Summary of Contents for Man COLORMAN
- Page 1 Operating Manual Folder superstructure COLORMAN Operating Manual – Folder superstructure – COLORMAN...
- Page 2 MAN Roland Druckmaschinen AG. These drawings/documents may not be used, reprinted or reproduced without the permission of MAN Roland. Any misuse will result in prosecution and give rise to a claim for damages. Operating Manual – Folder superstructure – COLORMAN...
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Page 3: Table Of Contents
7.1.5.9 Manual lint extractor....................37 7.1.5.10 General note ......................37 Protective equipment........................38 Static mounted protective equipment ....................39 Feed rollers and trolleys........................40 Slitter unit ............................41 Timing belt drive ..........................42 Operating Manual – Folder superstructure – COLORMAN... - Page 4 12.2 Blown air ............................. 53 13 Drive ............................. 54 13.1 Feed rollers and slitter unit ........................54 14 Operating levels .......................... 55 14.1 Folder superstructure .......................... 55 Appendix A Protective equipment for the folder superstructure (C16.65500-1947)57 Operating Manual – Folder superstructure – COLORMAN...
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Page 5: Overview
Spare Parts Catalogues. The manuals contain cross references which show the correlation between individual documents. Operating Manual Maintenance Manual Repair and settings instructions Spare Parts Catalogue 01-051231-0000 Fig. 1 Overview of technical documentation Operating Manual – Folder superstructure – COLORMAN... -
Page 6: Notes About This Operating Manual
WAF = Width Across Flats = Folding unit = Folder = Printing unit = Printing couple EDE = Colour deck = Reel splicer = Turner bar unit = Folder superstructure Tab 1 Abbreviations for press components Operating Manual – Folder superstructure – COLORMAN... -
Page 7: Ambient Temperature
Undercooled oil is too viscous, as a result of which the bearings will not be supplied with sufficient oil. Operating Manual – Folder superstructure – COLORMAN... -
Page 8: Important For Your Safety
• Do not wear loose clothing as it may be caught by movable parts. • Wear a hairnet for long hair. • Wear safety boots and hard hats. • Wear a hearing protector. Operating Manual – Folder superstructure – COLORMAN... - Page 9 Safe STOP is actuated immediately. As soon as the press comes to a standstill, all the electrical equipment is disconnected. If the deceleration time is too long, inform our customer service immediately. Operating Manual – Folder superstructure – COLORMAN...
- Page 10 All necessary disconnection procedures must be complied with when carrying out any work involving the above-mentioned systems. Switch off the system with the mains switch. Lock the mains switch. Operating Manual – Folder superstructure – COLORMAN...
- Page 11 • Avoid the risk of slippage. • Parts soiled by grease and oil have to be cleaned immediately. • Platforms, stairways and passages have to be kept free and unobstructed. Operating Manual – Folder superstructure – COLORMAN...
- Page 12 • Change oil-soaked clothes soon. Do not put oily rags into pockets. • Avoid breathing of oil mist and vapour as far as possible. Operating Manual – Folder superstructure – COLORMAN...
- Page 13 Adjust nip guards correctly, otherwise fingers may be seized in the nip - risk of bruising. Remove any tools or other loose parts such as bolts, nuts or cleaning rags from press area. Operating Manual – Folder superstructure – COLORMAN...
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Page 14: Lock Out / Tag Out Insctructions
„LOCK OUT / TAG OUT“ points of the press in this section of the manual, enabling him to implement a quick and effective „LOCK OUT / TAG OUT“ procedure. Continued overleaf. Operating Manual – Folder superstructure – COLORMAN... -
Page 15: Electrical Lock Out
Fig. 2 Example: control cabinet on printing unit Switchbox supply line for socket, lighting, supply for computer Switchbox supply line up to main switch (LOCK OUT) Supply line to switchbox Printing press switching unit Operating Manual – Folder superstructure – COLORMAN... - Page 16 - folding superstructure CAUTION In addition to switching off the main switch (LOCK OUT), also implement a „TAG OUT“ procedure! See overleaf for pneumatic „LOCK OUT“ procedure. 02-060403-1325 Fig. 4 Example “TAG OUT” Operating Manual – Folder superstructure – COLORMAN...
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Page 17: Pneumatic Lock Out
A „TAG OUT“ must also be attached! See overleaf for the individual LOCK OUT / TAG OUT points for the individual components. 02-060403-1330 Fig. 6 Fluid supply line stop valve Stop valve Operating Manual – Folder superstructure – COLORMAN... -
Page 18: Lock Out On The Printing Unit
Pneumatic LOCK OUT Fig. 184,2 184,2 184,2 184,2 232,5 232,5 232,5 184,2 232,5 184,2 184,2 184,2 02-060403-1130 Fig. 7 LOCK OUT at a printing unit Shut-off valve, side I outside Main switch, switchbox side II Operating Manual – Folder superstructure – COLORMAN... -
Page 19: Lock Out On A Turner-Bar Unit
The shut-off valve vents automatically. Symbol explanation: Electrical LOCK OUT (switchbox, side II) Fig. Pneumatic LOCK OUT (reel changer level, side II) Fig. LO_WE_4070605 Fig. 8 LOCK OUT on a turner bar unit Operating Manual – Folder superstructure – COLORMAN... -
Page 20: Lock Out On A Folder Superstructure
The shut-off valve vents automatically Symbol explanation: Electrical LOCK OUT (switchbox, side I) Fig. Pneumatic LOCK OUT (switchbox, side I) Fig. LO_FA_4070605 Fig. 9 LOCK OUT on a folder superstructure Operating Manual – Folder superstructure – COLORMAN... -
Page 21: Lock Out On A Webbing-Upp Device
The shut-off valve vents automatically. Symbol explanation: Pneumatic LOCK OUT (reel changer level, side II) Fig. LO_EZV_4070605 Fig. 10 Webbing-up device LOCK OUT [1] Section Operating Manual – Folder superstructure – COLORMAN... -
Page 22: Lock Out On A Folder
The shut-off valve vents automatically. Symbol explanation: 13-061010-1220 Electrical LOCK OUT Fig. Pneumatic LOCK OUT Fig. 11 LOCK OUT at a folder Fig. Electrics cabinet, side I Valve plate, pneumatics cabinet, side II outside Operating Manual – Folder superstructure – COLORMAN... -
Page 23: Lock Out On Al Reel Stand Lock Out On A Infeed Unit
Electrical LOCK OUT Fig. 13-060518-1020 Pneumatic LOCK OUT Fig. 12 LOCK OUT at a reel splicer or infeed unit Fig. Electrical LOCK OUT: main switch S II Pneumatic LOCK OUT: S II Dancing roller 13-060518-0935 Operating Manual – Folder superstructure – COLORMAN... -
Page 24: What To Do In The Event Of An Accident
Propping elements (timbers, trestles, etc.) for the reel splicer • Special tools • Clasp knife • Cutting tool • Friction saw • Cable drum • Inspection lamp • Torch • Key for the tool cabinet Operating Manual – Folder superstructure – COLORMAN... -
Page 25: Overview Of The Press
5 Overview of the press Overview of the press Fig. 13 Overview of the press 01-061107-1625 Main compressed-air line Maintenance unit for the main compressed-air line Operating Manual – Folder superstructure – COLORMAN... -
Page 26: Folder Superstructure
FA 06 FA 07 FE 06 FE 07 01-061107-1630 Fig. 14 Overview of folder superstructure Cut-off compensator adjustment Cut-off compensator adjustment Trolley Slitter unit Paper lint extraction unit Drive motor/feed roller Former Blown-air system Operating Manual – Folder superstructure – COLORMAN... -
Page 27: Specifications
Noise emission levels in the workplace (obtained using secondary measures) £ Reel splicer 83 dB (A) £ Operating console 83 dB (A) £ Folder delivery mechanism 83 dB (A) £ Printing unit 83 dB (A) Operating Manual – Folder superstructure – COLORMAN... -
Page 28: Control Panels
BT22, 23, 28, 30, 31 32, 33, 42, 43, 48, 50 EBENE 3 BT27, 47 EBENE 2 BT26, 46 EBENE 1 BT20, 40 01-060816-1300 Fig. 15 Folder superstructure control panels (FA 01, FA 02) Operating Manual – Folder superstructure – COLORMAN... -
Page 29: Control Panels Bt91, Bt93, Emergency Stop
The pushbuttons are arranged to make them easy to access. Ensure that the nearest “Emergency STOP” pushbutton is always accessible while the press is in operation. 14-060418-0930 Fig. 16 Control panels BT91, BT93 Emergency STOP Operating Manual – Folder superstructure – COLORMAN... -
Page 30: Control Panels Bt22, Bt23, Bt28, Bt30, Bt31, Bt32, Bt33, Bt42, Bt48, Bt50
“Safe STOP” is not activated, Danger for the operator. BTXX 01-060712-1545 Fig. 17 Control panels BT22, BT23, BT28, BT30, BT31, BT32, BT33, BT42, BT43, BT48, BT50 “Safe STOP” indicator lamps Safe STOP Inch forward Crawl Operating Manual – Folder superstructure – COLORMAN... -
Page 31: Control Panels Bt27, Bt47
7 Control panels 7.1.3 Control panels BT27, BT47 BTXX 01-060712-1550 Fig. 18 Control panels BT27, BT47 Webbing up Web pulling Web changing Chain return Operating Manual – Folder superstructure – COLORMAN... -
Page 32: Control Panels Bt26, Bt46
7 Control panels 7.1.4 Control panels BT26, BT46 BTXX 01-060712-1553 Fig. 19 Control panels BT26, BT46 Manual lint extractor Operating Manual – Folder superstructure – COLORMAN... -
Page 33: Control Panels Bt20, Bt40
[9] Parallel turner bars [4] Nipping section [10] Trolleys [5] Web tension [11] Slitter discs, skip slitters [6] Reel sidelay [12] Increase display value/Select function [13] Decrease display value/Cancel function [14] Function selected Operating Manual – Folder superstructure – COLORMAN... -
Page 34: Slitter Discs And Skip Slitters
Fig. 22 Example of the TROLLEY For adjustment and maintenance purposes, it is possible to operate a trolley group which is not preselected. If necessary, the operating pressure for the trolley group (edge or panorama) can be varied. Operating Manual – Folder superstructure – COLORMAN... -
Page 35: Web Tension
Fig. 24 Example of the NIPPING SECTION screen For adjustment and maintenance purposes, it is possible to operate a nipping section which is not preselected. If necessary, the operating pressure for the nipping section (edge or panorama) can be varied. Operating Manual – Folder superstructure – COLORMAN... -
Page 36: Parallel Turner Bar
+ XX,X mm the slitter unit towards SII, and the “–” button moves it towards SI. One button-press causes a movement of 0.2 mm. 14-060613-1040 Fig. 27 Example of the WE SLITTER UNIT screen Operating Manual – Folder superstructure – COLORMAN... -
Page 37: Reel Sidelay
A range of different functions are used depending on the individual configuration of the press. If a function is selected which is not used, no information will be displayed; the display remains empty. Operating Manual – Folder superstructure – COLORMAN... -
Page 38: Protective Equipment
(Lockout). 2. Place the “DO NOT SWITCH ON” warning sign on the main switch (Tagout). 3. Inform all colleagues who are involved. Additional notes: See appendix “Protective equipment for the folder superstructure”. Operating Manual – Folder superstructure – COLORMAN... -
Page 39: Static Mounted Protective Equipment
Static mounted protective equipment may only be removed for the purpose of installation or maintenance work. DANGER Each time before you start the machine, check that all protective grilles and protective covers are in place. Operating Manual – Folder superstructure – COLORMAN... -
Page 40: Feed Rollers And Trolleys
Feed rollers and trolleys DANGER Risk of being pulled into the press. Do not remove covers and finger guards. 14-060613-1145 Fig. 30 Feed rollers and trolleys Paper web Finger guard (S-roller) Cover Safety bolt Operating Manual – Folder superstructure – COLORMAN... -
Page 41: Slitter Unit
If the cover is opened while the press is in operation, the safety bolt triggers a “Safe STOP”. 14-060613-1150 Fig. 31 Folder superstructure slitter unit Paper web Cover Safety bolt Hoop guard Operating Manual – Folder superstructure – COLORMAN... -
Page 42: Timing Belt Drive
Timing belt drive DANGER Risk of being pulled into the press and of injury from the rotating belt disc. Do not remove the guards from the belt drives. S II 01-061121-1251 Fig. 32 Folder superstructure Operating Manual – Folder superstructure – COLORMAN... -
Page 43: Web Guide Rollers, Measuring Rollers, Feed Rollers
Retighten the rocking lever after adjustment work. Adjustment dial scale: • one revolution corresponds to an adjustment distance of 1.0 mm. CZ, CZ2 14-060427-0945 Fig. 33 Web guide rollers Adjustment dial Rocking lever Operating Manual – Folder superstructure – COLORMAN... -
Page 44: Feed Rollers
7.1.5.2. The outer and inner web position of the product 01-061121-1326 is influenced by the trolleys on both feed rollers. Fig. 34 Feed rollers 14-060613-1325 Fig. 35 Folde Paper web Feed roller Trolley Operating Manual – Folder superstructure – COLORMAN... -
Page 45: Trolleys
01-061121-1329 Depending on the operational status of the press, Fig. 36 Trolleys the trolley groups are automatically engaged or retracted. Operating Manual – Folder superstructure – COLORMAN... - Page 46 Contact pressure is too low:paper web is detensioned Contact pressure is too high:creasing occurs 01-060817-1200 Fig. 37 Detail of the trolleys Width of paper web (B) Press centre Edge trolleys Panorama trolleys Feed roller Operating Manual – Folder superstructure – COLORMAN...
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Page 47: Slitter Unit
Adjusting the slitter unit: See Repair and settings instructions, module 508. 01-061121-1327 Fig. 38 Overview of the slitter unit S II 01-061121-1020 Fig. 39 D Upper knife Lower knife Paper width (B) Theoretical centre Operating Manual – Folder superstructure – COLORMAN... -
Page 48: Paper Lint Extraction Unit
For cleaning purposes, the former area and the folder area each have a suction point for manual extraction. Operation and maintenance of the extraction unit: See manufacturer’s documentation. 14-060613-1420 Fig. 40 Paper lint extraction unit Extraction nozzle Operating Manual – Folder superstructure – COLORMAN... -
Page 49: Cut-Off Compensator Adjustment
The chosen values can be saved. This allows the repetition of preset production runs from the central control console. DANGER Do not reach between the register rollers while they are in operation. 01-061121-1254 Fig. 41 Cut-off compensator Operating Manual – Folder superstructure – COLORMAN... -
Page 50: Cut-Off Compensator Scanning
Do not reach between the register rollers while they are in operation. • Always keep the scanning heads clean. FA 06 FA 07 FE 06 FE 07 01-061107-1645 Fig. 42 Cut-off compensator scanning Operating Manual – Folder superstructure – COLORMAN... -
Page 51: Web Break Detector
The photocell of the web break detector must always be kept clean, otherwise a “Safe STOP” may be accidentally triggered. 01-061121-1253 Fig. 43 Web break detector 53960-LK-010001A Fig. 44 Web break detector optical sensors Paper web Clearance 80mm 20mm 60mm Operating Manual – Folder superstructure – COLORMAN... -
Page 52: Former
With a double former, two books can be produced in “non-collect” mode, and four in “collect” mode. If the press is fitted with a balloon former, the number of books produced is doubled. 01-061113-1325 Fig. 45 Former Operating Manual – Folder superstructure – COLORMAN... -
Page 53: Blown Air
One ball valve is fitted in the blown air feed line for each former. If a particular former is not in use, close the ball valve. 01-061121-1328 Fig. 46 Overview of the blown-air 14-060628-1105 Fig. 47 Ball valve Operating Manual – Folder superstructure – COLORMAN... -
Page 54: Drive
Call up the web tension screen on the central control console or on the display and select the appropriate feed roller. Command: • “+”: Increase web tension (gain) • “–”: Decrease web tension (gain) 01-061121-1252 Fig. 48 Folder superstructure drive Operating Manual – Folder superstructure – COLORMAN... -
Page 55: Operating Levels
– the screw with washer must be positioned correctly in the support bracket, see Fig. 49 ’Folding footboard - after refitting’ 14400-UE01-562701 Fig. 49 Folding footboard - after refitting [1] Support bracket [2] Screw [3] Washer [4] Sleeve [5] Footboard Operating Manual – Folder superstructure – COLORMAN... - Page 56 14 Operating levels FA 06 FA 07 FE 06 FE 07 01-061115-1145 Fig. 49 Folder superstructure operating levels Gallery Step on the former Fixed step Fold-away step Operating Manual – Folder superstructure – COLORMAN...
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Page 57: Appendix A Protective Equipment For The Folder Superstructure
Appendix A Protective equipment for the folder superstructure (C16.65500-1947) Appendix A Protective equipment for the folder superstructure (C16.65500-1947) Operating Manual – Folder superstructure – COLORMAN...
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