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© Feldbaum + Vogt GmbH
Dieselstr. 12
32791 Lage
Germany
Version modifications:
Version
Date
Name
1.0
Wiens
Copying this document, or disclosing it to third parties is not allowed without our approval. This document must not be used in any abusive way by the receiver or third
parties. Feldbaum + Vogt GmbH
DigiConvert Operating Instructions
Markem Imaje CSAT GmbH
DigiConvert
Mach. no. MC004-2014
P1082
Operating Instructions
Comments
1 of 79
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Summary of Contents for Markem Imaje DigiConvert MC004-2014 P1082
- Page 1 Markem Imaje CSAT GmbH DigiConvert Mach. no. MC004-2014 P1082 Operating Instructions © Feldbaum + Vogt GmbH Dieselstr. 12 32791 Lage Germany Version modifications: Version Date Name Comments Wiens Copying this document, or disclosing it to third parties is not allowed without our approval. This document must not be used in any abusive way by the receiver or third parties.
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Page 2: Table Of Contents
DigiConvert Operating Instructions Contents MACHINE ............................4 FIELD OF APPLICATION ....................... 4 MACHINE SPECIFICATION ......................4 WARNINGS AND SAFETY INSTRUCTIONS ................5 4.1..................5 ENERAL INFORMATION 4.2..........5 ONTACT FOR ALES AINTENANCE AND 4.3..................6 KILLED ERSONNEL 4.4. - Page 3 DigiConvert Operating Instructions 9.8.1..............42 LARMS FROM NDIVIDUAL 9.9..................43 YSTEM IAGNOSIS 9.10..............44 ENERAL ACHINE NFORMATION 9.11......................45 ERROR MESSAGES AND WARNINGS .................. 46 OPERATING THE ASSEMBLIES..................... 47 11.1...................... 47 EELER 11.1.1..........47 EELER TANDARD EELER...
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Page 4: Machine
DigiConvert Operating Instructions 1. Machine Fig.: 1 Machine overview 2. Field of Application The main focus of the manufactured products is on punching, cutting and winding up material webs. 3. Machine Specification Type DigiConvert Machine speed 1 m/min ... max. 50 m/min Machine speed (translative) 1 m/min ... -
Page 5: Warnings And Safety Instructions
DigiConvert Operating Instructions 4. Warnings and Safety Instructions 4.1. General information These operating instructions describe all functions and procedures that are necessary for a safe and proper operation of the machine. To ensure a precise and faultless utilisation of the machine, please make yourself familiar with the operating instructions before you start operation. -
Page 6: Skilled Personnel
DigiConvert Operating Instructions 4.3. Skilled Personnel The person who is responsible for the overall system is obliged to delegate and entrust the operation to skilled personnel. In accordance with this documentation, these are persons who: • Are familiar with the general safety and accident-prevention regulations. •... -
Page 7: Maintenance Instructions
DigiConvert Operating Instructions 4.6. Maintenance Instructions Working on the system Only personnel who have been authorised by Feldbaum + Vogt GmbH, or personnel who have been adequately trained and instructed are allowed to repair or modify the system. Improper maintenance or unauthorised opening of the control cabinet and its components can cause severe injuries and/or significant material damage. -
Page 8: Introduction
DigiConvert Operating Instructions Introduction 6.1. Fundamentals of Drive Engineering The following figure shows the basic components of an electrical drive system: Fig.: 2 Components of the Electrical Drive System The machine (mechanical process) is driven by an electric motor. If necessary, the mechanical coupling uses a mechanical gearbox to adjust speed and torque. -
Page 9: Operator Terminal
DigiConvert Operating Instructions 6.2. Operator Terminal The entire system is controlled via the main control panel, that consists of a touch screen monitor and several buttons. Fig.: 3 Main Operator Terminal 6.2.1. Main operator terminal The base functions, such as STOP, PREP, START, JOG, are activated by the buttons with these inscriptions on the screen. -
Page 10: Warning Light System For The Entire Machine
DigiConvert Operating Instructions 6.3. Warning Light System for the Entire Machine Signal column at the operator terminal Status red The red status means: ➢ Blinking: EMERGENCY STOP mode active, acknowledgement with the emergency stop reset button necessary The blue lamp of the emergency stop reset button shines continuously ➢... -
Page 11: Safety Functions
DigiConvert Operating Instructions 7. Safety Functions 7.1. Safety Hoods There are sources of danger (crushing points, catching points, etc.) on the machine that are dangerous for the operator. Using mechanical structures, most of these danger points have been designed such that they are no longer dangerous for the operator. However, machine operation requires some of these danger points to be accessible. -
Page 12: Emergency Stop Function
DigiConvert Operating Instructions In addition, the machine is equipped with a safe jogging switch. Press and hold the jogging switch to move the punch at a safe speed up to 5 m/min when the top centre safety hood is open. The entire machine is moved at this speed when all the outer hoods are closed. -
Page 13: Operating The Machine
DigiConvert Operating Instructions 8. Operating the Machine 8.1. Switching on the System The system is started up at the main switch on the control cabinet. First, the 24-VDC power supply is released. ETHERNET POWERLINK communication is initialised, and the controllers (control PLC and safety PLC) start up. -
Page 14: Icons And Colours
DigiConvert Operating Instructions 8.2.2. Icons and Colours Buttons: The button can not be operated. The button is blocked by the application or machine status. Released button for functions or submenus Pressed button for functions or submenus Colours of buttons and icons: Inactive function Function is selected Alternately blinking blue and grey... -
Page 15: Machine Control Buttons, Machine Status
DigiConvert Operating Instructions 8.3. Machine Control Buttons, Machine Status Four buttons are available for the basic operation of the system. These buttons are of the "target" type. This means that the operator wants to obtain a specific status by pressing the buttons. If the system is stationary in one of the above-mentioned states, the lamp of the related button shines. - Page 16 DigiConvert Operating Instructions Represents a bidirectional transition between two states. The change happens when you press or release the button Is triggered when you press the emergency stop switch. Standstill, no web tension built up (STOP) Stop mode is characterised by: •...
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Page 17: Switching Off The System
DigiConvert Operating Instructions 8.4. Switching off the System Basically, you can always switch off the system at the main switch on the control cabinet. However, we recommend switching off only when the machine is in STOP mode. After the system has been switched off, the machine should remain OFF for at least 5 minutes. -
Page 18: Menu Structure
DigiConvert Operating Instructions 9. Menu Structure 9.1. Welcome Screen Fig.: 5 Welcome screen The touch panel starts up after the system has been switched on at the main switch of the main control cabinet. The welcome screen appears. This screen remains displayed until you press the "Machine overview"... -
Page 19: Machine Overview
DigiConvert Operating Instructions 9.2. Machine Overview Fig.: 6 Machine overview The top figure "machine overview" shows all assemblies in the system. Important states of individual assemblies are shown below the related images. Here you can touch an individual assembly to select it. Next, a menu with the setting options of the assembly appears in the right-hand screen section. - Page 20 DigiConvert Operating Instructions Functions of the individual buttons in the top bar: Change of operator Selection of the Trend diagram page Selection of the Register regulator Page Selection of the Machine settings/product store page Quick operation Selection of the Messages and alarms page Showing current information about the machine Showing Help page Copying this document, or disclosing it to third parties is not allowed without our approval.
- Page 21 DigiConvert Operating Instructions Other buttons/displays: Display of the current / total actual metres. Display of the actual speed and input of the desired speed. Touch the orange box to enter the desired speed directly. Use the button to decrease or increase, respectively, the desired speed by 1.0 m/min.
- Page 22 DigiConvert Operating Instructions Modules: • Reeler, edge cuttings reeler, matrix reeler • Longitudinal cutter • Matrix removal • Punch • Translative pull • Translative compensation • Cutting table • Swivel frame • Web storage • Label delivery • Dunker motor Copying this document, or disclosing it to third parties is not allowed without our approval.
- Page 23 DigiConvert Operating Instructions Reeler, matrix reeler, edge cuttings reeler: Sense of rotation: Reel core: Relieved Tensioned Diameter [mm]: Actual web tension [N m]: Desired web tension: Motor torque [%] Motor status: Not initialised STO fault (e.g. emergency OFF active) Axis fault Motor selection: Deselected Selected...
- Page 24 DigiConvert Operating Instructions Matrix removal: Sense of rotation: Lead [%]: Motor torque [%]: Motor status: Not initialised STO fault (e.g. emergency OFF active) Axis fault Motor selection: Deselected Selected Punch: Force measurement Measurement/percentage bar of punching system: pressure (top: Machine side, bottom: Operator side) Measurement OK Measurement in alarm range Measurement in stop range...
- Page 25 DigiConvert Operating Instructions Translative pull: Lead [%]: Motor torque [%]: Motor status: Not initialised STO fault (e.g. emergency OFF active) Axis fault Motor Deselected selection: Selected Pneumatic Open, closed system: Malfunction: Pneumatic cylinder has not reached desired position or drive not ready. Translative compensation: Homing status: Controller OFF...
- Page 26 DigiConvert Operating Instructions Swivel frame: Malfunction: Swivel frame not ready Web storage: Utilisation [%] Utilisation of web storage Manual speed input Mode: Automatic speed control Malfunction: No 24-V supply voltage available Weights: Desired (target) Detected (actual) (Blinking) (Blinking) Copying this document, or disclosing it to third parties is not allowed without our approval. This document must not be used in any abusive way by the receiver or third parties.
- Page 27 DigiConvert Operating Instructions Label delivery: Lead [%]: Lead for winding up the dispensed labels Quantity: Number of delivered labels Delivery activated: (Visible when delivery activated) Homing signal: Pneumatic cylinder extended Motor status: Not initialised STO fault (e.g. emergency OFF active) Axis fault Motor selection: Deselected...
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Page 28: Change Of Operator
DigiConvert Operating Instructions 9.3. Change of operator The availability of some machine parameters depends on the currently logged-in user level. To change the current user level requires the following steps: 1. Touch the user level button 2. Touch the user input boxes that have become visible or touch password 3. -
Page 29: Drive Values Trend Diagram
DigiConvert Operating Instructions 9.4. Drive values trend diagram Fig.: 7 Drive values trend diagram To get to this page, press the button. In the Trend diagram screen you can select different assemblies. This is followed by an overview of the current motor data. Selectable for the current diagram are: •... -
Page 30: Machine Settings And Job Memory
DigiConvert Operating Instructions 9.5. Machine Settings and Job Memory Job administration is on the Machine settings page. To get to this page, press the button. The operator can save the data of the current job in the job memory. Furthermore, you can load the job data of several previously stored jobs with the associated parameter sets and configurations. - Page 31 DigiConvert Operating Instructions Selecting the storage location In the default setting, the jobs are stored on the compact flash card of the B&R industry PC. Using the buttons , you can select the storage location. The other commands of the job memory are related to this storage location.
- Page 32 DigiConvert Operating Instructions Renaming a job Use the following procedure to rename a job: 1. Select the job name you want to rename from the drop-down menu. 2. Enter the new job name at "Job selection". 3. Touch the "Rename" button. 4.
- Page 33 DigiConvert Operating Instructions FMS monitoring The force measurement system is used to measure the manually set pressure of the yoke. FMS monitoring alarms or stops the machine if the measured value is outside the valid range. Current measurement Monitoring is deactivated Alarm Leaving the valid value range triggers an alarm message.
- Page 34 DigiConvert Operating Instructions Cleaning the screen Displays the cleaning screen for 60 seconds. No touchscreen entries are processed during this time. Fig.: 9 Cleaning the screen Copying this document, or disclosing it to third parties is not allowed without our approval. This document must not be used in any abusive way by the receiver or third parties.
- Page 35 DigiConvert Operating Instructions User administration Calls the User administration page When the operator logs in (see 9.3 Change of operator) the login data are sent to an external system where they are checked. If the login data are valid, the external system provides the machine with the corresponding user level that is assigned to the login data.
- Page 36 DigiConvert Operating Instructions Pages: List of all pages or menus. Selection of page or menu where the allocation of authorisations is to continue. Version: Some pages or menus are equivalent as far as their contents is concerned, but they are allocated to different modules, for example.
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Page 37: Quick Operation
DigiConvert Operating Instructions 9.6. Quick Operation Fig.: 10 Quick Operation Quick operation is on the Machine settings page. To get to this page, press the button. Copying this document, or disclosing it to third parties is not allowed without our approval. This document must not be used in any abusive way by the receiver or third parties. - Page 38 DigiConvert Operating Instructions Reeler Overview Switch motor on/off (motor status see 9.2 Machine Tension/relieve core (reeler/unreeler only: Tensioned, Relieved) Specifying the web tension setpoint Current calculated reel diameter Set current reel diameter Apply set reel diameter Punch Overview Switch motor on/off. (Motor status see 9.2 Machine Draw up sheet by keeping the Approach sheet guide edge by button depressed for 2...
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Page 39: Register Regulator Trend Diagram
DigiConvert Operating Instructions 9.7. Register Regulator Trend Diagram The length of the material web changes slightly due to thermal expansion, increased pull, etc. There are register marks on the material that are captured by the machine. This adjusts the web path newly with each article so that the punching / printing position matches the desired position exactly. - Page 40 DigiConvert Operating Instructions Here you can see the following parameters: Scale register fault Adapts the Y-axis of the diagram. Register faults Here you can see the absolute measured fault value that was currently captured by the sensors. Representation is in [mm]. In addition, the time characteristic of the register fault is shown in the trend diagram.
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Page 41: Alarms - Historical View
DigiConvert Operating Instructions – 9.8. Alarms Historical View Fig.: 12 Alarms – historical view To get to this page, press the button. There can be various faults (system, axis) during regular operation. As a result, corresponding alarm messages are generated and entered in the alarm list that is provided for this specific purpose. This alarm list shows the last 1000 alarm messages. -
Page 42: Alarms From Individual Axes
DigiConvert Operating Instructions 9.8.1. Alarms from Individual Axes Depending on the occurred fault, each servo amplifier generates corresponding error messages in text form. These messages can be shown for each individual assembly in the bottom window. Press the arrow buttons to switch over between the stations. Press the button to acknowledge the axis alarms. -
Page 43: System Diagnosis
DigiConvert Operating Instructions 9.9. System Diagnosis Fig.: 13 System diagnosis Use system diagnosis to diagnose the controller. From "Messages and alarms", you get to this page when you press the button Diagnosis possibilities For now, the following diagnosis possibilities are implemented in the System Diagnostics Manager: •... -
Page 44: General Machine Information
DigiConvert Operating Instructions 9.10. General Machine Information Fig.: 14 General machine information To get to this page, press the button. This page lists the operating times, Ethernet interfaces and analogue signals. Copying this document, or disclosing it to third parties is not allowed without our approval. This document must not be used in any abusive way by the receiver or third parties. -
Page 45: Help
DigiConvert Operating Instructions 9.11. Help Fig.: 15 Help page To get to this page, press the button. The following possibilities are available for navigating in help: Navigate to the beginning/end of the current page. Scroll up/down inside the current page. Scroll one page back/forward. -
Page 46: Error Messages And Warnings
DigiConvert Operating Instructions 10. Error Messages and Warnings The machine controller generates various error messages and warnings. They inform the operator about a malfunction or incorrect operation of the machine. Warnings appear in a yellow pop-up window. Fig.: 16 Pop-up window with warning They serve as a hint, and are closed when you acknowledge by pressing the button. -
Page 47: Operating The Assemblies
DigiConvert Operating Instructions 11. Operating the Assemblies 11.1. Reeler The unreeler is intended to create the torque at the reeling shaft that is necessary to maintain the selected web tension. The torque is calculated as a function of the specified web tension of the current diameter, and the web width of the processed material. - Page 48 DigiConvert Operating Instructions • Tensioning/relieving the reel core • Activating / deactivating the reeler • Entering the sense of rotation • Taking over the diameter • Web width in [mm] • Web tension in [N m] Tensioning/relieving the reel core Touch the reel core icon in the main menu to tension / relieve the reel.
- Page 49 DigiConvert Operating Instructions Specifying the web tension This specification depends on the reeler type. This entry is in N/m percent if the reeler is operated as a torque-controlled shaft. Touching the orange box opens a numerical input box where you can enter the value directly as a number.
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Page 50: Reeler Submenu Reeler
DigiConvert Operating Instructions 11.1.2. Reeler Submenu Reeler Press the button to display the reeler submenu. The button can be found in the top line of the main menu. Fig.: 19 Reeler submenu Copying this document, or disclosing it to third parties is not allowed without our approval. This document must not be used in any abusive way by the receiver or third parties. - Page 51 DigiConvert Operating Instructions The submenu is subdivided into the following sections: Settings Help text Parameters Accept / discard entries In the settings section, the operator has the following possibilities: 1. Diameter stop 2. Start diameter 3. Core reel 4. Web break detection 5.
- Page 52 DigiConvert Operating Instructions 1. Settings: Diameter stop Activating diameter stop The following settings are possible: "OFF", "Machine stop only", "Warning and machine stop". Depending on the selection, the parameters below are activated / deactivated. Early warning at A message is displayed on the monitor when the diameter reaches the value selected here. The message disappears after acknowledgement.
- Page 53 DigiConvert Operating Instructions 5. Setting: Standby Standby reduction This avoids an unnecessary temperature rise in the servo drives. Expedient for material that must not be stretched for a long time. The following parameters are released when activated. After time in PREP Web tension is reduced after this time has elapsed in PREP mode.
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Page 54: Configuration Menu
DigiConvert Operating Instructions 11.1.3. Configuration Menu Press the button to display the reeler submenu. The button can be found in the top line of the main menu A user with tool setter rights must be activated for this. The submenu is subdivided into the following sections: Category Help text Settings... - Page 55 DigiConvert Operating Instructions Category: Startup Here, the operator has the following settings available: 1. Material density 2. Optionality 1. Setting: Material density Density of the web material The setting "Density of the web material" describes the specific weight of the material reeler. It is expedient to set this value as accurately as possible, so that acceleration and braking forces can be calculated accurately.
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Page 56: Longitudinal Cutter, Translative Pull And Matrix Removal
DigiConvert Operating Instructions 11.2. Longitudinal Cutter, Translative Pull and Matrix Removal 11.2.1. Main Menu Touch the screen in the area of the displayed icon in the machine overview to get to the main menu. Fig.: 20 Longitudinal cutter Here, the operator has the following possibilities: •... - Page 57 DigiConvert Operating Instructions Actuating the pulling cylinder Press the left-hand button to operate the pulling cylinder. The green background shows that the pulling cylinder is actuated. (The right-hand cylinder is only available in translative pull). Activating / deactivating the drive Press the button to deactivate the drive.
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Page 58: Menu Smo Longitudinal Cutter
DigiConvert Operating Instructions 11.2.2. Menu SMO longitudinal cutter For the SMO longitudinal cutter, an extended menu is displayed in addition to the main menu. Fig.: 21 Menu SMO longitudinal cutter This menu is used for the remote control of order settings and functions of the longitudinal cutter. Further information and instructions on how to set it up can be referenced in the original operating instructions of the longitudinal cutter. - Page 59 DigiConvert Operating Instructions Web width Here you can set the web width of the material. Current web Input of web width. width Take over the value you have entered by pressing the button "Take over job data". Track width Here you can enter the width of the track to be cut. That means, this distance is set between the two knives.
- Page 60 DigiConvert Operating Instructions Open / close brake The brakes are opened/closed by pressing the button. The brakes prevent the knives from shifting sideways. Lift / lower knives The knives are lifted/lowered by pressing the button. Open / close clamping The clamping of the driven cylinder of the longitudinal cutters is opened/closed by pressing the button.
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Page 61: Punching Station
DigiConvert Operating Instructions 11.3. Punching station The punching stations are used to punch the material as required. The punching station consists of two or more cylinders that are pressed together. The gearbox converts the motor revolutions into the slow revolutions of the cylinder axis, and permits exact position control. -
Page 62: Main Menu
DigiConvert Operating Instructions 11.3.2. Main Menu Touch the icon on the monitor in the machine overview to open a pop-up window in the right-hand screen section. Fig.: 22 Punching station Here, the operator has the following possibilities: • Activating / deactivating the assembly •... - Page 63 DigiConvert Operating Instructions Activating / deactivating the drive Press the button to deactivate the drive. Press the button again to reactivate the drive. Applying the sheet The operator must open the punch beforehand for this. By pressing and holding the button for at least 2 seconds lets the punch approach the position to apply the sheet.
- Page 64 DigiConvert Operating Instructions Starting the translative synchronous mode switches on the electrical shaft between the punch and the translative module. This is only necessary after the translative module has been selected. This action is only possible in PREP mode. Pressing and holding the button for at least 2 seconds executes the action.
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Page 65: Punch Submenu
DigiConvert Operating Instructions 11.3.3. Punch Submenu Press the button to display the submenu. Fig.: 23 Punch submenu Punch mode: Press the button to select punch mode. You can select "Translative" (partial occupation of the magnetic cylinder with a punching sheet) or "Window repeat length"... - Page 66 DigiConvert Operating Instructions 1. Number of teeth of the tool cylinder: Enter the number of teeth of the punch tool cylinder here. Enter the new number of teeth here when you install another tool. The resulting punching cylinder circumference is shown in mm for information. 2.
- Page 67 DigiConvert Operating Instructions Register regulator Press the button to switch the register regulator ON / OFF. The register regulator should be switched on if you process preprinted material. Switch off the register regulator if a preprint does not exist. There are additional possibilities with the "With register regulator" setting: •...
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Page 68: Translative Compensation
DigiConvert Operating Instructions 11.4. Translative compensation 11.4.1. Main Menu Touch the screen in the area of the displayed icon in the machine overview to get to the main menu. Fig.: 24 Translative compensation Translative compensation is usually operated from the punch. Alternatively, you can control it separately from this menu. - Page 69 DigiConvert Operating Instructions Here, the operator has the following possibilities: • Activating / deactivating the assembly • Switching on the electrical shaft between the punch and the translative module • Entering the lead in [%], when regulation is at lead. Activating / deactivating the drive Press the button to deactivate the drive.
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Page 70: Web Storage
DigiConvert Operating Instructions 11.5. Web Storage 11.5.1. Main Menu Touch the screen in the area of the displayed icon in the machine overview to get to the main menu. Fig.: 25 Web Storage Here, the operator has the following possibilities: •... - Page 71 DigiConvert Operating Instructions Current fill level Here, the current fill level is displayed in percent. Clamping Activates/deactivates the clamping of the carriage with the weights. Weights Here you can set the number of desired weights. The loaded weights are detected by the sensors.
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Page 72: Label Delivery
DigiConvert Operating Instructions 11.6. Label Delivery 11.6.1. Main Menu Touch the screen in the area of the displayed icon in the machine overview to get to the main menu. Fig.: 26 Label Delivery Here, the operator has the following possibilities: •... - Page 73 DigiConvert Operating Instructions Delivery web tension Here you can select the web tension for delivery. Number of deliveries before/after faulty label Here you can set how many labels are to be delivered before/after the actual faulty label. Starting extraction Starts the extraction process; this means the current label that is still located at the sensor position is earmarked for the extraction process.
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Page 74: Counting Functions Main Menu
DigiConvert Operating Instructions 11.7. Counting Functions Main Menu Touch one of the boxes to open the pop-up window for the counter functions. Fig.: 27 Counting function Copying this document, or disclosing it to third parties is not allowed without our approval. This document must not be used in any abusive way by the receiver or third parties. - Page 75 DigiConvert Operating Instructions Here, the operator has the following possibilities: • Activating / deactivating counter functions • Selecting the count station • Specifying item length in web run direction • Number of items across the web • Items per line •...
- Page 76 DigiConvert Operating Instructions Stop after production quantity If you want the machine to stop after a given number of metres or items has been reached, enter the corresponding value here. Entering 0 deactivates the function. The two other parameters are calculated automatically when you enter a value.
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Page 77: Maintenance Instructions
DigiConvert Operating Instructions 12. Maintenance Instructions Clean the filter mats of the main control cabinet weekly. Replace them if necessary. Replace the batteries of the B&R at the PC when a corresponding message appears in the alarm list. Recommendation: Replace the batteries every 3 years. Please refer to the instructions below in accordance with the PLC type used in the machine. - Page 78 DigiConvert Operating Instructions Type: Industry PC Fig.: 29 Replacing batteries in the industry PC Copying this document, or disclosing it to third parties is not allowed without our approval. This document must not be used in any abusive way by the receiver or third parties.
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Page 79: Figures
DigiConvert Operating Instructions 13. Figures Fig.: 1 Machine overview ........................4 Fig.: 2 Components of the Electrical Drive System ................8 Fig.: 3 Main Operator Terminal ......................9 Fig.: 4 Machine status definition ......................15 Fig.: 5 Welcome screen ........................18 Fig.: 6 Machine overview ........................
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