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Valiani OMNIA Instruction And Maintenance Manual

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OMNIA
Instruction and Maintenance
Manual

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  • Page 1 OMNIA Instruction and Maintenance Manual...

  • Page 3: Table Of Contents

    OMNIA SUMMARY PREFACE ................................1 TO ENSURE PROPER AND SAFE USE ........................1 CONVENTIONS USE IN THIS MANUAL ......................... 1 SAFETY PRECAUTIONS (NOTE) ..........................1 SAFETY PRECAUTIONS (DANGER) ........................2 SAFETY PRECAUTIONS (CAUTION) ........................3 CEE REGULATION ..............................3 NOTE ABOUT THIS MANUAL ..........................4 SCOPE OF THE INSTRUCTION MANUAL .......................
  • Page 4 OMNIA 5.7.4 Pneumatic connection ..........................30 5.7.5 Data connection ............................30 5.7.6 Connecting operator safety mats ......................31 CONTROLS DESCRIPTIONS AND PREPARATION FOR USE ..................33 EMERGENCY BUTTONS ............................. 33 POWER ON SWITCH ............................34 STARTING THE VACUUM PUMP AND SELECTING THE SUCTION ZONES ............34 LOADER CONTROLS ............................

  • Page 5: Preface

    OMNIA PREFACE Thank you for choosing Omnia. The Omnia has been designed for automatic feeding of the material to be processed and to carry out cutting and creasing for packaging boxes. Brushless motors and continuous cycle processing make it the most effective solution for medium and large runs.

  • Page 6: Safety Precautions (Danger)

    After confirming that smoke is no longer being emitted, contact your sales representative or nearest Valiani vendor for repairs. Never attempt to perform repairs yourself. Repair work by inexperienced personnel is extremely dangerous.

  • Page 7: Safety Precautions (Caution)

    OMNIA SAFETY PRECAUTIONS (CAUTION) Caution Do not use or store the machine in a location exposed to direct sunlight or the direct draft of an air conditioner or heater. Such locations may impair the performance of the cutting plotter. Do not use the machine in an excessively dusty or humid location. Such locations may impair the performance of the cutting plotter.

  • Page 8: Note About This Manual

    The instructions, drawings, images and documents contained in this manual are of a technical nature and confidential property of the Valiani. They cannot be reproduced in any way, either entirely or in part, without prior written permission from the company.

  • Page 9: Warranty Conditions

    OMNIA 1.10 WARRANTY CONDITIONS Valiani guarantees that it’s products are soundly made and are free of manufacturing defects. For guarantee details please refer to the specific guarantee document supplied with this manual. 1.11 GENERAL INFORMATION Carefully following the assembly, usage and maintenance standards described in this manual will ensure lasting performance and protect your investment.

  • Page 10: Warnings

    OMNIA WARNINGS LABELS PRESENT ON THE MACHINE The machine is fitted with various labels to show either data or safety concern areas for the operator. Referring to the photograph below these are: Figure 2-1...

  • Page 11: Details Of The Various Labels

    OMNIA DETAILS OF THE VARIOUS LABELS Figure 2-2 LABEL 1: Plate showing manufacturer data, model, year, serial number, weight, electrical and pneumatic information of the machine. LABEL 2: Adhesive label: Hand Entanglement / Rotating Gears warning LABEL 3: Adhesive label: Rotating gears warning.

  • Page 12: Safety Equipment Fitted To The Machine

    OMNIA SAFETY EQUIPMENT FITTED TO THE MACHINE The machine is equipped with various safety devices and an emergecy stop button, to the drivetrain, that protects the operator from possible injury resulting from contact with moving parts. Two types of safety protection are provided:...

  • Page 13: Operator Safety Measures

    OMNIA OPERATOR SAFETY MEASURES According to the type of work conducted with the machine some maintenance work will require the operator to wear gloves and safety glasses. While servicing the machine, it is recommended to use personal protective equipment: •...

  • Page 14: Introduction

    MACHINE DESCRIPTION The Omnia consists of a loader, the machine that performs the processing and an unloader to be assembled on site for easier transportation (see paragraph 5). The depth of the cutting blade can be easily adjusted by turning the knob on the head.

  • Page 15: Cutting Tools

    (25° Angle) Note: For any special need, other blades might be available. Please contact your local Valiani dealer, or the manufacturer for further information. Black - Oscillating Cutting Knife...

  • Page 16: Pen Plotting Tool (Optional)

    Soft rubbers up to 12 mm thick. 002733 T21 Blade – Double Edge HD Blade Note: For any special need, other blades might be available. Please contact your local Valiani dealer, or the manufacturer for further information. PEN PLOTTING TOOL (OPTIONAL) Gold - T-Mark Tool: T-Mark is a tool that allows writing or drawing on the material, creating dynamic drawing or text on the cardboard patterns.

  • Page 17: Creasing Tool (Optional)

    OMNIA CREASING TOOL (OPTIONAL) Brown – T-Creasing Tool: The Packaging Tools set, consists of one head (Tool holder) with an assortment of creasing wheels of various geometry, which have been designed to process a wide range of materials, for those who need to crease folding cardboard, flute board, corrugated board and coroplast.

  • Page 18: Interchangeable Cutting Heads (Optional)

    C - 90° head (grey) for straight cut: This cutting head has been specifically designed for the vacuum table series of machines and benefits from Valiani’s vast experience in the CMC machinery market. Thanks to a wide Teflon foot it guarantees a wider cutting footprint and superior accuracy, especially on thick and hard materials (max 5mm –...

  • Page 19: Technical Data

    H – Fork The fork is the tool used to manually change the cutting heads and is always supplied with VersaTool. TECHNICAL DATA MODEL Omnia 80 Omnia 80 DUO Omnia 100 800x750mm 800x600mm 1050x750 Max cutting area (31.5” x 29.52”) (31.5”...

  • Page 20: Improper Use Of The Machine

    IMPROPER USE OF THE MACHINE Omnia is not suitable for operation in potentially explosive atmospheres (ATEX) Omnia cannot be used for processing materials other than those indicated in paragraph 3.9. In particular, materials such as: •...

  • Page 21: Transporting Or Moving A Packed Machine

    Figure 4-1 Check that the machine has not been damaged while being transported. If there are signs of damage inform the shipping company and Valiani s.r.l. immediately and, if possible, take photographs of the damaged packaging. DANGER! Do not attempt to unload or move the machine carton manually.

  • Page 22: Storing A Packed Machine

    Should there be any damaged or missing parts, please notify both the forwarding company that made the delivery and Valiani immediately Note: Depending on the shipping methods, some of the operations listed below may not be Figure 5-1 necessary or may differ slightly.

  • Page 23: Installation Area And Operator Zone

    OMNIA INSTALLATION AREA AND OPERATOR ZONE While choosing the area to be used for the installation of the machine, it will be necessary to consider the overall dimensions of the machine (see paragraph 14), the positioning of the various accessories for its use and the...

  • Page 24: Machine Assembly

    OMNIA MACHINE ASSEMBLY Proceed according to the numbering below for the unloading and assembly of the machine. Nr.4 Screws Nr.4 Screws Nr.4 Adjustable feet Figure 5-3 DANGER! Make sure that the forklift used can carry the weight of the machine and that the forks...
  • Page 25 OMNIA Depending on the shipping method, it may be necessary to reposition the PC arm perpendicular to the base, then proceed as follows • Disassemble the shipping bracket by unscrewing the 8 screws pointed in the figure, paying attention to not pull the electrical cables.
  • Page 26 OMNIA Once the arm has been repositioned in the working position, remove the blocks of the beam and the head as described below: Insert the 16 mm open key supplied in the groove of the locking pin (1) to keep it still, at the same time use the 19 mm open key supplied to unscrew the locking screw (2).

  • Page 27: Loader Assembly

    OMNIA LOADER ASSEMBLY Proceed according to the numbering below for the unloading and assembly of the loader. Nr.4 Screws Nr.4 Adjustable feet Nr.4 Screws Nr.4 Viti Figure 5-10 DANGER! Make sure that the forklift used is able to carry the weight of the machine and that the...

  • Page 28: Trolley Assembly

    OMNIA TROLLEY ASSEMBLY • Please refer to assembly sheet attached. PARTS ASSEMBLY Proceed as described below for the coupling of the machine and the loader. • Position the machine in the designated location taking into account, in addition to the overall dimensions of the machine, the loader, the unloader and the unloading trolley, also any spaces for maintenance (see par.
  • Page 29 OMNIA Figure 5-14 • Remove the protective covers from the loader by unscrewing the locking screws. Figure 5-15...
  • Page 30 OMNIA • Guide the loader to the machine, taking care to align it with the marks on the back of the machine. The marks  and  drawn on the back of the machine must match the outline of the loader.
  • Page 31 OMNIA Figure 5-19 • Insert the slide between the two anchoring brackets and mount it with the relative screws, washers, nuts (do not over tighten the nuts, the slide must be able to rotate freely). • Screw the two knobs with washers on the sides of the slide by passing them inside the slots on the anchoring brackets.

  • Page 32: Electro/Pneumatic And Data Connections

    OMNIA Depending on the material to be processed and its size, it may be appropriate to add an extension to the discharge chute. Two extensions are supplied with the machine, you just need to insert them in front of the chute and lock them with the relative knobs and washers.

  • Page 33: Electrical Connection

    OMNIA • Connect the loader connector to the machine panel and close the locking tabs. Figure 5-23 • Close the machine panel and the loader panels removed previously (Figure 5-22 and Figure 5-15). 5.7.2 ELECTRICAL CONNECTION Attention: it is mandatory that the electrical system, to which the machine is connected, is equipped with a differential switch.

  • Page 34: Pneumatic Connection

    OMNIA 5.7.4 PNEUMATIC CONNECTION Attention: it is mandatory that the pneumatic system, to which the machine is connected, is equipped with a tap for the air valve and a drain for the pneumatic circuit. The pressure regulator (1) is mounted on the left side of the machine.

  • Page 35: Connecting Operator Safety Mats

    Arrange the safety mats on both sides of the machine with the cables exiting towards the machine, as shown in the diagram: Figure 5-28 Model 350mm Omnia 80 13.78” 3615mm 810mm 200mm 3280mm 230mm Omnia 80 DUO 142.32” 31.89” 7.87” 129.13” 9.05” Omnia 100 0”...
  • Page 36 OMNIA Once the safety mats have been positioned, fix them on the floor with plugs or similar and proceed as follows: • Remove the machine panel (Figure 5-22) Figure 5-29 • Pass the connection cables under the machine until they enter the base through the appropriate opening.

  • Page 37: Controls Descriptions And Preparation For Use

    OMNIA CONTROLS DESCRIPTIONS AND PREPARATION FOR USE All commands relating to the machine's work cycle come from the computer. However, there are some commands that must be given directly from the machine and these are: • Emergency buttons. • Power on switch •...

  • Page 38: Power On Switch

    Figure 6-2 The two valves (2,3) Figure 6-2, if open, will ensure that when the software activates suction it is extended to the corresponding sectors of the table Figure 6-3. Omnia 80 Omnia 100 Figure 6-3 Note: Switching on the pump does not directly produce suction on the surface as this is controlled via software.

  • Page 39: Material Pick-Up Roller

    OMNIA MATERIAL PICK-UP ROLLER The presser located on the top of the loader allows slightly deformed materials to be crushed so as not to cause false readings to the “sheet ready” photocell. Based on the thickness and stiffness of the materials, it can be adjusted in order to have a fair compromise between the pressure on the material and the intervention height.

  • Page 40: Preparing For Use

    OMNIA The light tower is equipped with a telescopic arm that allows it to be lengthened: To change the height of the turret, loosen the ring nut while holding the upper part of the turret. Pull the upper part up to the desired height, then re-lock by tightening the ring nut.

  • Page 41: Positioning The Material On The Loader Table

    OMNIA 6.7.1 POSITIONING THE MATERIAL ON THE LOADER TABLE Two loading/processing modes are available; the first foresee to have all materials stacked on top of each other, the second to have the same material/job loaded on two stacks side by side.
  • Page 42 OMNIA 6.7.1.2 MATERIAL POSITIONING FOR DUAL SHEETS MODE Note: The side of the sheets facing the front of the feeder can be min 200mm (7.87 ") wide and max 340mm (13.38") wide. Note: in order to have the machine working at its best we recommend to have the two stacks of the same height (materila quantity).

  • Page 43: Switching On The Vacuum Pump

    OMNIA While positioning material attention to: 0 (zero) Point nr.2 - the side with a width between 200 and 340 mm, touches the front of the feeder. - the left side touches the reference plate (Point 0 nr. 2). Figure 6-13 Place a movable stop on the right and back side to keep material aligned.

  • Page 44: Tangential Tool Preparation

    OMNIA 6.7.3 TANGENTIAL TOOL PREPARATION DANGER: Use protective gloves is strongly recommended, be very careful as the pressure of the moving part (2) could cause the blade exit. To mount or replace the blade holder, proceed as follows: Note: Depending on the blades being used for the desired processes, the relative dedicated blade holder must be mounted (blade holder for L100 / L1W blades or blade holder for flat blades T16 / 17).

  • Page 45: Oscillating Cutting Tool Preperation (Optional)

    OMNIA 6.7.4 OSCILLATING CUTTING TOOL PREPERATION (OPTIONAL) DANGER: Use protective gloves is strongly recommended, be very careful as the pressure of the moving part (2) could cause the blade exit. TC5/10/15 TC25 TC5/10/15 TC25 Figure 6-16 • Loosen the locking set screws (1) and remove the movable blade guard (2).

  • Page 46: Type Oscillating Tool Preparation (Optional)

    OMNIA 6.7.5 X TYPE OSCILLATING TOOL PREPARATION (OPTIONAL) DANGER: Use protective gloves is strongly recommended, be very careful as the pressure of the moving part (2) could cause the blade exit. Figure 6-17 Remove the blade guard (1) by pulling it outwards.

  • Page 47: Preparing The Creasing Tool

    OMNIA 6.7.7 PREPARING THE CREASING TOOL Figure 6-19 Insert one of the nine creasing wheels available (2) as shown in the diagram above until the magnet (3) at the base of the tool holds to the creaser. 6.7.8 FITTING A CUTTING BLADE VERSATOOL (OPTIONAL)

  • Page 48: Repalcying The Foot/Roller On White Head - Versa Tool (Optional)

    OMNIA • Insert the blade holder (1) into the cutting head and tighten the set screw (2). • Reassemble the head (see chapter 6.7.12). Figure 6-22 6.7.9 REPALCYING THE FOOT/ROLLER ON WHITE HEAD - VERSA TOOL (OPTIONAL) Warning! Handle the blade carefully, protect it, if necessary, to avoid cutting. During reassembly use a rubber object to keep it in its housing during tightening of the locking screw.

  • Page 49: 6.7.10 Head Access

    OMNIA 6.7.10 HEAD ACCESS To access the heads to change the cutting tools or to adjust the working height, simply pull the protection upwards until it flips over the sheet metal casing. A magnet will secure it in the open position.
  • Page 50 OMNIA Figure 6-27 Once the screws are loosened insert tools in the appropriate slots (1 or 2) making sure it has reached the correct position, as shown in the diagram below. Note: The pin “Y1” must coincide with the slot “Y2”.

  • Page 51: 6.7.12 Assembling The Versatool Head

    OMNIA Attention: The VersaTool assembly must be completed by reinserting the magnet support (Y) and tightening the screw (X). Figure 6-29 6.7.12 ASSEMBLING THE VERSATOOL HEAD When mounting a head (W) on the VersaTool, insert it under magnet holder and when it adheres to the flange, tighten the screw (Z) (Figure 6-29).

  • Page 52: Adjustments

    OMNIA ADJUSTMENTS To ensure a perfect result it may be necessary to perform some manual adjustments, such as: ADJUSTING CUTTING AND CREASING DEPTH To cut, it is essential that the cutting blade depth slightly exceeds the thickness of the material being cut. To obtain this condition it is necessary to carry out the following operations: Loosen the knob (1), turn the head register (2) anticlockwise (to increase), or clockwise (to decrease) the blade cutting depth.

  • Page 53: Adjusting The Down Pressure Of The Cutting Head

    OMNIA ADJUSTING THE DOWN PRESSURE OF THE CUTTING HEAD To cut special hard materials, or to avoid the wheel on the cutting head leaves a mark on soft materials, it may be necessary to adjust the pressure of the air in the cylinder controlling the head down pressure. Adjustment can be made as follows: Remove the protection glass by unscrewing the four locking screws (A).

  • Page 54: Routine Maintenance

    OMNIA ROUTINE MAINTENANCE Very little maintenance is required, and it is limited to the operations detailed in the following paragraphs. CAUTION! Please disconnect the machine from the electrical mains supply, before carrying out any maintenance operations CLEANING One of the most important maintenance tasks is the frequent and complete cleaning of the following parts: Worktable (daily) •...

  • Page 55: Lubrification

    OMNIA LUBRIFICATION Cutting blade running guide (every 1 - 2 months for all VersaTool cutting heads type) Remove the blade as previously described. Lubricate the guide at points (1) and (2) with a small amount of spray grease taking particular care not to allow any grease to reach the rubber roller.

  • Page 56: Pneumatic System Maintenance (Every 1-2 Months )

    OMNIA PNEUMATIC SYSTEM MAINTENANCE (EVERY 1 -2 MONTHS) Make sure the tanks (A)(C) of the air treatment unit located at the entry to the pneumatic circuit of the machine do not contain any water generated by the compressor and if so empty the tank releasing the valve (B). Check the oil level as well and if necessary re-fill it following the below steps;...

  • Page 57: Replacing The Conveyor Belt

    OMNIA REPLACING THE CONVEYOR BELT If it is necessary to replace the conveyor belt, proceed as follows for its replacement. Make sure that the machine is turned off and disconnected from the mains power supply. • Dismantle the two protection strips by removing the relative fixing screws (Figure 5-12 and Figure 5-13) •...
  • Page 58 OMNIA Note: To be able to reposition the pull roller in the same position, make a mark (4) on the plate (if not already present) as shown in figure 8-5. Loosen the 4 locking bolts (1), then loosen the lock nut (2) and then the adjustment screw (3) until the head rests on the surface (Pay attention to the sensor cable).
  • Page 59 OMNIA • Extract the coupling pin to open the drive belt. Figure 8-7 • Place the new conveyor belt on top of the table, making sure that the guides below match up. • Insert the coupling pin in order to connect the old carpet with the new one.

  • Page 60: Trouble Shooting

    TROUBLE SHOOTING This section relates to possible problems that could occur during normal use of the machine. For any problems not covered in this manual please contact your sales representative, your nearest Valiani dealer or the Valiani technical support. CONNECTION PROBLEMS The Ethernet connection error message reports when the V-Studio software is not capable of linking with the machine.

  • Page 61: 10 Decommissioning And Dismantling

    OMNIA 10 DECOMMISSIONING AND DISMANTLING When dismantling or disposing of the machine it should always be noted that: • The client, under 91/689/EEC directives, or byelaws in force in the relevant country, is responsible for the disposal of the machine and its components.

  • Page 62: 12 Warranty

    OUT OF WARRANTY REPAIRS must be accompanied by the duly completed repair form in each of its fields. This In the event of Valiani being requested to perform a repair of the Product at any form is attached to each machine manual.

  • Page 63: Eu - Declaration Of Conformity

    Via delle Regioni, 305-307 – 50052 Certaldo [FI] - ITALIA Tel. (+39) 0571 666 598 www. valiani.com – email: info@valiani.it Declares under our sole responsibility that the machine OMNIA has been made in compliance with the following directives: • EU Machinery Directive 2006/42/CE of the European Council concerning the approximation of the laws of the Member States relating to machinery;...

  • Page 64: 14 External Dimension

    2630mm 2435mm 2210mm Omnia 80 151” 118.7” 103.54” 95.86” 87” 4085mm 3265mm 2880mm 2685mm 2460mm 200mm 1320mm 955mm 1245mm Omnia 80 Duo 160.82” 128.54” 113.38” 105.7” 96.85” 7.87” 51.97” 37.6” 213.4” 4370mm 3515mm 3130mm 2935mm 2710mm Omnia 100 172” 138.4”...
  • Page 66 002695 – rev.02...

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