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Grafisk Maskinfabrik DC330mini Operating Manual

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· GM CONVERTING UNIT ·
OPERATING MANUAL
DC330MINI-NANO
Grafisk Maskinfabrik A/S
Bregnerødvej 92, DK-3460 Birkerød · Denmark · Phone: +45 4581 2300
Internet: www.gm.dk · e-mail: gm@gm.dk ·Fax:+45 4581 9956

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  • Page 1 · GM CONVERTING UNIT · OPERATING MANUAL DC330MINI-NANO Grafisk Maskinfabrik A/S Bregnerødvej 92, DK-3460 Birkerød · Denmark · Phone: +45 4581 2300 Internet: www.gm.dk · e-mail: gm@gm.dk ·Fax:+45 4581 9956...

  • Page 2: Eu Declaration Of Conformity

    GM · CONVERTING UNIT Rev 1.6 03/03- 2017 EU Declaration of Conformity We Manufacturer: Grafisk Maskinfabrik A/S Bregnerødvej 92 DK-3460 Birkerød Denmark Telephone: + 45 45 81 23 00 Fax: + 45 45 81 99 56 Herewith declare that the product...

  • Page 3: Table Of Contents

    GM · CONVERTING UNIT EU Declaration of Conformity ........................2 Safety instructions ..........................5 DC330mini/nano note ......................... 6 Control panel ............................6 Touch panel ............................7 The main screen ........................... 8 5.1. Web entry ............................9 5.2. The varnish station ..........................9 5.3.
  • Page 4 GM · CONVERTING UNIT 18.4. Mounting of the ink roller....................... 44 18.5. Mounting of side blades and doctor blade ..................45 18.6. Filling of ink ............................ 46 18.7. Mounting of print cylinder ......................46 18.8. Adjustment of impression ....................... 47 18.9.

  • Page 5: Safety Instructions

    GM · CONVERTING UNIT Safety instructions This chapter describes the safety guidelines that must be observed under all circumstances when installing,commissioning, operating and maintaining the CONVERTING UNIT. In this operating manual and on the unit, the following symbols will draw your attention especially to hazards, risks and safety relevant information: Indicates a potentially dangerous situation.

  • Page 6: Dc330Mini/Nano Note

    This manual is for the DC330mini and the DC330nano The DC330mini line is identical to the DC330 – only difference is that it is much more compact. The DC330 nano does not have a flexo unit – it is lamination only.

  • Page 7: Touch Panel

    GM · CONVERTING UNIT Touch panel The touch panel is the main control unit on the converting unit. All values regarding a job are entered through the panel. It responds to light pressure onto the panel, thus responding when the user pushes a virtual button or numeric value shown in the panel.

  • Page 8: The Main Screen

    GM · CONVERTING UNIT The main screen The majority of machine functions are operated on the main screen. A large graphic representation of the machine is used for controlling: • mandrel expansion • spindle modes • nip rollers • varnish roller •...

  • Page 9: Web Entry

    GM · CONVERTING UNIT 5.1. Web entry The web entry into the machine can be run in two different modes: In Stand-alone mode, a roll is placed on the unwinder, labels out or labels in. The web must be fed through the DCmimi buffer, which creates web tension, and controls the unwinder.
  • Page 10 The laminate unwinder will not rotate when the laminate nip is off. This is to prevent the laminate foil from rotating freely through the laminating station. For the DC330Mini, the following images illustrate the web path if running with an adhesive laminate and the web path if running with supergloss laminate.

  • Page 11: The Uv Lamp

    GM · CONVERTING UNIT 5.5. The UV lamp The UV lamp is turned on and off be pressing the light bulb with the text 'UV'. When turned on, a few seconds will pass before an attempt is made to ignite the lamp. When the UV lamp ignites, it goes in to a heating sequence, which lasts about one minute.

  • Page 12: Safety Instructions

    GM · CONVERTING UNIT 5.6. Safety instructions The following subsections describe any risks associated with handling the UV lamp and safety precautions: a. Ozone(O3) The UV lamp generates Ozone which is normally exhausted to the atmosphere. If a strong smell of Ozone is detected check the ducting for any leakages.

  • Page 13: The Die-Cutting Station

    GM · CONVERTING UNIT CAUTION: Never use flammable solvents near the UV dryer when the lamps are in operation. If a fire should break out, only use fire extinguishers of the dry powder type. e. High voltages UV lamps operate at high voltages (450V - 1400V) depending on the lamp type; additionaly when striking the lamps, ignitor circuitry will generate pulses in excess of 2kV.

  • Page 14: Waste Rewinder

    GM · CONVERTING UNIT To lower the die do the following: 1) Make sure the handles on the pressure bridge are lose 2) Turn on the air by pressing the cylinder symbol on the touch screen. 3) Turn the handles on the pressure bridge softly until they are firm. NOTE: Turning them down with excessive force will damage the die cylinder.

  • Page 15: Rewinding

    GM · CONVERTING UNIT When produceing with slitting knives, it is very important to remember to mount the clamp (see figure3). It will stabilize the two axles and ensure a clean cut . When not using slitting knifes, the handle must only be moved when the clamp is removed.

  • Page 16: Menu Buttons

    GM · CONVERTING UNIT Menu buttons Just below the machine drawing, you will find two white boxes. In the left box, two counters are placed: A meter counter and a label counter. Each can be cleared by pressing the clear button [0]. Additionally, the label counter can be turned on and off with the checkbox next to the counter.
  • Page 17 GM · CONVERTING UNIT The green button in the center bottom part of the screen is the start button. Press this to start the machine. Pressing the 'Die-cut parameters' button will enter the die-cut setup menu. Pressing the 'Parameter menu' button will open the parameter menu, which contains values and features not directly related to the die-cut station.

  • Page 18: Parameters

    GM · CONVERTING UNIT 6.1. Parameters The 'Automatic stop at low unwinder diameter' feature makes the converting unit stop when the roll on the unwinder spindle becomes smaller than the value. The diameter range is 80 .. 200 mm (3.1 .. 7.9"). The 'Automatic stop at label preset' feature makes the converting unit stop when the label counter reaches or exceeds the preset value.
  • Page 19 GM · CONVERTING UNIT If the spot varnish option is installed in the machine, it can be activated with the 'Use spot varnish' checkbox. In addition, the exact size of the spot varnish cylinder must be keyed in, either in "teeth", or in mm (or inches).

  • Page 20: Die-Cut Parameters

    GM · CONVERTING UNIT 6.2. Die-cut parameters This converting unit is equipped with a die-cutting station, which can run in several modes. Correct setup is crucial to the operation of the die-cutting station. Remember to change the plate in the die cut station before entering new parameters.
  • Page 21 GM · CONVERTING UNIT Analog mode: If analog mode is selected, the operator must enter the size of the die-cutting cylinder. The unit is "teeth" (Z). One tooth is 1/8 inch. This figure is entered in 'Die-cutting teeth'. Digital mode: The die-cut station must know a few details about the cutting plate and the print, in order to operate correctly.
  • Page 22 GM · CONVERTING UNIT Running: When the start button is pressed, this screen appears: Most parts of the screen are exactly as when the machine is not running, but some things have changed. The red button is the stop button. When this button is pressed, the machine will decelerate and stop. The value above the stop button is the measured web speed.

  • Page 23: Speed Control

    GM · CONVERTING UNIT the direction the arrows are pointing. The offset can also be adjusted on a knob mounted on the varnish station. The 'Clear blind' button is for syncronizing the die-cut station with the printed web, using a specific registry mark.

  • Page 24: Web Tension And Scale Print Adjustments

    GM · CONVERTING UNIT 6.4. Web tension and scale print adjustments By pressing the “tool” symbol on the machine in “running” mode the web tension parameter can be accessed. Tool icon. The tool button will open the web tension and scale dialog: Web tension will change the gearing of the in and outgoing nips in the machine.

  • Page 25: Alarms And Messages

    GM · CONVERTING UNIT Alarms and messages A number of alarms and messages can be shown in the panel in various situations. All alarms are accompanied by a symbol, showing if it is merely an info message, a warning, or a serious error (malfunction).
  • Page 26 GM · CONVERTING UNIT Fatal problem! An unexpected error has occurred, which has caused the Press the flashing symbol machine to stop abruptly. In this situation, the message to clear the alarm. display will switch between this text and the actual explanatory message text, along with intermittent beeps.
  • Page 27 GM · CONVERTING UNIT UV error: Low voltage The supply voltage for the UV power supply is too low. UV error: Lamp overheated or case open The UV lamp has become too hot, or the lamp casing has been tampered with. Please check cooling unit and lamp case.
  • Page 28 GM · CONVERTING UNIT Spot varnish station failed. Internal error in the spot varnish controller. Contact Program error. manufacturer. Contact manufacturer. Spot varnish station failed. Internal error in the spot varnish controller. Contact Internal E-stop. manufacturer. Contact manufacturer.

  • Page 29: Language And Units Setup

    GM · CONVERTING UNIT Language and units setup On the startup screen (right after power-up), press the 'Setup' button, to get to this menu: When more languages have been installed in the panel, these can be selected with the radio buttons in the left part of the screen.

  • Page 30: Special Parameters

    GM · CONVERTING UNIT Special parameters The following menu is reached by pressing 'Next' on the language setup screen. Nip roller sizes: The machine uses 304.8 mm (12”) rollers with a diameter of 97.02. Altering the size of the nips will change the overall tension in the machine.

  • Page 31: Registration Accuracy

    GM · CONVERTING UNIT Registration accuracy The registration accuracy is defined as the deviation in the first cutting line relative to the registration mark. If there is deviations due to differences in gab size between the labels, it has to do with the distortion setting or the dispro factor of the plate.

  • Page 32: Markreader Sunx Lx Series

    GM · CONVERTING UNIT Markreader SUNX LX series Quick overview of the SUNX markreader. To make the adjustment of Sunx LX Markreader, there must be a colored mark. Press the blue button shortly and place a colored mark under the reader, and press the ON/SELECT button shortly.

  • Page 33: Distortion And Dispro Factor

    GM · CONVERTING UNIT Distortion and dispro factor The dispro factor is defined as the percentage the die plate is shortened in order to have the correct length when wrapped around the magnetic die. On figure 1 (right side) the distances D1 and D2 are the length of the die plate measured from the top of the knife and the bottom of the plate.
  • Page 34 GM · CONVERTING UNIT A series of tests has been done on standard label material. Tool: 25” Gerhard cylinder. Plates: 304.8 mm plate distorted for a 25” (200Z) die. Three different dispro factors tested. The gab size between the labels was 2.8 mm giving a distance of 304.8 mm – 2.8mm = 302 mm between the first and last cutting line.

  • Page 35: Varnish Station - Prevent Dripping

    GM · CONVERTING UNIT Varnish station – prevent dripping 1) Check the dimension of the print roller. It must be 97.2+(0.3)mm. 2) Remember to mount the lower station cover (metal plate). 3) The standard roller is 320 mm wide. The roller can be tooled down to 300mm to prevent varnish build op on the sides of the web / dripping due to wiper blades not being in tight contact with anilox roller.

  • Page 36: Dust Problems With V-Knifes & Damages To Anvil Roller

    GM · CONVERTING UNIT Dust problems with V-knifes & damages to anvil roller. This issue does only relate to machine with V-knifes. Rotary knife systems does not have dust problems. The standard V-knife has an angel of 45, this can generate dust with some materials. If there is a problem, we can deliver a knife with a 30...

  • Page 37: Die Cut Bridge Adjustment

    GM · CONVERTING UNIT Die cut bridge adjustment To adjust the stroke of the die bridge follow this procedure 1. Dismount the bridge and put it on a table or stable surface. 2. Use an allan key and a wrench to adjust the gab at the 4. set points. 3.

  • Page 38: General Information For Gm Diecut Station

    GM · CONVERTING UNIT General information for GM diecut station...
  • Page 39 GM · CONVERTING UNIT Pneumatic air cylinders: The two air cylinders can disengage the magnetic die cylinder because the die is supported with springs below the bearing houses. The stroke of the piston plate is 1.5mm, enough to stop die cutting, but not enough to get the cog wheels out of grip.
  • Page 40 GM · CONVERTING UNIT Gap: The “gap” is the distance between the surface of the die cylinder and the surface of the anvil cylinder. The distance cannot be adjusted because the bearers on the cylinders control it. The gap on GM machines is 0,48mm (label) or 0,76mm (postcards etc.) Pressure adjusting: When the die is engaged (down) adjust the pressure so high that you get a perfect die cut and not higher.

  • Page 41: Varnish Station

    GM · CONVERTING UNIT Varnish station The UV-varnishing unit is used after the digital printing unit to varnish the web. The varnishing unit is designed for the use of UV - curing ink/lacquer. Also water based priming is possible with hot air dryer mounted.
  • Page 42 GM · CONVERTING UNIT Ink Roller Anilox roller Ductor Roller Ink tray Paper web Impression cyllinder The paper web is fed through the press on stationary rollers (impression rollers and turning rollers). Above the web is the print head with the plate cylinder, which can be raised and lowered. The plate is inked up by the anilox roller, which is adjusted with two handles to more or less pressure on the plate roller.

  • Page 43: Anilox Roller Types

    GM · CONVERTING UNIT 18.2. Anilox roller types The amount of the ink to be transferred to the plate and paper web is determinate by the form and size of the anilox roller's cells. If a lot of ink is to be transferred to the paper web an anilox roller with a coarser screen - low line number - must be used, If less ink is required e.g.

  • Page 44: Mounting Of The Anilox Roller

    GM · CONVERTING UNIT 60 lines per cm. Used for full inking up/varnishing on highly absorbent paper qualities. This coarse screen is best suited for special inking-up rollers. 70 - 80 lines per cm. For full inking-up/varnishing with full solids on finer paper such as e.g. High Gloss qualities.

  • Page 45: Mounting Of Side Blades And Doctor Blade

    GM · CONVERTING UNIT 18.5. Mounting of side blades and doctor blade 1. Knurled nut for blade adjustment. 2 .Fixing of side wipers. 3. Doctorblade with outward bevelling. 4.Sidewiper. The doctor blade can be adjusted when there is ink on the anilox roller. Adjust the two knurled nuts so that the doctor blade can just reach in and wipe off the ink with a light pressure on the anilox roller.

  • Page 46: Filling Of Ink

    GM · CONVERTING UNIT NOTE! The blade may not be set too hard as both doctor blade and anilox roller will be exposed to unnecessary wear and tear. NOTE! The blade may only be ON when there is ink on the roller. Ink reduces friction. Impurities in the ink or dried ink residues can damage the doctor blade, giving lines in the image and at worst scratches in the anilox roller.

  • Page 47: Adjustment Of Impression

    GM · CONVERTING UNIT 18.8. Adjustment of impression With the hand wheels (1) the print head is lowered and raised. The hand wheels are also used for adjustment of impression. The impression of the print head in both sides can be adjusted, so the plate is printing even and uniform all over the web.

  • Page 48: Cross Register

    GM · CONVERTING UNIT 18.9. Cross register When the knurled handle (1) is turned; Clockwise - impression is shifted towards the operating side of the press. Counter clockwise - impression is shifted towards the rear of the press. NOTE! The ball bearing on the arm that pushes the print cylinder across should be greased once every week.

  • Page 49: Triangle Adjustment Of The Flexo Unit (Coarse Adjustment)

    GM · CONVERTING UNIT 18.10. Triangle adjustment of the flexo unit (Coarse adjustment) In order to obtain best possible varnish/print quality on the flexo unit an initial coarse adjustment is necessary. Under normal conditions this should be performed once a month at least or every time after cleaning the flexo unit.

  • Page 50: Troubleshooting

    GM · CONVERTING UNIT 3. Finally check the first adjust and repeat the two steps until all measures are OK. 18.11. Troubleshooting If the impression between plate and web is too weak the image is not imprinted evenly. This is seen as holes in solids and type.

  • Page 51: Spot Varnish Guide

    GM · CONVERTING UNIT Spot varnish guide. Introduction The spot varnish function of the converting unit enables the system to put down print in register. This can be used for various applications; spot varnish effects (only part of the web varnished), Cold foil (a glue is printed in patterns to make silver/gold effects) and single color printing.

  • Page 52: Step By Step Guide

    GM · CONVERTING UNIT 19.1. Step by step guide • To startup spot printing follow the steps below. Please see picture section in the back of this guide when there are references to buttons or menus. • Enter the Z size of the plate cylinder in the parameters menu of the touch screen. Always use the Z size, never enter in mm.

  • Page 53: Trouble Shooting

    GM · CONVERTING UNIT 19.2. Trouble shooting Problem Print runs out of register Check print length. Check mark reader. Re-tune mark reader. Do spot scaling Print quality is poor Check tape and plate thickness. Check support lines on plate. Re-adjust station No varnish at startup Turn off slow run feature (can only be done with UV varnish) Init fault “gears not in grip”...

  • Page 54: The Parameter Screen

    GM · CONVERTING UNIT 19.4. The parameter screen When using spot varnish the spot varnish cylinder teeth point must be entered and the "use spot varnish" check box selected. Only use the "automatic slow run" when water based is used. The automatic slow run will leave a blank spot on the web when starting up.

  • Page 55: The Run Screen

    GM · CONVERTING UNIT 19.5. The run screen The run screen is displayed when the start button is pressed. The start button will change from green to red when pressed. From the run screen the measured print length and spot varnish deviation can be seen. Please monitor them careful when printing spot varnish.

  • Page 56: Print Scaling

    GM · CONVERTING UNIT 19.6. Print scaling When the tool icon is pressed the small dialog box above id displayed. This will alow the operator to make the spot varnish system go faster or slower. Print quality will be compromised. but it can be used to get a "bad job"...

  • Page 57: Lamination (Tips And Tricks)

    GM · CONVERTING UNIT Lamination (Tips and tricks) If you have fish-eye's in the laminate it is normally a sign of lack of adhesive in some points. Tricks for for self-adhesive laminates a) Make sure that the lamination roller is clean and flat. No dirt on sides. Run 3-4 bars pressure. b) Increase pressure on center nip roller to 5 bars - then it works as a "2 lamination roller"...

  • Page 58: Operator Maintenance Chart

    GM · CONVERTING UNIT Operator Maintenance Chart Unit Module Every Activity Tools Remarks Converter All nips 1 day Clean for Cloth, alcohol and rollers varnish and glue Converter Anilox/ductor 7 days Clean for Cloth, uv wash Replace doctor blade if it’s damaged doctor blade ink varnish/ink tray...
  • Page 59 GM · CONVERTING UNIT Unit Module Every Activity Tools Remarks Converter Die cut Lube the Thin oil, Check the filth pads. Must be hours bearer rings SAE 20 soaked in oil. Keep a oil can near the die Converter Die cut Grease the gearwheels and check the side Grease Note some models have shims...

  • Page 60: Dimensions

    GM · CONVERTING UNIT Dimensions...

  • Page 61: Spare Parts And Consumables

    GM · CONVERTING UNIT Spare parts and consumables Stock number Description DC-001Q Anilox roller 80L 15cm3/m2 (for full flood varnish) DC-001X Aniloxroller 120L 10cm3/m2 (for cold foil on paper) DC-002P Print roller Ø97.2 / W=320mm, including gear wheel and rubber coating (blue type) DC-003P Ductor / Pick-up roller ø97.2 B=310 L=314mm SH40 X-014E...

  • Page 62: Specification

    GM · CONVERTING UNIT Specification Consumption of power: 5kw UV system, 1kW cooling system, 5kW converter unit. Supply voltage: 3x400V 32A /phase 50/60 Hz Residual current circuit breaker (RCCB) >300mA Compressed air: 4 - 6 bar, 10 l/min Digital die size 12"...

  • Page 63: Cliché Roller Drawing

    GM · CONVERTING UNIT Cliché roller drawing This Cliché cylinder is the standard for GM Converting Unit. An optinal sleevesystem can be ordered. Call ur local GM sales office for further information.

  • Page 64: Specification Die Cylinder

    GM · CONVERTING UNIT Specification die cylinder The gap is the distance between the magnetic cylinder (magnetic zone) and the anvil cylinder. This is 0.48mm on all standard machines with a 25” die cylinder. Please check the order confirmation for the specific machine to make sure that it was shipped with a standard die tool.

  • Page 65: Installation Guide

    GM · CONVERTING UNIT Installation guide To secure that the installation and training can be carried out without problems and waste of time due to missing materials or on site preparations for the installation it is very important that the following preparations and items are ready before the arrival of the machine: Unloading the machine: - A fork lift with min.

  • Page 66: Starting Up The Machine

    GM · CONVERTING UNIT Starting up the machine: Test and training can not be carried out unless the following materials are available on site: Label material, min. 2000m with a web width of 330mm. (It is not possible to run a web with a width less than 330mm as the standard print roller is 320mm) A printed test job must be prepared and ready, min.

  • Page 67: Training

    GM · CONVERTING UNIT Training: The training on the converting line is training into how to run this specific one colour UV flexo press: It is not an education in how to be a printer. The training needed depends a lot on the knowledge and skill of the staff that has to operate the machine.
  • Page 68 GM · CONVERTING UNIT To be signed of the customer: Action Sign Comments Buffer installed an working Unwind system ok Varnish station ok Lamination ok Die station ok Slitting system ok Matrix rewind ok Rewinder ok Training ok Manual has been read...

  • Page 69: Notes

    GM · CONVERTING UNIT Notes...

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