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Intoprint RF510 Operation Manual

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Rev. 1.1
Operations Manual

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Summary of Contents for Intoprint RF510

  • Page 1 Rev. 1.1 Operations Manual...

  • Page 2: Specifications

    Specifications System Data Full HPGL vector cutting compatible with Contour Cutting SmartMark™ opto-electrical line sensor Average Speed 10 feet/min | 3.04 meters/min Web Width Maximum 5" | 10 – 21.5 cm Max Frame Length 14" (35.5 cm) Max Input Roll Diameter 8"...

  • Page 3: Dimensions And Weight

    Power Requirements RF510 500 watts. 115 / 230 VAC / 47 – 63 Hz Dimensions & Weight Depth 21" (53 cm) Width 31" (79 cm) Height 22" (56 cm) Weight 185 lbs (85 kg)

  • Page 4: Items Shipped Unassembled From Machine

    An accessory kit is shipped with the equipment in the crate. These items are required for operating the RF510. The tools included in this kit are specifically sized for the machine and should be stored nearby for easy access. The kit contains the following items:...
  • Page 5 Accessory Kit Cont. Component ID Description H20-007 45° Knife Blade (Red Cap) H20-008 60° Knife Blade (Green Cap) H20-017 30° Knife Blade (Blue Cap) PL-00-02-865 Control Depth Knife Holder If the slitter add-on was purchased, the following parts will be included as well: CN-016-10 Slitter Blade 10pk DT-149...

  • Page 6: Table Of Contents

    5.1 IntoPrint RF Series File Setup Adobe Illustrator ....... . .
  • Page 7 6.2 Webbing the Laminate on the RF510 ........
  • Page 8 11.1 Supply Mandrel ............. . . 57 11.1.1 Tension .
  • Page 9 11.8.8.7 Skew Menu ............62 11.8.8.8 Scale Menu .
  • Page 10 Index Accessory ............4, 4–5, 5, 44, 45–50, 49 Accumulator .
  • Page 11 Registration Marks ............. . 7–11, 33 Remote Panel .

  • Page 12: Safety

    1 Safety...
  • Page 13 Read safety precautions before operating any machinery or equipment. To minimize the event of an accident or injury, knowledge of the machine’s components before use are highly suggested. Wear proper clothing. Do not wear loose clothing, neckties, necklaces, or jewelry, which may be caught in moving parts.

  • Page 14: Site Preparation

    2 Site Preparation...

  • Page 15: Location

    The following are guidelines in preparing the customer site for installation of an IntoPrint equipment. 2.1 Location Provide a sturdy level area for equipment weighing 200+ lbs. Provide adequate clearance around the machine to allow easy access for inspection and maintenance.
  • Page 16 Close the fuse block cover and verify that the desired voltage is showing. Reference “Figure 2: Fuse Block” on page 16 ⚠ Risk of Electrical Fire: Use a 5 amp fuse for 115 VAC input and a 2.5 amp fuse for 230 VAC input. Do not change the fuse location in the fuse block.

  • Page 17: Installation Of Rf510

    3 Installation of RF510...

  • Page 18: Setup Finisher

    The IntoPrint RF510 is a tabletop label finishing device. Once removed from its crate, place the unit on a table that can support 200+ Lbs (90 kg). 3.2 Connection to PC Do not connect the RF510 to the computer until told to do so by the installation USB stick installation program. 3.3 IntoPrint Installation Disc The finisher utilizes either USB interface or Ethernet connection to the computer.
  • Page 19 Press F7 on your keyboard to select the seventh option “Disable driver signature enforcement” “Figure 5” on page 19. As soon as you press the key, your system will boot into Windows. Now you can install the driver for the RF510. Figure 5 Install Setup Cutter Driver.
  • Page 20 3 Installation of RF510 Click yes for auto cutter driver installation “Figure 7” on page 20. Figure 7 Figure 8 Connect cutter to network or usb while machine is powered on “Figure 8” on page 20. Confirm the software found the correct amount of equipment being installed.
  • Page 21 Open remote panel and if prompted the firmware version does not match the remote panel version “Figure 11” on page 21 proceed to Step 4.b. Go to Start menu - IntoPrint - RF510 Firmware load. Follow on screen prompts. Figure 11...

  • Page 22: Control Panel

    4 Control Panel...

  • Page 23: Home Page

    4.1 Home Page The front Control Panel is the primary user interface for the RF510. It is used for input of speed and Force as well as several other functions "Figure 12: Front Panel" on page 23. 4.1.1 Load The Load key is used to initialize the system Figure 12: Front Panel and to Load the media into the accumulator.

  • Page 24: Speed

    4 Control Panel 4.1.4 Speed Pressing Speed displays the Speed menu to control the speed and acceleration. Setting the Speed to 100 is the fastest, trading off quality for speed. A Speed of 1 has the best quality, trading off speed for quality.

  • Page 25: Setting Up Your Label Job

    5 Setting Up Your Label Job...

  • Page 26: Intoprint Rf Series File Setup Adobe Illustrator

    5 Setting Up Your Label Job 5.1 IntoPrint RF Series File Setup Adobe Illustrator An easy to use template that is user friendly and handy for multi-label design projects. This step by step is also available separately. 5.1.1 File Prep...
  • Page 27 4.1.2 Adding Labels Cont. Note: Duplicate your label across the Minimum Label Gap: page as many times as possible, 0.2″ (5mm) while keeping the spacing even. This ensures the waste removal matrix operates smoothly. Tips: Equal Spacing Formula: Add label width + gap = use this as your distance.

  • Page 28: Artboard Resizing

    5 Setting Up Your Label Job 5.1.3 Artboard Resizing Tip: Change the artboard size to Editing Artboard ensure smoother running of the Shortcut: “Shift + O” finisher. Edit your artboard by dragging the top of the artboard down to approximately 1/8” from the cut line.

  • Page 29: Checking Reg Mark

    4.1.4 Adjusting Layers Cont. Once you have selected the necessary items to move, drag the small colored square icon to the appropriate layer. To quickly select only the print data, start by clicking a cut line, Select, Same, Stroke Color, then Select, Inverse. 5.1.5 Checking Reg Mark The RF Series uses a 0.25”...

  • Page 30: Saving Files

    5 Setting Up Your Label Job 5.1.6 Saving Files The Layers panel should have 4 layers. It is suggested to save 2 versions of the file. A Complete File, and a Print File. File options and layers are as shown below. Complete File (AI File): All Layers Visibility On, this ensures the ability to edit...
  • Page 31 4.1.7 Tips for Label Placement Cont. Figure 1a During the label placement Correct process in Illustrator, the bottom side of the artboard will be the leading edge entering the waste matrix removal. Be mindful of the orientation in label placement. Avoid long Figure 1b horizontal edge cuts, resulting Incorrect...
  • Page 32 5 Setting Up Your Label Job 4.1.7 Tips for Label Placement Cont. Figure 2c In "Figure 2c" on page 32, for a Correct consistent waste matrix removal, Feed Direction No Unsupported Points the design with the point facing downward is preferred, due to it being the first portion entering the waste matrix removal.

  • Page 33: Explanation Of Smartmark

    A registration mark and a die line must be created to use with the label artwork so that the RF510 can cut the labels accurately. This is done by creating a new file that contains the artwork and registration mark on one layer and the die or cut line on a separate layer.

  • Page 34: Webbing Guide For Rf510

    6 Webbing Guide for RF510...

  • Page 35: Webbing The Rf510

    Figure 14: Web Path Menu 6.1 Webbing the RF510 To web the IntoPrint RF510 follow the steps below. The RF510 is designed to be a rear-webbed machine, with the inside tracking guides (donuts) set to 1″ from the rear plate.

  • Page 36: Webbing The Laminate On The Rf510

    6 Webbing Guide for RF510 Figure 15: Feed Roller Install 6.2 Webbing the Laminate on the RF510 �� Note: Laminate should always be ¼″ narrower than your label stock Load and center laminate onto upper left mandrel (sticky side up).

  • Page 37: Webbing Test For Rf510

    Hit Load Button on front panel of RF510, the input accumulator will lower to bottom and the output accumulator will rise to the top. Once accumulators stop moving, hit the Load button a second time to disarm the system.
  • Page 38 6 Webbing Guide for RF510 Figure 16a: Webbing Test Figure 16b: Webbing Test Figure 16c: Webbing Test If material moves from “Figure 16a: Webbing Test” on page 38 to “Figure 16c: Webbing Test” on page 38 then material needs to move the direction of the shift under the output nip.

  • Page 39: Test Cut On Rf510

    7 Test Cut on RF510...
  • Page 40 7 Test Cut on RF510 Once the RF510 is webbed, a test cut may be preformed to ensure the proper cut depth. The labels should peel out with ease without cutting into the liner. Hit load button (arms system). Press and hold the down arrow button to bring out cutter carriage above the material.

  • Page 41: Sending Cut Files To Rf510

    8 Sending Cut Files to RF510...
  • Page 42 8 Sending Cut Files to RF510 Launch Adobe Illustrator Open label in AI (File > Open). Select die-line in layers (will highlight blue) Cut or die line is in layers dialogue box (if layers box not open, go to top menu bar & select Window > layers (confirm the ‘eye’ is in the left box to show cut line).

  • Page 43: Using Accessories

    9 Using Accessories...

  • Page 44: Weed Bar

    9 Using Accessories 9.1 Weed Bar The Weed Bar is used when cutting medium to larger sized shapes. The bar is spring-loaded and can be installed or removed without using any tools "Figure 19: Weed Bar & O-Rings" on page To remove: Push the bar toward the rear of the machine and lift it out from the operator end to release it.

  • Page 45: Maintenance & Consumables

    9.2 Maintenance & Consumables Operating routine maintenance on this machine will require the tools that are shipped in the Accessory Kit. 9.3 Fuses Two spare fuses are provided with the Finisher. A 110V AC will use one 5-amp fuse. 220V AC uses two 2.5-amp fuses (remove the shorting clip to use two fuses).
  • Page 46 9 Using Accessories Figure 20: Fuse Door Fuse Block Fuse Block Cover   Figure 21: Fuse Block Fuse for 115V system fuses for 230V system on both sides ...

  • Page 47: Changing The Knife Blade

    9.5 Changing the Knife Blade The Knife Blade should be replaced when the force has been increased by more than 20% or the cut quality has degraded. The first sign of blade degradation usually occurs in the corners of the cut and may lead to poor weeding. Remove the used blade.
  • Page 48 9 Using Accessories Safely discard the blade. Insert a new blade. Take out a new blade from its plastic case and remove the protective latex cap. Cap color indicates blade angle (Red: 45° blade, Green: 60° blade, Blue: 30° blade). Carefully insert the new blade into the holder.

  • Page 49: Changing The Cut Strip

    Tighten the thumbscrew on the tool block to keep the Knife Holder in place. 9.6 Changing the Cut Strip The Cut Strip should be replaced when the cut quality deteriorates. Move the knife carriage to the rear of the cutter. Clean any debris from the cut strip groove before removing the existing strip.
  • Page 50 Press down firmly to ensure proper seating. �� Note: It is important to install the Cut Strip fully and evenly, otherwise material “cut through” may occur in some sections across the cutter. “Normal life” and “Advanced life” cut strips are available for the RF510.

  • Page 51: Cleaning The Rf510

    10 Cleaning the RF510...

  • Page 52: Biweekly Cleaning

    10 Cleaning the RF510 Routine cleanings of the cutter is dependent on the usage, as well as the climate and contaminants in the cutter’s environment. It is recommended the following be practiced as noted for each procedure. ⚠ Always disconnect the power source while cleaning any part of the machine. Keep the power source disconnected until the cleaning process is completed.

  • Page 53: Rubber Rollers

    Figure 26: Grit Roller, Pinch Wheels, Cut Strip Pinch Wheels Grit Roller Cut Strip (ref)    10.1.3 Rubber Rollers Use rubber roller cleaner and a soft cloth. Adhesive build-up may be removed using the roller cleaner and gently scraping the surface. ��...

  • Page 54: Annual Cleaning

    10 Cleaning the RF510 10.3 Annual Cleaning Be aware and follow static discharge safety procedures that may damage sensitive electronic components. Wear a grounding strap connected to earth ground. Wear safety glasses to protect eyes. ⚠ Always disconnect the power source while cleaning any part of the machine. Keep the power source disconnected until the cleaning process is completed.

  • Page 55: Pc Remote Panel

    11 PC Remote Panel...
  • Page 56 Advanced features are only available as a PC based remote panel for IntoPrint RF510. Those features can be run from the PC Remote Panel. Click Start → All Programs → IntoPrint → RF510 Remote Panel. The home page is shown below in "Figure 27: PC Remote Panel Home Page" on page 56.

  • Page 57: Supply Mandrel

    The tension of the laminate mandrel is set by the lower knob on the left side of the machine. 11.3 Matrix Mandrel The Matrix menu is not necessary to operate the RF510. 11.4 Input/Output Nip Current Nip Speed is the turning nip motor speed. Max Nip Speed is the maximum nip speed allowed to turn.

  • Page 58: Input Accumulator

    11 PC Remote Panel Auto Speed Adjust Rate is how much the speed can be adjusted by the software when increasing or decreasing nip speed. Load Speed is the speed of the nip during the load process. 11.5 Input Accumulator Accumulator Position: The amount of media that is in the Input Accumulator "Figure 29: Input „...

  • Page 59: Takeup Mandrel

    Comm Port: Changing the communication port in relation to the cutter. „ Default Gain: Default gains will default the x, y, z tuning to default values in the cutter. „ Reinit Nvrom: Initializes all settings on the RF510. „ Mandrel Calibration: Displays the Mandrel Calibration Menu. „...

  • Page 60: Mandrel Calibration

    11 PC Remote Panel Serial number: Displays the Serial number of the Figure 31 Machine Menu „ cutter. It can be used to inform you of available software updates. 11.8.2.1 Mandrel Calibration The Mandrel Calibration sets the power level to stop motors "Figure 35: Mandrel Calibration Menu"...

  • Page 61: Com Port

    11.8.2.2.2 COM Port Figure 35: Mandrel Calibration Menu Select the port button to set the communication port used to converse with the cutter. 11.8.2.2.3 LAN Settings In order to change the LAN setting you must be connected to the cutter via-USB. DHCP —...

  • Page 62: Cutting Head

    11 PC Remote Panel 11.8.6 Cutting Head Figure 37: Display Pot Graph Flag Sensor diagnostic. 11.8.7 Knife Minimum angle of cut, knife offset. 11.8.8 SmartMark™ "Figure 30: SmartMark™ Sensor Menu" on page 59 11.8.8.1 Registration X & Y Axis Moves cut in relation to the target. 11.8.8.2 Scan Length Sets the length the target is looked for.

  • Page 63: Scale Menu

    11.8.8.8 Scale Menu Amount moved searching for scale target. 11.8.8.9 Cut Frame Rotate Calculates and sets frame rotation error. 11.8.8.10 Flag and SmartMark Sensor Sensor values and LED intensity. 11.8.8.11 Minimum Reflectance Change. Set intensity to sense a target. 11.8.9 Consumable Parts List A list of p/n that can be ordered.

  • Page 64: Troubleshooting

    12 Troubleshooting...

  • Page 65: Pinch Wheel Maintenance

    12.1 Pinch Wheel Maintenance Pinch Wheels are critical to the RF510 material handling performance. They should be regularly inspected and cleaned as needed. Best practices will prolong the performance and life of the Pinch Wheels. However, for normal usage they will need to be replaced as typical wear and tear over time.

  • Page 66: Rf Series Error Codes

    12 Troubleshooting 12.4 RF Series Error Codes Error Code Description Action/Additional Info All panel lights off, check cable from power switch to Blank No power MMC board, fuses on power entry module (if present), wall plug has electricity. No error Can’t erase configuration area Can’t write configuration area Impossible Result: Knife rotate...
  • Page 67 Error Code Description Action/Additional Info too many parameters in device control command Invalid character in escape command Escape command not implemented Device control parameter out of limits The motor current sensor on the DSPIC is not working. As this is a non-critical error this error DSPIC ADC failed.
  • Page 68 12 Troubleshooting Error Code Description Action/Additional Info 36 — D031 Bad front panel key received Must run diagnostic D008, Bad calibration constants then calibrate cutter. HPGL compatible command parser error RS232 device overrun (PIC18 to PIC32) RS232 framing error (PIC18 to PIC32) RS232 parity error (PIC18 to PIC32)
  • Page 69 Error Code Description Action/Additional Info Reference motor position too far from actual motor position. This can be caused by speed or acceleration too high, jerking material Excessive position error x-axis from a heavy roll, media jam, bad calibration constants, power surge, SERVO motor / encoder failure, MMC PCB failure.
  • Page 70 12 Troubleshooting Error Code Description Action/Additional Info Excessive velocity x axis Software failure in end point calculated end point calculation. Excessive velocity y axis Software failure in end point calculated end point calculation. Acceleration too long or 90 — 94 Impossible result (software error) slew time →...
  • Page 71 Error Code Description Action/Additional Info Unexpected CorExtend Unuseable Unexpected coprocessor 2 Realign red dot with target tar1 Target missed origin and press select or press load to cancel job. Realign red dot with target tar2 Target missed skew and press select or press load to cancel job.
  • Page 72 12 Troubleshooting List of actions performed during boot up and self test. A display hanging on one of these codes points to the electronics assembly. Boot “a” codes Description a001 Power up complete starting external RAM test (boot flash) a002 INIT routines complete (PIC32 initialized to run) (boot flash) Power up complete (branch to main successful, now starting PIC32 a003...
  • Page 73 Boot “a” codes Description a019 Wait for INITSVO a020 Wait for CALIBINIT a021 Wait for SET_NOT_READY a022 Wait for PID_INIT a023 Wait for reset SERVO bypass a024 Wait for enable SERVO interrupt a025 Wait for test DIAG mode a026 Wait for test front panel mode a027 Wait for INITPOS a028...
  • Page 74 12 Troubleshooting Boot “a” codes Description a039 Programming DSPIC a040 Programming PIC18 a041 Programming USB a042 Programming PIC32 a043 Programming complete (starting user program) a045 EEROMINIT call EEROMINIT_CHECKSUM a046 Programming MOTAMP a061 Download of XMODEM record did not start with SOH character (retry) a062 Download of XMODEM record number incorrect (retry) a063...
  • Page 75 Boot “a” codes Description a076 ACCTZINIT a077 ADCINIT a078 FOGL _INIT a079 FORDYNAMINIT a080 GLOBUF_ ALLOC a081 SET_BALA _INIT a082 INITCBUF a083 MOT DYNAM INIT a084 COMM dynamic INIT a085 SPI INIT a086 OPEN COMM a087 USB DETACH a088 USB ATTACH a089 Release DSPIC from reset...

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