 "Printer" on page 128. Write protection See Chapter 22.8.2 "Write protection" on page 112. 27.4 Workpiece Adjustable settings see Chapter 26.4 "Workpiece" on page 128. Write protection See Chapter 22.8.2 "Write protection" on page 112.
Page 141: Pad Cleaning
27.5 Pad cleaning Adjustable settings see Chapter 26.5 "Pad cleaning" on page 129. Pad cleaning activation The machine can be optionally fitted with a pad cleaning system. By pressing the push button pad cleaning can be activated or deactivated. Symbol Function Activated Pad cleaning is active and all set functions will be applied.
Page 142: Interface
27.7 Interface The Interface menu combines all settings which effect the automation interface. The menu is divided into several sub-menus. This menu provides access to functions whose settings need to be changed. Each selectable function is described on the following pages. 27.7.1 Print release Adjustable settings see Chapter 26.7.1 "Pad safety"...
Page 143: Pad Blower
27.7.2 Pad blower Adjustable settings see Chapter 26.7.2 "Pad blower" on page 132. Write protection See Chapter 22.8.2 "Write protection" on page 112. 27.7.3 Auxiliary functions Adjustable settings see Chapter 26.7.3 "Auxiliary functions" on page 132. Write protection See Chapter 22.8.2 "Write protection"...
Page 144: Cycle Signal
27.7.4 Cycle signal Adjustable settings see Chapter 26.7.4 "Cycle signal" on page 133. Write protection See Chapter 22.8.2 "Write protection" on page 112. 27.7.5 Automatic auxiliary signal Adjustable settings see Chapter 26.7.5 "Automatic auxiliary signal" on page 134. Write protection See Chapter 22.8.2 "Write protection"...
Page 145: Sensors Cleaning Tape
27.7.6 Sensors cleaning tape Adjustable settings (push buttons ) see Chapter 26.7.6 "Sensors cleaning tape" on page 134. Lack of tape The function for lack of tape can be activated using push button . For this the sensor must be fitted and connected. Push button can only be activated if push button has been activated.
Page 146: Datasets
27.8 Datasets Functions see Chapter 26.8 "Datasets" on page 135. The Presets menu can be viewed by pressing push button 27.8.1 Presets The Presets menu is protected with a password prompt and can only be accessed by employees of the manufacturer. See Chapter 32 "Password"...
Page 147: Foot Switch
27.9 Foot switch This menu only appears when the light barrier function is activated. See Chapter 27.11 "Safety guard" on page 148. Adjustable settings see Chapter 26.9 "Foot switch" on page 138. Write protection See Chapter 22.8.2 "Write protection" on page 112.
Page 148: Safety Guard
27.11 Safety guard The machine can be equipped with various safety guards. The light curtain safety guard is activated using push button The two-hand operation safety guard is activated using push button Depending on the safety guard in place, the operation and functions of the machine will differ.
Page 149: Automatic Power On
27.12 Automatic power on By pressing the push button , Automatic power on can be activated or deactivated. If the function is activated the machine’s control unit will be switched on automatically. Automatic power on takes place under the following conditions: •...
Page 150 Admin Settings...
Page 151: Diagnostics
Diagnostics 28.1 Overview • This operation mode can be selected from the “Operation mode” menu. • A diagnostics menu can be called up in order to determine current signal statuses. In the event of malfunctions, it may be possible to ascertain the cause or source of fault here.
Page 152: Inputs
28.4 Inputs Display of the signal statuses of the digital inputs of the control unit. The inputs in a yellow frame have safety functions. 28.5 Outputs Display of the signal statuses of the digital outputs of the control unit. The outputs in a yellow frame have safety functions. Diagnostics...
Page 153: Counter
28.6 Counter Operating hours The number of hours for which the machine has operated with the control unit switched Workpiece counter total Total number of workpieces that have been printed by the machine. Pad stroke counter The number of pad strokes in print operation (print and cleaning cycles). 28.7 Date/time The date and time of the system clock can be set.
Page 154: Notifications
28.8 Notifications Display with a list of notifications which have occurred. It can also be used to track previous incidents. Diagnostics...
Page 155: Service
Service 29.1 Overview • This operation mode can be selected from the “Operation mode” menu. • Service information is displayed. • Password functions can be carried out. 29.2 Service menu Service hotline The telephone numbers of the service hotline for Europe and the USA are displayed. The Password functions menu can be viewed by pressing push button 29.3 Password functions...
Page 156 Unlock Admin Settings The Admin access area can be unlocked once only. • Contact the service department to generate a release code. • Cite the keycode from field • The service department will then generate a release code which should be entered in field •...
Page 157: Notifications And Errors
Notifications and Errors Operating and error notifications can be shown in the operating terminal display. 30.1 Operating Notifications In AUTOMATIC MODE, operating notifications appear at the lower edge of the menu win- dow in blue. The notification will automatically disappear when the cause is resolved. Notification Description No automatic auxiliary signal...
Page 158: Error Notifications
30.2 Error Notifications 30.2.1 Display Error notifications appear at the lower edge of the current menu window in red. The notification window can be viewed by pressing the push button. Depending on the category of the notification, the notification window may also be dis- played immediately.
Page 159: List Of Notifications
30.2.3 List of notifications Notification (Help text) Description STOP button pressed on the printer! The STOP button on the printer has been pressed and is locked in place. The button (Unlock STOP button by twisting.) must be unlocked by twisting. External emergency stop is disconnected! The EMERGENCY STOP circuits on the auto- mation interface have been interrupted.
Page 160 Notifications and Errors...
Page 161: Automation Interface
Automation Interface 31.1 Function The automation interface can be used to integrate the machine into higher-level control units. The signal exchange for notifications and control functions is carried out over this inter- face. Please contact the manufacturer for the integration of special functions and extensi- ons.
Page 162: Terminal Assignment
31.3 Terminal assignment 31.3.1 25-pole port The signals marked in yellow in the table are safety-related and it is imperative that they are observed when integrating the machine into higher-level systems. Only circuit components which correspond to the required safety category may be connec- ted.
Page 163: 15-Pole Port
31.3.2 15-pole port The signals marked in yellow in the table are safety-related and it is imperative that they are observed when integrating the machine into higher-level systems. Only circuit components which correspond to the required safety category may be connec- ted.
Page 164: Control Procedure Information
31.5 Control procedure information 31.5.1 25-pole port Voltage supply for control signals External signals must be produced with potential-free switching elements. The control vol- tage (24 V DC) provided on the automation interface must be used for the voltage supply. The supply of external voltage is not permitted.
Page 165 Pin 8 (IN) Pad safety The activation of the input and the desired switching behavior must be set in the menu. See Chapter 26.7.1 "Pad safety" on page 131. The pad safety signal must be present at the input before the pad moves towards the workpiece.
Page 166 Pin 17 (IN) START Pad cleaning The signal has a set switching behavior and cannot be adjusted. A signal edge from LOW to HIGH starts a pad cleaning cycle. This function is active in every operation mode. When a print cycle is being carried out in the AUTOMATIC operation mode the signal is ignored.
Page 167: 15-Pole Port
31.5.2 15-pole port Pin 1 (IN) Prog. IN 1 Pin 2 (IN) Prog. IN 2 Pin 3 (IN) Prog. IN 3 Pin 4 (IN) Prog. IN 3 Pin 5 (OUT) Prog. OUT 1 Pin 6 (OUT) Prog. OUT 2 Pin 8 (OUT) Prog. OUT 3 Pin 10 (OUT) Prog.
Page 168: Switching Behavior For Auxiliary Functions
31.6 Switching behavior for auxiliary functions The auxiliary functions enable the movement of the workpiece. This allows several posi- tions to be printed onto a workpiece in a print cycle. The examples show a turning device. A linear shifting of the workpiece holding fixture is also possible.
Page 169: Position Fixture
31.6.2 2 Position Fixture The switching behavior of the inputs and outputs is adapted for a workpiece holding fixture with two positions. Inputs used: Pin 1 (IN) Prog. IN 1, Pin 2 (IN) Prog. IN 2 Outputs used: Pin 5 (OUT) Prog. OUT 1, Pin 6 (OUT) Prog. OUT 2 The inputs and outputs with a HIGH signal are each indicated in the table.
Page 170: Position Fixture
31.6.3 3 Position Fixture The switching behavior of the inputs and outputs is adapted for a workpiece fixture with three positions. Inputs used: Pin 1 (IN) Prog. IN 1, Pin 2 (IN) Prog. IN 2 Outputs used: Pin 5 (OUT) Prog. OUT 1, Pin 6 (OUT) Prog. OUT 2 Pin 8 (OUT) Prog.
Page 171: Definition Of Safety Zones
31.7 Definition of safety zones The machine’s safety guards can be set up in different ways, depending on requirements. 31.7.1 Safety guard with a light curtain Printer Workpiece Safety guard (in some cases with safety doors) Light curtain insertion area Operator In this set-up there is only one safety zone within the safety guard.
Page 172: Safety Guard With Two Light Curtains
31.7.2 Safety guard with two light curtains Printer Workpiece in insertion area Workpiece in print area Safety guard (in some cases with safety doors) Light curtain insertion area Light curtain print area Operator The machine has a feed device for the workpieces. This example features a rotary table with two workpiece fixtures.
Page 173: Safety Guard - Two-Hand Operation
31.8 Safety guard – two-hand operation If two-hand operation is used as a safety guard, the circuit of the automation interface will change. The connections for the light barriers will be used for the connection of two-hand opera- tion. For this, the function must be activated in the ADMIN SETTINGS menu. See Chapter 27.11 "Safety guard"...
Page 174 Automation Interface...
Page 175: Password
Password IMPORTANT INFORMATION This page can be removed from the instruction manual in order to limit the dissemi- nation of passwords. This will help to ensure that passwords are only made available to authorized per- sons. The passwords can not be changed. Password-protected access to the Settings menu can be gained via a push button which is labeled with this symbol.
Page 176 Password...
Page 177: Annex
Annex 33.1 Supplementary documents Further documents are available depending on the machine equipment and design. These documents are part of the machine documentation and must be carefully stored and observed. The following documents may be available in the annex from Page 178 onwards: 33.1.1 Pneumatics diagram •...
Page 178 Trusted Partner for Your Product Decorating Needs A MEMBER OF Trans Tech 475 North Gary Avenue, Carol Stream, IL 60188 Tel +1 (630) 752 4000 Fax +1 (630) 752 4467 Email sales@itwtranstech.com www.itwtranstech.com www.itwids.com Annex...

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Transtech SealCup Express Instruction Manual

2 Imprint

3 Important Information

4 Contents

5 Safety Instructions

6 Used Symbols

7 Terminology

8 Technical Data

9 Transport and Installation

10 Assembly Instructions

11 Commissioning

12 Pad Cleaning

13 Pad Assembly Screw Fastening

14 Pad Assembly Magnetic Holder

15 Cliché Assembly (EU)

16 Cliché Assembly (US)

17 Cliché Replacement

1101 MCI Ink Cup

19 Express Liner Ink Cup

20 Setting up the Print Image

21 Safety Guard

22 Operating Elements

23 Switching on the Machine

24 Automatic

25 Manual Mode

26 Settings

27 Admin Settings

28 Diagnostics

29 Service

30 Notifications and Errors

31 Automation Interface

32 Password

33 Annex

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