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Zünd D3 Operating Manual

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Operating Manual
D3 Digital Cutter

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Summary of Contents for Zünd D3

  • Page 1 Operating Manual D3 Digital Cutter...
  • Page 2 Keep it in a safe place for future use! Original operating manual Software-/Firmware version: FW1.77-1 Creation date: 08-2023...

  • Page 3: Table Of Contents

    Contents Contents 1 Introduction............................7 1.1 Using the operating manual......................8 1.2 Points to note when reading this operating manual.................9 1.3 Publishing details..........................9 2 Product description........................11 2.1 Important information about the product..................11 2.2 Orientation............................12 2.3 Product identification........................14 2.4 Intended use........................... 14 2.5 Cutter overview..........................15 2.6 Modules, tools..........................16 2.7 Material handling..........................
  • Page 4 Contents 4.5 General settings..........................77 4.6 User level............................78 4.7 Malfunctions............................ 80 4.8 Daily checks prior to start-up......................84 4.9 Behavior in dangerous situations....................87 4.10 Start-up............................89 4.11 operating mode..........................91 4.12 Moving the beam/module manually....................93 4.13 Handling modules/tools.........................95 4.14 Material hold-down........................109 4.15 Material transport........................
  • Page 5 Contents 7 Tools.............................. 205 8 Modules............................207 9 Material handling.......................... 209 10 Additional specifications......................211...
  • Page 6 Contents...

  • Page 7: Introduction

    Introduction 1 Introduction Dear customer, With your decision to purchase our product you are participating in the worldwide success of Zünd cutter systems. The modular design of our systems provides the following benefits, among others things: • A system solution that meets your individual requirements in terms of speed and quality. •...

  • Page 8: Using The Operating Manual

    Introduction 1.1 Using the operating manual The supplied operating manual is intended to enable you to operate the machine safely, perform routine maintenance and use the machine optimally in every way. To do this, you need to be able to find what you need in the documentation. Scope of the operating manual Volume 1 - Operating instructions This volume contains information on engineering, commissioning, operation...

  • Page 9: Points To Note When Reading This Operating Manual

    Introduction 1.2 Points to note when reading this operating manual Text references Chapter headings are numbered consecutively in the chapters, with the first figure corresponding to the chapter number. Where reference is made to sections outside the current chapter, note the first figure and turn to the corresponding chapter, which contains the cited section.
  • Page 10 Introduction...

  • Page 11: Product Description

    Product description 2 Product description This chapter contains information on the following: • Representation conventions in the operating manual • Usage possibilities of the machine • Structure of the main components • Important technical data • General technical description of the machine 2.1 Important information about the product Tip: "Tip"...

  • Page 12: Orientation

    Product description 2.2 Orientation Directions such as "right, left" or "front, back" refer to the standard position of the control panel. in front in rear left right X axis Y axis 2.2.1 System A and system B From here on out the supplements "A" and "Bwill be used to describe the different machine components.
  • Page 13 Product description Important: Follow the instructions that explicitly prescribe the use of one of the two systems. Tip: To identify the system on the cutter, there are stickers with the lettersAandBon the following components: • on the operating unit • on side of the beam •...

  • Page 14: Product Identification

    Product description 2.3 Product identification 2.3.1 Rating plate Position of the signs Type designation Rating plate Year of manufacture Additional UL sign Serial number Additional connection values UL mark of conformity Additional FCC sign Nominal voltage CE mark of conformity Rated current Product name Frequency...

  • Page 15: Cutter Overview

    Product description 2.5 Cutter overview Cutter extension, front (optional) Vacuum generator (turbine or pump) Electronics unit A Electronics unit B Left safety device of beam B Maintenance unit A Maintenance unit B Power box A Power box B Right safety device of beam A Control panel or workstation (optional) Cutter extension, rear (optional) Beam A...

  • Page 16: Modules, Tools

    Zünd cutters are highly specialized and can be easily converted to process other materials through the use of modules and tools. As standard, three modules can be fastened onto either of the two module carriages of the D3. Tip: You can find detailed information in section...
  • Page 17 Product description 2.6.1 Universal applications Universal Module - UM Universal carrier modules for a wide range of tools. • UM-ZS: high-speed Z axis • UM-ZP:high-powered Z axis • UM-60L: especially for using very large tools Tools for use in the UM Electric Oscillating Tool - EOT Cutting tool with high oscillation frequency for soft and medium hard materials.
  • Page 18 Product description Wheel Knife Tool - WKT Low-maintenance tool for the processing of glass and carbon fiber fabrics as well as technically demanding textiles for insert cutting. Universal Cutting Tool - UCT Universally usable cutting tool for materials of up to 5 mm thickness. Scoring Cutting Tool - SCT Combination tool for scoring and cutting cardboard and coating blankets of up to 5 mm material thickness.
  • Page 19 Product description Raster Braille Tool - RBT Efficient procedure for the creation of tactile Braille markings (for the blind). 2.6.2 Routing, engraving: Router Module - RM-A Universally usable router system, fitted with a 1.0 kW motor spindle. • Efficient dust extraction, actively air-cooled •...
  • Page 20 Product description 2.6.3 Punching, perforating Punch Modules - PUM High performance tools for perforating leather materials, rubber and textiles with up to 8 holes per second. 2.6.4 Drawing, marking, labeling Marker Modules - MAM Marking and labeling of various types of materials. Use of standard commercial leads.

  • Page 21: Material Handling

    Product description 2.7 Material handling 2.7.1 Cutter with material transport The conveyor belt is a cutting board and transport belt at the same time. Cut parts are automatically transported away from the cutting area while the cutter is loaded at the same time. The material transport allows the production of orders that are longer than the cutter.

  • Page 22: Options

    Product description 2.8 Options 2.8.1 ICC camera The ICC camera allows perfect registration in which the exact position of printed material on the processing surface is determined. The integrated laser pointer is used as an aid for the precise determination of the reference point. Electrically driven tools can also be connected to the camera.
  • Page 23 Product description Accessories Quantity Task Conveyor Static Flat open-ended 1 pc. Tension conveyor belt spanner SW14 with 2 auxiliary drives 19 mm tape, double- 1 pc. Fixing the cutting board sided Special lubricant for PE/ 20 ml Service PVC tubes Teflon grease 20 ml Service...

  • Page 24: Technical Description

    Maintenance unit B is accessible via the left service doors. The air pressure is adjusted for the respective consumers on beam B via a maintenance unit. The maintenance units are accessible via the respective service doors to carry out settings or maintenance work. 2.10.2 Movement system The D3 series has four electronically driven axes:...
  • Page 25 Product description Axis Function Movement system Beam movement Drive via toothed belt/steel belt Material transport, material transport Conveyor clamping elements, transport extension (optional) elements, auxiliary drive (optional) Movement of the module carriage Drive via toothed belt/steel belt Height adjustment of the module Example Universal Module, Router Module Rotary movement of the module Example Universal Module...
  • Page 26 Product description Z axis - height adjustment of the module Machine-controlled setting of the processing height (e.g. Universal Module). T axis - rotary movement of the module Modules with integrated T axis (e.g. Universal Module).

  • Page 27: Technical Data

    Product description 2.11 Technical data 2.11.1 Dimensions 2.11.1.1 Base cutter (mm) The effectively usable working surface (D x E) depends on the tool or module. Type (mm) L-3200 2525 1800 XL-3200 2995 2270 4296 3200 2XL-3200 3465 2740 3XL-3200 3935 3210...
  • Page 28 Product description 2.11.1.2 Base cutter (inch) The effectively usable working surface (D x E) depends on the tool or module. Type (in) L-3200 99.4 XL-3200 117.9 33.7 19.2 32.7 2XL-3200 136.4 3XL-3200 154.9...
  • Page 29 Product description 2.11.1.3 Cutter extension - CE (mm) Type CE1600 CE3500 Length (mm) 1545 3445 L-3200 XL-3200 2XL-3200 3XL-3200...
  • Page 30 Product description 2.11.1.4 Cutter extension - CE (inch) Type CE1600 CE3500 Length (in) 60.82 135.63 L-3200 XL-3200 2XL-3200 3XL-3200...
  • Page 31 Product description 2.11.2 Weights 2.11.2.1 Base cutter (kg) Type Weight (kg) max. floor load (kg/m) L-3200 1290 XL-3200 1460 2XL-3200 1600 3XL-3200 1800 2.11.2.2 Base cutter (lbs) Type Weight (lbs) max. floor load (lbs/in) L-3200 2835 XL-3200 3220 2XL-3200 3530 3XL-3200 3960 2.11.2.3 Material weight (kg)

  • Page 32: Electrical Connection

    Product description 2.11.3 Electrical connection 2.11.3.1 Base machine Electrical connection 400 V, 50/60 Hz Value Unit Voltage 3-phase, 400 L1, L2, L3, N, PE V Mains frequency 50/60 Hz Power input 3 phases 7.8 kW Current consumption 3 phases max. 15 A Mains fuse, min.
  • Page 33 Product description Vacuum turbine 1 - 9 kW Value Unit Voltage L1, L2, L3, PE, 400 V Mains frequency 50/60 Hz Power input - 3 phases 1 - 9 kW Mains fuse, min. 32 A Vacuum turbine 1 - 9 kW Value Unit Voltage L1, L2, L3, PE, 208 V...

  • Page 34: Environmental Conditions

    Product description 2.11.4 Environmental conditions Value Operating temperature +10 °C to +35 °C Storage temperature -20 °C to +55 °C Relative humidity 10 - 80%, non-condensing 2.11.5 Compressed air supply 2.11.5.1 Compressed air connection requirements Important: The compressed air connection must fulfill the following requirements: Air purity: class 2.4.2 according to ISO 8573-1:2010 •...
  • Page 35 Product description Air pressure [MPa] max. air consumption [l/min] Maintenance unit House connection Base machine (vacuum elements) covered with base consumption Center winder roll-up unit Compressed air regulator P3 Air pressure [MPa] max. air consumption [l/min] Maintenance unit House connection Router Module - RM-A Minimal Quantity Lubrication - MQL Material transport (transport...

  • Page 36: Performance Features

    Product description Compressed air regulator P2 Air pressure [MPa] max. air consumption [l/min] Maintenance unit House connection Electric Oscillating Tool - EOT-250 Power Rotary Tool - PRT Universal Routing Tool - URT 0.6 - 1.0 Marker Module - MAM Extraction Switch Module - ESM Compressed air regulator P3 Air pressure [MPa] max.
  • Page 37 <75 dB and ~85 dB. Electromagnetic emissions The D3 series meets the requirements of the following technical standards: • EN 61000-6-2 EMC, interference resistance in industrial environments •...
  • Page 38 Product description...

  • Page 39: Safety

    Safety 3 Safety This chapter contains information on the following: • Definition of the intended use of the machine • Generally applicable safety instructions and safety regulations to be observed • Explanation of the meaning of symbols and pictograms which are used in this manual and in signs on the machine •...
  • Page 40 Safety • Use of materials that are not defined in the contract and in this operating manual. • Failure to observe the applicable parameters for the processing of the relevant material. • Maintenance work on an unsafe machine. • Failure to follow the operating instructions. •...

  • Page 41: Hazard Warnings, Important Instructions

    Safety 3.4 Hazard warnings, important instructions Explanation of the notes Both in the operating manual and on the device itself, dangers and important instructions are designated by special symbols and signal words as follows: Danger: The safety instruction Danger • refers to imminent danger •...
  • Page 42 Safety Tip: Tip in combination with the light bulb refers to user tips and useful information which enhance the usability, prolong the service life of the machine and make the work significantly easier. Tip: With tips combined with the sheet, we provide usage tips and useful information which can improve the energy efficiency of the machine or optimize its environmental effects.

  • Page 43: Areas Of Responsibility

    Safety 3.5 Areas of responsibility Manufacturer's areas of responsibility • The manufacturer is responsible for the safe condition of the machine on delivery, including operating manual and accessories, according to the sales documentation. Areas of responsibility of the owner or person authorised by them: •...

  • Page 44: Personal Protective Equipment

    Safety 3.7 Personal protective equipment The safety equipment required for operating the machine is dependent on the following factors: • Module and tool system used • Processing material used When operating the machine or carrying out maintenance or servicing work, wear tight fitting clothing and appropriate personal protective equipment.

  • Page 45: Rules And Occupational Safety

    Safety 3.8 Rules and occupational safety • Operation of the machine is always subject to local regulations regarding work safety and accident prevention. • Make sure that there is adequate lighting during operation. • Check protective devices every time before starting the machine. •...

  • Page 46: Danger Areas

    Safety 3.10 Danger areas 3.10.1 General danger area Danger area The danger area is restricted to the working surface or the active area of the drive system. Never reach into this work area during processing. 3.10.2 Minimum clearance between the two systems As long as beam B is right at the front or beam A is located fully at the rear edge of its travel range, the work areas are defined so that no collisions can be caused.
  • Page 47 Safety 3.10.3 Danger area on the module carriage Caution: Risk of injury on the module carriage! The danger area on the module carriage is not secured by safety devices. • Do not reach into the danger area during manual initialization. •...
  • Page 48 Safety 3.10.4 Danger area during initialization Caution: Risk of injury during manual initialization of the tool! The front safety devices are not active during manual initialization. • Do not reach into the danger area during manual initialization • For initialization, use the Integrated Tool Initialization (ITI) if the tool allows it (for more information, see as well as the corresponding tools operating Integrated Tool Initialization - ITI...
  • Page 49 Safety 3.10.5 Danger area during cleaning Caution: Risk of injury when cleaning the machine! Blades, router bits and punching inserts have very sharp edges which are sometimes hidden by moving equipment (spring-loaded gliding disc). • Before starting to clean, remove all modules and tools from the module carriage. •...

  • Page 50: Warnings On The Product

    Safety 3.11 Warnings on the product Description Variant 1 (CE) Variant 2 (ANSI) Mandatory sign: Wear protective gloves Art. no.: 5800412 (50 mm) Art. no.: 5801106 (65 mm) Mandatory sign: Wear eye protection Art. no.: 5800467 (50 mm) Art. no.: 5801058 (65 mm)
  • Page 51 Safety Description Variant 1 (CE) Variant 2 (ANSI) Warning sign: Hand injuries due to crushing Art. no.: 5800342 (50 mm) Art. no.: 5801059 (65 mm) Warning sign: Electrical hazard Art. no.: Art. no.: 5200367 (110 mm) 5200367 (110 mm) Warning sign: Electrical hazard Art.
  • Page 52 Safety Description Variant 1 (CE) Variant 2 (ANSI) 5800344 (25 mm) Art. no.: 5801062 (40 mm)

  • Page 53: Protective Devices

    Safety 3.12 Protective devices EMERGENCY STOP control devices Safety device (protective trip switch, light barriers) Control panels 3.12.1 Safety device Caution: The beam may cause serious injuries in case of a collision. Note that the high level of kinetic energy of the drive results in a significant braking distance. Light barriers and protective trip switches are no guarantee against injuries! The safety device consists of protective trip switches and light barriers on the beam ends.

  • Page 54: Control Panels

    Safety Effects on the options connected to the cutter • Synchornised movements are stopped. • Units that are not safety-relevant or important for the operation of the machine remain switched on. Recommissioning • Restore operational safety. • Free the protective trip switches or light barriers of obstacles. •...
  • Page 55 Safety 3.12.4 Shutdown in an emergency An emergency shutdown allows the machine to be stopped quickly in case of emergency. Effects for the cutter • The drive motors (beams, module carriers) are braked to a standstill and are then disconnected from the energy supply.
  • Page 56 Safety 3.12.6 Light curtain (optional) If the light curtain is interrupted by an object or person while an object is moving, the machine automatically comes to a standstill. Effects for the cutter • The drive motors (beams, module carriage) are slowed to a standstill. •...

  • Page 57: Mechanical Hazards

    Safety 3.13 Mechanical hazards 3.13.1 Collection, retraction Caution: Risk of injury from entanglement, getting caught and being pulled in! The machine and the tool system has moving parts. Possible consequences • Bruises, crushing, lacerations to fingers or hands • Bruising to the head and arms •...

  • Page 58: Risk Of Burns

    Safety 3.13.3 Cut and puncture injuries Caution: Injury risk from sharp objects! Blades, router bits and punching inserts have very sharp edges which are sometimes hidden by moving equipment (spring-loaded gliding disc). Possible consequences • Cutting and stabbing injuries to the hands and arms Precautionary measures •...

  • Page 59: Risks Arising From The Emission Of Toxic Dust

    Safety 3.16 Risks arising from the emission of toxic dust Warning: Risk of poisoning from the emission of toxic dust! Processing certain materials can lead to the creation of harmful toxic dust. • Obtain information about the toxicity of the material to be processed from the manufacturer. •...

  • Page 60: Environmental Hazards

    Safety 3.18 Environmental hazards Warning: Processing residues, operating materials, cleaning agents etc. can cause damage and pollute the environment if they enter the soil, waterbodies or the sewage system. Explanation of the hazard label Hazard label for substances that are harmful to the environment Safety regulations and protective measures •...
  • Page 61 Safety Always wear your personal protective gear (protective gloves, goggles, mouth guard etc.) when handling chemicals. Explanation of the hazard label Hazard label for very toxic or toxic substances Hazard label for hazardous substances or irritant materials Hazard label for irritating substances...
  • Page 62 Safety Note: Chemicals classified as irritants are used to operate and clean this machine (cleaning agents, operating fluids). Safety datasheets for the substances in question can be downloaded from the Zünd homepage (www.zund.com). Safe handling of chemicals Important: Dispose of chemicals in accordance with national regulations. Follow the manufacturer's instructions (MSDS).

  • Page 63: Risk Of Fire And Explosion

    Safety 3.20 Risk of fire and explosion Warning: There is a risk of fire when routing and cutting flammable materials Terminate the routing/cutting and leave the tool to cool off in case of • smoke emission. • Discolorations on the router/blade which point to increased heat development Warning: Risk of dust explosions Flying sparks or electrostatic charges result in the risk of dust explosions during the extraction of...

  • Page 64: Danger From Laser Beam

    Safety Combustible gases: e.g. methane, propane, etc. Behaviour in the event of a fire • Turn off the machine using the main switch • Assess the situation: If there is danger, leave the area immediately and call the fire department. Only try to extinguish the fire if your personal safety is not at risk.

  • Page 65: Safety Precautions For Service Personnel

    Safety In addition to these safety instructions, you must also observe the situation-related safety notes in the chapters "Controls and operation" and "Maintenance and cleaning". 3.23 Safety precautions for service personnel The reliability, readiness and service life of the machine greatly depend on you carrying out your work in a conscientious manner.
  • Page 66 Safety...

  • Page 67: Controls And Operation

    Controls and operation 4 Controls and operation This chapter familiarizes you with the controls, guides you through the operational procedures and describes the following operating steps: • Daily commissioning • Operation of the main components • Detailed information on the operation of the machine •...

  • Page 68: Controls

    Controls and operation 4.2 Controls 4.2.1 Overview EMERGENCY STOP control devices Control panel and work station Maintenance units (dependent on cutter configuration) 4.2.2 Control panels Two identical control panels are located next to each other in the workstation. The functions are available for beam A and beam B respectively.
  • Page 69 Controls and operation Control panel Display Soft keys Navigation keys Numeric keypad VAC (vacuum) key STOP key ONLINE key SHIFT key Travel keys Tool up/down key Function keys...
  • Page 70 Controls and operation 4.2.3 EMERGENCY STOP control devices Activating an EMERGENCY STOP control device triggers a machine standstill in the event of an emergency. The cutter is fitted with five EMERGENCY STOP control devices as standard. They are located as follows: •...
  • Page 71 Controls and operation 4.2.4 Maintenance units Two maintenance units are installed, which can each be equipped differently for beam A and beam B. Maintenance unit Maintenance unit A Maintenance unit B Fixing bracket for an additional, optional maintenance unit Air connection Stopcock Water separator Air pressure setting...
  • Page 72 Controls and operation Interface unit A Interface unit B Status and error display...

  • Page 73: Menu Navigation

    Controls and operation 4.3 Menu navigation 4.3.1 Navigation keys Functions in the cutter menu Use these keys to navigate through the menu • If submenus are available, use this key to change to the next menu level • Select setting/function Switching from a sub-menu to the previous menu level Function in the editor Use these keys to move the cursor to the right or left...

  • Page 74: Menus And Functions

    Controls and operation Information Function keys Allocation of the function keys Communication Settings such as: interface, port, IP address, mask, MAC address Switch between tabs with the key. Scroll up/down within the tab with the key. 4.3.4 Pop-ups, dialog boxes Pop-up menus or dialog boxes are displayed for the following actions: •...

  • Page 75: Function Keys

    Controls and operation 4.4.2 Selection Use the navigation keys to select an entry from the list. B Confirm the selection with OK and cancel by pressing ESC. 4.4.3 Select commands, functions Mark the required command with the navigation keys and select with The command can also be activated directly via the menu number.

  • Page 76: Entering Values

    Controls and operation A Simultaneously press the SHIFT key and the function key (F1 - F8) for which you would like to change the function. B The function key selection window opens. C Enter the menu number of the desired menu entry using the number field. D Confirm the selection with OK or cancel by pressing ESC.

  • Page 77: General Settings

    Controls and operation 2-1-1-5 Reference pt. Y 2-1-2-4 Reference pt. X 2-1-2-5 Reference pt. Y 2-1-3 Act. ref. no. 2-4-3 Replot timeout 2-7-3 Height 4-1 User level 4-3 Start user 4-4-1 User 2 4-4-2 User 3 6-7 Date and time 8-2 Table number 4.5 General settings 4.5.1 Setting the language...

  • Page 78: User Level

    Controls and operation Menu Description 2-4-1 Clear buffer All the data stored in the data buffer is deleted. The file may have to be resent. 4.6 User level Access to menus and functions is blocked depending on the user level. The user levels have a hierarchical structure.
  • Page 79 Controls and operation 4.6.3 Changing the password for user levels 2 and 3 Tip: The passwords for user levels 2 and 3 can be changed in the Operator user level or higher. A Change to the 4-4 Change password menu. B Select the user.

  • Page 80: Malfunctions

    Controls and operation 4.7 Malfunctions 4.7.1 Troubleshooting Caution: Risk of injury due to incorrectly remedied faults. • Ensure that the error on the device is remedied correctly. • Contact your Zünd partner. Make note of the following information if you need help from the service department to rectify an error in your cutter: •...

  • Page 81: Error Display

    Controls and operation 4.7.2.2 Error shown on the status and error display The error is displayed as a sequence. All superfluous digits of the error code will be omitted in this display! If several errors occurred one after the other then these are combined together in a group. The error which occurred first is displayed at the start of the group.
  • Page 82 Controls and operation 4.7.4 Engaging the automatic circuit breaker Danger: Hazardous voltage in the power box Risk of death or injury from electric shock! • Do not remove the internal power box cover (power unit) under any circumstances. • Contact your service partner if you have any problems with the energy supply. Note: Risk of damage to the cutter If an automatic circuit breaker has been triggered, the cause may be an electrical defect in a...
  • Page 83 Controls and operation A Stop work. B Remove the outer cover of the power box (see on page Remove the power box cover (A10, A21) 179). C Push the switch lever upwards when the automatic circuit breaker is triggered. Option Description The automatic circuit breaker triggers again Shut down the cutter.

  • Page 84: Daily Checks Prior To Start-Up

    Controls and operation 4.8 Daily checks prior to start-up Caution: There is a risk of injury if the machine is damaged! Machine faults can result in defects and accidents. • Never start up a machine if it is damaged. • Report all defects and faults to your supervisor and arrange for them to be rectified immediately by qualified personnel.
  • Page 85 Controls and operation 4.8.1 Checking the light curtain Test piece Figure 1: Inspection process on the yellow light grid (type 445L) green LED Light curtain without interruption red LED Light curtain interrupted...
  • Page 86 Controls and operation Figure 2: Inspection process on the red light grid (type 450L-E) Transmitter without interruption Top receiver interrupted Receiver without interruption Bottom transmitter interrupted Top transmitter interrupted Bottom receiver interrupted A Switch on the cutter (e.g., press the F1 key). B Start the self-test with the 3-3-8 S-Test menu.

  • Page 87: Behavior In Dangerous Situations

    Controls and operation 4.9 Behavior in dangerous situations 4.9.1 Shutdown in an emergency When a hazard or a possibly hazardous situation occurs, activate an EMERGENCY STOP control device immediately. Effects for the cutter • The drive motors (beams, module carriages) are braked to a standstill and are then disconnected from the energy supply.
  • Page 88 Controls and operation 4.9.2 Reset EMERGENCY STOP control devices A Restore operational safety. B To unlock, turn the emergency stop control device clockwise. C Acknowledge the error message on the control panel. Results The machine is ready for operation. 4.9.3 Commissioning a stopped machine The cutter automatically shuts down under the following circumstances: •...

  • Page 89: Start-Up

    Controls and operation 4.9.4 Idle time before online After a collision in online mode, beam B travels to a safe position 0/0 upon changing on online again. After beam B has reached the waiting position, beam A carries on working. As soon as the set waiting time has expired, beam B continues processing the job.
  • Page 90 Controls and operation Main switch, off position Main switch, on position Switch the main switch to the on position. Results The cutter switches on. The start page appears on the display. 4.10.2 Initialize the machine Ensure that: • there is sufficient clearance between both beams. •...

  • Page 91: Operating Mode

    Controls and operation 4.11 operating mode The cutter can be put into three operating modes: • OFFLINE • ONLINE • STOPPED A combination of keys can optionally be used to switch from any operating status to either of the other two operating modes.
  • Page 92 Controls and operation 4.11.3 STOPPED Note: The operating mode STOPPED protects the operator from the machine being set in motion using remote controls. In this operating mode, commands are received but they are not processed. Even commands from the operating software (e.g., to change to the ONLINE operating mode) are ignored. A red illuminated LED on the ONLINE key indicates that the operating mode STOPPED is active.

  • Page 93: Moving The Beam/Module Manually

    Controls and operation 4.12 Moving the beam/module manually Note: The safety light barrier prevents damage to the beam and module in the event of a collision. If the distance is to small between both beams, the light barrier triggers and prevents a collision of both beams.
  • Page 94 Controls and operation Figure 3: with parallel aligned control panel Figure 4: with rotated control panel The module carriage can be moved using the travel keys in the OFFLINE and STOPPED operating modes. The assignment of the keys corresponds to the direction of travel. Operation for beam A and beam B are separate, as illustrated.

  • Page 95: Handling Modules/Tools

    Controls and operation 4.13 Handling modules/tools Modules are independently recognized by the cutter control unit. Tools, on the other hand, do not have automatic recognition and must be manually allocated to a module. Tool-specific parameters (initialization, moving speeds, acceleration) are saved to the corresponding tool and can be called up again at any time.
  • Page 96 Controls and operation 4.13.1 Module/tool/tool insert Tip: You will find detailed informtation in section Modules, tools as well as in the individual instructions of your modules and tools. Module (e.g., UM, MAM) Tool (e.g., UCT, VCT, SDT) Tool insert: router, blade, pen...
  • Page 97 Controls and operation 4.13.2 Module/tool change position 4.13.2.1 Define position You can define any two positions at which the module changes can take place. Position 1 (1-5-7-2 Position 1) and position 2 (1-5-7-5 Position 2) are set in the same way. The setting of position 1 is described by way of the example below.
  • Page 98 Controls and operation 4.13.3 Inserting/replacing the module 4.13.3.1 Overview of the module arrangement Module carriage, slot 1 Module carriage, slot 2 Module carriage, slot 3 Beam A Beam B...
  • Page 99 Controls and operation 4.13.3.2 Module carriage Module carriage, slot 1 Module carriage, slot 2 Module carriage, slot 3 Pneumatic connections Locking mechanism Drop bar Laser pointer/camera (optional) with electrical connections...
  • Page 100 Controls and operation 4.13.3.3 Inserting a module A 1-5-1 Change module/tool . The module carriage moves to the module change position. B Place the module on the mounting ledge. C Tilt the module backwards onto the module carriage. D Lower the module until the stop. E Use the 4 mm Allen key to lock the module in place.
  • Page 101 Controls and operation 4.13.3.4 Removing the module A Select 1-5-1 Change module/tool in the cutter menu. The module carriage moves to the module change position. B Unscrew the module fastener using the 4 mm Allen key. C Remove the module. 4.13.4 Activating a module It is often necessary to activate a module in order to check the settings.
  • Page 102 Controls and operation 4.13.5 Marking the tool Label all tools of the same type with a consecutive number. Corresponding adhesive labels are supplied with the equipment. 4.13.6 Tool manager The tool manager is a user interface to handle tools in combination with a universal module (UM). A sensor on the module detects the presence of the inserted tool.
  • Page 103 Controls and operation 4.13.6.1 Inserting/replacing the tool A Select 1-5-1 Change module/tool. B If necessary, select the module/tool change position. C Insert the tool and - if electrically or pneumatically driven - connect to the power supply. D Confirm the selection with OK. The tool manager opens.
  • Page 104 Controls and operation 4.13.6.3 Selecting a tool already inserted A Insert the tool. B Select 1-1-1-1 Select tool in the menu. In the dialog, all tools already assigned to this module are listed. C Select the tool inserted. 4.13.6.4 Deleting a tool A 1-1-1-1 Select tool .
  • Page 105 Controls and operation 4.13.7 Connecting powered tools Driven tools (e.g. EOT, DRT, POT) require an energy supply (electrical, pneumatic). This energy supply is controlled by the cutter control unit. Electrically driven tools are connected to the connector control of the laser pointer or the ICC camera (optional).
  • Page 106 Controls and operation 4.13.7.2 Connecting pneumatically driven tools The tool is applied and assigned to the module. Pneumatically driven tools and modules are connected to the pneumatic connections on the module carriage. The pressure is set using a maintenance unit (see settings).
  • Page 107 Controls and operation A Press down on the corresponding air pressure connection coupling. B Insert the compressed air hose. 4.13.8 Mount protective stoppers for pneumatic connection Note: Always use a protective plug to protect connection P4 from dirt in the air supply. If particles of dirt get into the tool, it will be damaged.
  • Page 108 Controls and operation 4.13.9 Tool positions, Z axis E.g.: UCT After initialization, three tool positions can be moved to with Pos. Position Description Signal Parking position Moves to the highest position on the Z axis Up position Zero point + up position Down position Zero point + Down position + Z offset...

  • Page 109: Material Hold-Down

    Controls and operation 4.14 Material hold-down Tip: The material hold-down must be controlled via system A. Note: Damage risk from vacuum being to high for vacuum turbines. The vacuum turbine audibly does not run at constant speed. • Select a lower vacuum level. •...
  • Page 110 Controls and operation 4.14.2 Cover open vacuum areas Processing material Covering open vacuum area A If possible, position the material to be processed at the zero point of the work surface. B Use a tarpaulin or airtight material to cover the open vacuum area. 4.14.4 Checking the vacuum range A Select the 1-8-3-5 Active zones function.
  • Page 111 Controls and operation B Select OK to confirm. Results The active module moves to the defined vacuum width. 4.14.5 Vacuum setting, both sides (optional) The outer vacuum zones can be switched off and on from both sides when required. This avoids leakage air, and the vacuum only takes effect where it is actually required.
  • Page 112 Controls and operation 4.14.5.1 Implementing vacuum setting on both sides Switched off zones Switched on zones (active vacuum zone) vacuum from Vacuum to A Place the material on the working surface. B Place the on the Vacuum from position. Select 1-8-3-3 Setting vacuum from. active pointer C Place the on the Vacuum to position.
  • Page 113 Controls and operation 4.14.6 Setting the vacuum intensity (optional) Important: Regulation of the vacuum intensity is only possible, if your machine is fitted with a vacuum turbine. The output of the vacuum turbine is adjustable from levels 1-10. Levels 1-9 are regulated by the negative pressure sensor of the cutter controller.
  • Page 114 Controls and operation The vacuum switches on or off. Variant 2 A Press the VAC key. B Press the 2 key. Results The vacuum switches on or off.
  • Page 115 Controls and operation 4.14.8 Switching between air cushion / vacuum (optional) Important: This function is only available if the vacuum generator is fitted with a vacuum pump that has a changeover valve. Machines which are fitted with a vacuum pump with switching valve produce an air cushion between the processing material and work surface during material transport.

  • Page 116: Cycle Times

    Controls and operation Air cushion before or during the material transport Menu Setting 1-7-1-17-1 Air cushion Switch short blast before material transport on or off. 1-7-1-5 Vac. beh. always fixed time-optimised 4.14.9 Working with air-permeable materials The vacuum is controlled via a pressure sensor. When a vacuum is created, the speed of the vacuum generator is kept constant.

  • Page 117: Material Transport

    Controls and operation 4.15 Material transport Tip: Control must be carried out from system A. Material transport takes place after a completed work step. In which the processing material is transported further on a conveyor belt. The conveyor belt is gripped and fed to beam A using two clamping elements, while the processing material is fixed with transport elements or a transport bar.
  • Page 118 Controls and operation 4.15.1 Transport elements, transport bar (optional) Screw, compressed air on/off Screw to fix the transport elements Transport element Transport bar (optional) 4.15.1.1 Adjusting the transport elements A Loosen the screw for fixing the transport element. B Position the transport element (pay attention to the hose length). C Tighten the screw for fixing the transport element.
  • Page 119 Controls and operation 4.15.1.3 Installing the transport bar Turn off the cutter with SHIFT - B Loosen the transport element fixing. C Position the transport elements. D Loosely screw the transport bar to all transport elements using the supplied self-locking screws. E Tighten the transport element fixing.
  • Page 120 Controls and operation 4.15.2.2 Automatic feed Tip: Material transport takes place with beam A. To enable a maximum feed and prevent a collision, beam B automatically moves all the way to the front. The feed length is defined (1-7-1-2 Length) during automatic feeding.
  • Page 121 Controls and operation A feed is executed. If the feed length is greater than the length of the work surface, this process is repeated until the specified length is reached.

  • Page 122: Integrated Tool Initialization - Iti

    Controls and operation 4.16 Integrated Tool Initialization - ITI The tool is initialized via permanently installed, automatic initialization system. Two ITI's are installed on the machine as standard, either to the left or right of the working surface. Two further ITI's can be installed as an option.
  • Page 123 Controls and operation ITI left (initialization of beam A tools in slots 1, 2) ITI right (initialization of beam A tools in slots 2, 3) ITI right (initialization of beam B tools in slots 2, 3) ITI left (initialization of beam B tools in slots 1, 2) From the beam's perspective.
  • Page 124 Controls and operation 4.16.1 Important menu settings General settings Menu Setting 1-1-1-2-2 Auto init Initialize active tool with ITI 1-1-1-2-3 Up Z pos Enter the up position 1-1-1-2-4 Down Z pos Enter the down position 1-6-3 additional underlay Switch ON/OFF whether an additional underlay is being used. Set the height of the cutting base Menu Setting...

  • Page 125: Initialization Process

    Controls and operation 4.16.2 Initialization process During initialisation, the tool tip (e.g. blade) is set to the exact height of the cutting board surface. This position serves as basis to determine the cutting depth (down position) and the tool position in raised state (up position).

  • Page 126: Automatic Initialization

    Controls and operation 4.16.3 Automatic initialization Note: Risk of damage to the cutter and tools! • Use the ITI for compatible tools only. • For more information, consult the operating manual of the relevant tool. Tip: By starting the automatic initialization function, the active tool automatically moves to the correct ITI: •...
  • Page 127 Controls and operation 4.16.4 Calibrating the cutting board To achieve perfect results, the thickness of the used cutting board must be calibrated. Calibration is necessary under the following circumstances: • Wear on the cutting board. • When using a new cutting board. If a second board is used, for example for routing, this additional underlay must also be calibrated (Use of additional underlay on page 128).
  • Page 128 Controls and operation 4.16.4.2 Use of additional underlay Cutting board Additional underlay (e.g., routing underlay) Height of additional underlay Tip: Use the tool to calibrate the additional underlay with which it is used. A Place the additional cutting board on the working area. B Activate the additional cutting board with 1-6-3 additional underlay.

  • Page 129: Laser Pointer, Reference Point

    Controls and operation 4.17 Laser pointer, reference point 4.17.1 Laser pointer Connection 1 - port 1 Connection 2 - port 2 Connection 3 - port 3 Laser pointer exit Connecting powered tools on page 105. 4.17.2 Pointer selection Optionally, either the current tool or the laser pointer can be set as the pointer. The position of the pointer is used to define, for example, the reference point or the vacuum width.

  • Page 130: Reference Point

    Controls and operation 4.17.3 Reference point Tip: The reference point can optionally be set with the selected pointer on system A or B. A reference point can be defined on the processing surface of the cutter. This reference point is the starting point for the processing procedure and corresponds to the zero point of the processing file.
  • Page 131 Controls and operation Reference point Zero point X/Y axis, cutter...

  • Page 132: Icc Camera, Automatic Registration (Optional)

    Controls and operation 4.18 ICC camera, automatic registration (optional) 4.18.1 ICC camera Connection 1 - port 1 Connection 2 - port 2 Connection 3 - port 3 Fixing screw Stop Laser beam exit Camera lens on page 105. Connecting powered tools 4.18.2 Registration marks The ICC camera is used to determine the position of printed material on the processing surface using software.
  • Page 133 Controls and operation Tip: When using the ZCC software register, marks with a diameter of6 - 8 mm0.2 - 0.3 inare recommended for use. Registration marks Registration mark requirements in case of reflective materials Color - the image evaluation in the front end software can also use the color to detect the registration mark, along with the shape.
  • Page 134 Controls and operation 4.18.3 Setting the ICC camera position Fixing screw Spacer Material Cutting board A Open the spacer. B Untwist the fixing screw. C Lower the ICC camera until the stop. D Twist the fixing screw. E Close the spacer.

  • Page 135: System Calibration

    Controls and operation 4.19 System calibration Systems A and B can be adjusted to one another to increase the connection accuracy. This calibration can be performed if inaccuracies occur between the two systems. The calibration is necessary: • In case of inadequate connection accuracy of both systems. •...
  • Page 136 Controls and operation Note: The cutter automatically performs a system calibration after a restart. Figure 5: Line sample after cutting with System A...
  • Page 137 Controls and operation 4.19.1 Requirements Caution: Injury risk due to objects being ejected! Foreign bodies on the table plate are collected by the beam or the module/tool/module carriage and pushed away! Possible consequences • Facial injuries and other injuries. • Damage to the machine.
  • Page 138 Controls and operation 4.19.2 Cutting the line sample Start position A On the system, select A in the 1-6-5-1-2 Calibration menu. B Press the Start key and follow the further instructions. C Place A4-size material onto the center of the table approx. 200 ‒ 300 mm from the right edge. D Use the travel keys on control panel A to move the laser pointer to the lower right corner of the vinyl.
  • Page 139 Controls and operation X- (example −3) X+ (example +4) Selection value Procedure if the center lines of the line samples deviate from one another A Depending on the selection value prefix, select either the X+ or X- soft key on the control panel. B Press the softkey until consistent cuts are achieved.
  • Page 140 Controls and operation 4.19.4 Y calibration Caution: Danger from very fast beams and module movement of system B. After confirming the last correction value, the module travels to beam B at a high rate of speed towards front right. Make sure that no people or objects are in the danger area. Result Selection value (Example -3)
  • Page 141 Controls and operation How to proceed in case of a match Confirm the match with OK. Results • Beam B cuts the next cutting sample. • Repeat the process until all three cutting samples have been cut. • The module on beam B travels towards the front left. •...

  • Page 142: Module Carriage Slot Protective Plate

    Controls and operation 4.20 Module carriage slot protective plate Warning: Crushing risk! The module carriage area is not monitored by safety devices. • Do not reach into the active area of the cutter during operation. • Protect non-occupied slots with slot protective plates. On the one hand, the slot protective plate is used as a safety device, and on the other it is used to protect a free module slot from contamination.

  • Page 143: Signal Lights (Optional)

    Controls and operation 4.21 Signal lights (optional) Signal lights are used to visually indicate the cutter's operating status, warnings and any errors. Signal color Operating state/meaning/effect STOPPED Cutter stops Error OFFLINE Cutter stops Yellow Machining continues; a warning appears on Warning the operating unit Green...

  • Page 144: Module And Tool Holder (Optional)

    Controls and operation 4.22 Module and tool holder (optional) Note: Always store unused tools and modules correctly in order to avoid damaging them. Store any unused modules and tools in the module and tool holder. The module and tool holder has space for two tools and modules.

  • Page 145: Tips For Cutting

    Tips for cutting 5 Tips for cutting Efficiency and production quality can be affected by many factors. If you are not satisfied with the quality of your job, the following questions can help: 1 Can the tool used cut the material? 2 Can the blade used cut the material? 3 Is the blade of high quality? 4 Have the cutting data been processed in a way appropriate for the cutter?
  • Page 146 Tips for cutting 5.2.1.1 Drag knife Drag knives are used in combination with non-powered tools (UCT, SCT, PPT, VCT, KCT,...). • Maximum processing speed • Cheap to purchase and maintain • High cutting force • Particularly suitable for foils, paper, thin folding carton, banners, etc. •...
  • Page 147 Tips for cutting 5.2.1.3 Rotary knife Decagonal (ten-sided) knife (e.g., Z50) • Very high processing speed • Suitable for large radii, straight or large parts • Recommended for breathable materials such as textiles, carbon fiber, glass fiber, etc. • Very large overcut 5.2.1.4 Circular knife Circular knife (e.g.
  • Page 148 Tips for cutting sharpness and stability. Zünd blades are specifically designed and sharpened to handle a wide range of materials. The additional specifications provided for each blade contain a list of the materials for which it can be used. 5.2.2.2 Cutting angle The cutting angle has a major effect on the cutting force.
  • Page 149 Tips for cutting 5.2.2.4 Overcut The pre-cut x is the distance from the centre of the axis of rotation to the first point where the cutting edge cuts the material surface in the direction of travel. The post-cut x is the measurement from the centre of the axis of rotation to the last point where the cutting edge cuts the material surface.
  • Page 150 Tips for cutting Example Z20 Example Z11 Material Cutting board Material thickness Set depth Cutting depth = material thickness t + set depth z Pre-cut Post-cut Sample calculation Z20 Sample calculation Z11 Formula x = 1.2 + 0.11 x TM = 0.58 x TM Cutting TM = 10.2 mm...

  • Page 151: Preparing Cutting Data

    Tips for cutting 5.3 Preparing cutting data Tip: Zünd recommends using Zünd Cut Center - ZCC as the processing software. The data are optimally prepared for the requirements of Zünd cutters. If the front end software sends the curves to the cutter in the form of arc functions, the cutter control unit generates the resolution automatically according to the quality level set.
  • Page 152 Tips for cutting 5.4.2 Speed The speed only has a limited effect on the quality of the cutting result. That is why it should be limited only if the cutting or routing process requires it. The maximum speed that can be reached depends on the cutting contour. High speeds can only be reached in sufficiently long straight sections or sufficiently wide radii.

  • Page 153: Recognising Processing Errors

    Tips for cutting 5.5 Recognising processing errors 5.5.1 Blade clamped at an angle If the blade does not lie exactly at the zero point, a cut is produced that runs parallel to the original cutting path. Contour as per processing file Effectively cut contour due to blade clamped at an angle Deviation of the blade to zero point...
  • Page 154 Tips for cutting 5.5.2 Blade displaced from turning center If the blade tip is not positioned in the turning centre of the tool, the rotational axis of the blade will be displaced. This results in the following quality defects: • The start and end point of the cutting path do not match up •...
  • Page 155 Tips for cutting 5.5.3 XY correction Slight inaccuracies when clamping the blade can be corrected using the XY correction. Correction values, general The penetration point and/or the cut direction of each test cut act as measuring points for the calculation of the correction values. You should therefore observe exactly where the blade penetrates when cutting the 4 lines and mark the penetration points.
  • Page 156 Tips for cutting • Enter the calculated value Y in the field 1-1-1-4-3 Correct Y • Perform a test cut and recalculate the correction value, if necessary. • The Y-correction is complete when the cuts are on the same line (tolerance: ± 0.1 mm). Where necessary, check this using a magnifying glass.
  • Page 157 Tips for cutting 5.5.4 Correcting the overcut Overcut distance at penetration point Overcut distance at the end point An overcut is usually generated at the penetration point At the tip of the blade, the end point of the straight lines when blades have two cutting edges (e.g.
  • Page 158 Tips for cutting 5.5.5 Cutting from 2 sides Overcut Optimized Cutting of corners with overcut. An overcut can be avoided if the cutting path is divided and cutting is carried out from 2 sides. The disadvantage is a longer production time.
  • Page 159 Tips for cutting 5.5.6 Contour error due to overcut on rounded parts Problem Underside The contour cut on the underside of the material corresponds to the desired contour as per the processing file. Top side The contour cut on the top side of the material contains the contour error resulting from the overcut.
  • Page 160 Tips for cutting Solution • Use the X-correction to move the rotational axis of the tool and make a compromise between the top side and underside. • However, moving the rotational axis of the tool will also change the start and end point of the cutting path.
  • Page 161 Tips for cutting Calculating the overcut Depending on the cutting depth, the blade geometry will produce a different level of overcut. When undercuts are created, a distinction is made between pre-cut x and post-cut x . The pre-cut x the distance from the centre of the axis of rotation to the first point where the cutting edge cuts the material surface in the direction of travel.
  • Page 162 Tips for cutting Sample calculation Z11 Formula = 0.58 x TM Cutting TM = 5.2 mm depth Pre-cut = 3,016 mm Post-cut = 3,016 mm Performing X-correction with X/2 Only perform the X correction with the value X/2 after the XY correction has already been performed once.

  • Page 163: Oscillating Cutting

    Tips for cutting 5.6 Oscillating cutting Tip: Oscillating cutting offer the following advantages: • The main cutting direction is vertical as opposed to horizontal. • The horizontal cutting forces are reduced. 5.6.1 Comparison of EOT/POT specifications Tool Stroke A Frequency f [Hz] Stroke speed zv [m/s] [mm] EOT 0.5...

  • Page 164: Tips For Increasing The Rate Of Production

    Tips for cutting 5.6.2 Calculation of maximum speed for EOT / POT 5.7 Tips for increasing the rate of production For high production speeds with good quality,Zünd recommends the following method: • Set the holding times for the tool (Before Down, After Down, Before Up, After Up) to 0 ms. This is usually necessary for tools with a pneumatic Z-axis.

  • Page 165: Identifying And Rectifying Quality Problems

    Tips for cutting Option max. speed [m/s] Without auxiliary drive With auxiliary drive Roll-off unit, universal, passive Roll-off unit shaft, passive Roll-off unit, universal, active 0.25 Roll-off unit shaft, active Center winder Roll-up unit shaft, active Roll-up unit basket, active 0.25 BHS feeder BHS stacker...
  • Page 166 Tips for cutting Jerky, stuttering cutter movement Processing data are of poor quality. Revise the processing data. Send curves to the cutter as arc functions. The acceleration is too high Reduce the acceleration 1-1-1-3-3 Acceleration The vector intermediate angle, for Check the stop angle (may be too small which the speed is reduced to zero if –...
  • Page 167 Tips for cutting Set depth too low Set greater set depth 1-1-1-2-7 Z- offset "continuous path" set incorrectly. Switch on "continuous path" 1-1-1-3-1-6 Prescribed maximum speed Continuous Path exceeded. Connections from beam A to beam B not correct Blade incorrectly clamped. Check mechanical blade position.
  • Page 168 Tips for cutting...

  • Page 169: Maintenance

    Maintenance 6 Maintenance This chapter contains information on the following: • Safe maintenance of the machine • Using operating resources • Maintenance work and maintenance intervals • Instructions for disposal • Starting up after periods of standstill The maintenance list takes into account the cutter (base machine). Maintenance activities for modules, tool inserts and options are found in the respective operating instructions.

  • Page 170: Safe Maintenance Of The Machine

    Maintenance 6.1 Safe maintenance of the machine General safety instructions • Do not exceed maintenance deadlines. • Switch the cutter to maintenance mode: switch off and secure against restarting. Also attach a sign to the control panel reading "DO NOT SWITCH ON". •...
  • Page 171 Maintenance Description Task marker pen, slotted screwdriver, needle-nosed pliers, cutter blades Test piece For testing the light curtain (optional)

  • Page 172: Operating Materials

    Maintenance 6.2.2 Operating materials 6.2.2.1 Handling operating materials (hazardous substances, chemicals) Observe the hazard pictograms as well as the H and P sets (formerly R and S sets) which may be affixed to the packaging of the operating materials (cleaning agents, lubricants and adhesives). Additional information can be found in the respective safety data sheets.
  • Page 173 Maintenance Gears To lubricate the gears, a Teflon special grease for precision gears is used. Name Specification Fin Grease MP 2/3 — 6.2.2.4 Auxiliary materials Gluing the conveyor belt Name Specification 2-component adhesive (cartridge) 50 ml + mixing jets and spatulas Masking tape Roll, 2 cm wide Gaffer tape...

  • Page 174: Maintenance List For Trained Operating Personnel

    Maintenance 6.3 Maintenance list for trained operating personnel 6.3.1 Special interval Every 24 operating hours with a router module (RM-A, RM-L) The amount of chips produced during machining depends on several parameters. Therefore, the interval is only a guideline that can be extended or shortened depending on the presence of chips within the beam.

  • Page 175: Every Six Months

    Maintenance on page 189 Clean/oil Y axis guide rails Y axis, oiling the guide bearing and filling the oiler on page 190 Maintenance unit Drain condensation water (see on page Draining the maintenance unit condensate water 197) 6.3.5 Every six months X axis Cleaning/oiling the X axis, guide rails/guide carriage on page 187...

  • Page 176: Maintenance List For Authorized Service Technicians

    Maintenance 6.4 Maintenance list for authorized service technicians Caution: Personal injury possible Heavy or sharp-edged components as well as access to live assemblies • Turn off the cutter at the main switch. • This work may only be performed by authorized service technicians. 6.4.1 Special interval Conveyor replacement Vacuum plate...
  • Page 177 Maintenance Check length compensation Advance Check feed system Clean rubber pads of the feeder elements Clean feed guide rail Clean and oil feeder element piston rods X axis drive, direct drive Clean chipping protection brushes Clean and oil the guide rails/guide carriage Check guide carriage for ease of movement, replace if necessary Clean drive belts Clean drive and guide rollers...

  • Page 178: Cutter Maintenance Mode

    Maintenance Maintenance unit Drain condensation water Check pressure settings ITI tool initialization Check mechanical adjustment with the adjusting gauge Calibrate (1-9-4-1-2 Calibration) Hose routing (option) with guide rails (gantry size L/XL/2XL/3XL-3200, 2XL/3XL-1600, 3XL-2500 and support rack) Clean/oil the guide rails with guide carriage (see Oiling the hose routing) Compressor (option)

  • Page 179: Service Flaps And Covers

    Maintenance 6.6 Service flaps and covers Caution: For safety reasons, all other covers that are not listed here should only be opened for service work by Zünd personnel or personnel authorized by Zünd. Item Name Task Side support cover (A13, A16) Oiling and cleaning the left guide rails Side support cover (A4, A7) Oiling and cleaning the right guide rails...
  • Page 180 Maintenance A Lift the cover. B Tilt out the cover.
  • Page 181 Maintenance 6.6.2 Removing front/rear cover (A22, A23) The machine is in the maintenance position. A Lift the cover. B Tilt out the cover.
  • Page 182 Maintenance 6.6.3 Remove the beam covers (A1a, A3a, A1b, A3b) Tip: The covers are additionally fastened onto the beam with Velcro. A Switch the cutter to maintenance mode. B Manually push the beam into the desired position. C Unscrew the screws at the ends (spanner size 3) and remove with the washers. D To remove the left cover, push the module carriage to the right.
  • Page 183 Maintenance 6.6.4 Removing the front side support covers (A4, A7, A13 , A16) The machine is in the maintenance position. A Remove the safety screws. B Remove the cover plates from the ITI. C Remove the covers.

  • Page 184: Moving The Support Rack

    Maintenance 6.7 Moving the support rack The support rack can be moved to perform service work on the cutter. Fixing bracket Slot Screw with washer Screw with washer Base A Slightly loosen the screws from both fixing brackets. B Loosen the screws from the base. C Press the base outward until the screws hit the slots.

  • Page 185: Visually Inspecting The Machine For Damage

    Maintenance 6.8 Visually inspecting the machine for damage Caution: There is a risk of injury if the machine is damaged! Before daily start-up, ensure that there is no damage on the cutter. • Never start up a damaged cutter or damaged options. •...

  • Page 186: Cleaning The Machine

    Maintenance 6.9 Cleaning the machine Caution: Risk of injury from sharp tools! • Remove all modules and tools from the machine before cleaning. For further information, see Danger area during cleaning. Note: Do not use compressed air to clean the machine. Loose cuttings and other dirt will end up in the bearings and drive belts and damage them.

  • Page 187: Cleaning/Oiling The X Axis, Guide Rails/Guide Carriage

    Maintenance A Activate an EMERGENCY STOP control device before starting work or after initialising the machine. B Repeat the process sequentially for all remaining EMERGENCY STOP control devices. Results If the machine stops correctly, operational safety is ensured. 6.11 Cleaning/oiling the X axis, guide rails/guide carriage Hollow screw Guide carriage Lubrication connection...
  • Page 188 Maintenance J Move the beam forwards and backwards ten times over the length of the guide carriage above the lubrication connection. K Perform steps G - J for the second guide carriage. L Dismantle the lubricating set. M Repeat the oiling of the guide carriage on the same beam on the other side. N Repeat the oiling of the guide carriage on the second beam.

  • Page 189: Clean/Oil Y Axis Guide Rails

    Maintenance 6.12 Clean/oil Y axis guide rails A Put the cutter into maintenance mode (see Cutter maintenance mode on page 178). B Remove the beam covers (see Remove the beam covers (A1, A3)). C Clean entire length of the guide rails using a lint-free cloth. D Soak a lint-free cloth with special guide rail oil and oil the guide rails.

  • Page 190: Y Axis, Oiling The Guide Bearing And Filling The Oiler

    Maintenance 6.13 Y axis, oiling the guide bearing and filling the oiler Tip: The oil bottle or a syringe with cannula can be used for oiling. Oiling with syringe and cannula is easier. Syringe Oiling points Cover Underlay Access to the oiler in the cover A Put the cutter into maintenance mode (see on page 178).

  • Page 191: Oiling The Hose Routing

    Maintenance H Remove the syringe. Oil the lower oiling point in the same way. J Use a lint-free cloth to remove excess oil from the module carriage and the cover. K Remove the cardboard base or drip tray. L Repeat oiling on the module carriage of beam B in the same way. M Remove the cardboard underlay or drip tray.

  • Page 192: Clean Chipping Protection, Brushes

    Maintenance 6.15 Clean chipping protection, brushes A Put the cutter into maintenance mode (see on page 178). Cutter maintenance mode B Use a vacuum cleaner to extract chips and dust from the brushes. 6.16 Cleaning the inside of the beam Note: Chips can cause damage to the Y drive...
  • Page 193 Maintenance • When vacuuming, be careful not to push any chips into the recesses of the guide rollers or holes. A Push the beam forward. B Remove the beam covers (see on page 182). Remove the beam covers (A1a, A3a, A1b, A3b) C Vacuum up the chips from the ends of the beams to the middle.

  • Page 194: Iti, Clean Light Barrier

    Maintenance 6.17 ITI, clean light barrier The machine is in the maintenance position. Thoroughly clean the ITI with a lint-free cloth and remove dust and processing residue.

  • Page 195: Cleaning Transport Elements/Transport Bar

    Maintenance 6.18 Cleaning transport elements/transport bar • The machine is in the maintenance position. • The following tools and materials are ready: • Lint-free cloth • Alcohol Warning: Risk of fire and explosion and risk of chemical burns through the use of alcohol! Alcohol is highly inflammable and poses a risk to health.
  • Page 196 Maintenance • Observe the manufacturer's safety regulations. Note: Disposal Dispose of chemicals and items contaminated with chemicals in accordance with local regulations. Transport element Transport bar Clean the transport elements/transport bar with a lint-free cloth and alcohol.

  • Page 197: Draining The Maintenance Unit Condensate Water

    Maintenance 6.19 Draining the maintenance unit condensate water The D3 cutter has two separate maintenance units for systems A and B. Always drain both maintenance units of condensate water. Stopcock Container Drain screw Disposal The condensate water can become contaminated by oil. Therefore, the condensate water must be disposed of properly according to the specific national regulations.

  • Page 198: Replacing The Vacuum Turbine Cooling Air Filter Under The Cutter

    Maintenance 6.20 Replacing the vacuum turbine cooling air filter under the cutter Position filter Filter pad (120 x 120 mm) Grid Cover A Remove the cover. B Insert the new filter pad and grid according to illustration. C Attach the cover.

  • Page 199: Replacing The Vacuum Turbine Cooling Air Filter Next To The Cutter

    Maintenance 6.21 Replacing the vacuum turbine cooling air filter next to the cutter Hose clip Filter pad (185 mm diameter) A Open the hose clip. B Remove and dispose of the filter pad. C Position the new filer pad with the fleece inwards. D Fix the filter pad with the hose clip.

  • Page 200: Resetting 12.5/14.0 Kw Vacuum Pump Motor Protection Relay

    Maintenance 6.22 Resetting 12.5/14.0 kW vacuum pump motor protection relay The motor protection relay cuts the 12.5/14.0 kW power supply to the vacuum pump under the following circumstances: • Overload • Short-circuit • Phase failure • Current asymmetry • Overheating Note: Repeatedly triggering the motor protection relay may damage the vacuum pump! Contact customer service.

  • Page 201: Icc Camera, Cleaning The Lens (Optional)

    Maintenance 6.23 ICC camera, cleaning the lens (optional) Warning: Risk of fire & explosion and risk of chemical burns through the use of isopropanol Isopropanol is highly inflammable and poses a risk to health. • Keep away from sources of ignition. •...

  • Page 202: Instructions For Disposal

    Maintenance 6.24 Instructions for disposal Note: Contact Zünd customer services or your service partner before you dispose of your cutter. Tip: Zünd cutters do not contain hazardous substances such as heavy metals, asbestos, batteries, toners, ceramics, radioactive substances or similar. Our cutters are modern industrial devices which correspond to current standards and guidelines for the disposal of old appliances.

  • Page 203: Starting Up After Periods Of Standstill

    Maintenance 6.25 Starting up after periods of standstill Note: Before extended periods of downtime or when starting up your cutter after periods at a standstill, contact the Zünd Customer Service department or your service partner. Generally, the machine can be started up immediately, even after prolonged periods of standstill. However, some options require running-in routines, which must be heeded in order to ensure continued maintenance-free operation.
  • Page 204 Maintenance...

  • Page 205: Tools

    Tools 7 Tools...
  • Page 206 Tools...

  • Page 207: Modules

    Modules 8 Modules...
  • Page 208 Modules...

  • Page 209: Material Handling

    Material handling 9 Material handling...
  • Page 210 Material handling...

  • Page 211: Additional Specifications

    Additional specifications 10 Additional specifications...
  • Page 212 Additional specifications...

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