Inst Xl Eng 22122011nk.pdf

AUTOMATIC CUTTER

Operation and Maintenance Manual Translation of the original instructions Support:

Phone

+39 015 925344

Fax

+39 015 925346

E-Mail

[email protected]

Operation and Maintenance Manual – Rev.00/2012 Page I

Automatic Cutter - XL Series

XL series

AUTOMATIC CUTTER XL series

Automatic Cutter - XL Series

Important:  Read this manual carefully before operating the machine.  Keep this manual together with the machine.  Do not remove pages from or damage the manual.  Upon receiving this manual the Customer becomes responsible for informing the machine users about all use and safety procedures related to the machine.

Fotoba s.r.l. congratulates you for choosing one of their products, the result of technical experience and constant research, the vital elements that guarantee you quality and safety. In this manual you will find all the technical and operating information concerning the product you purchased, which will allow you to achieve the best performance under completely safe conditions.

Operation and Maintenance Manual – Rev.00/2012 Page II

INSTRUCTION MANUAL REVISIONS

Revision

Description / Issue

Chapter / paragraph

Checked

1 Date ……………

…………………………………… …………………………………… Signature: ................................

2 Date ……………

…………………………………… …………………………………… Signature: ................................

3 Date ……………

…………………………………… …………………………………… Signature: ................................

Operation and Maintenance Manual – Rev.00/2012 Page III

Automatic Cutter - XL Series

AUTOMATIC CUTTER XL series

TABLE OF CONTENTS

Automatic Cutter - XL Series

CHAPTER 1. 1.1 1.2

Introduction..................................................................... 2 General rules ................................................................... 2

CHAPTER 2. 2.1

INTRODUCTION ......................................... 1

CE CERTIFICATION .................................... 5

Compliance Statement ...................................................... 6

CHAPTER 3.

GENERAL INFORMATION ........................... 9

3.1 Manufacturer data .......................................................... 3.2 Machine Identification Label ............................................. 3.3 Machine Description ........................................................ 3.3.1 Web materials to be handled ........................................ 3.3.2 Width of the web material ............................................ 3.3.3 Intended work ............................................................ 3.4 General technical specifications ........................................ 3.5 Machine description ........................................................ 3.5.1 Unwinder ................................................................... 3.5.2 Unwinder XL 250 - 320 ................................................ 3.5.3 TJOL Unwinder (Optional) ............................................ 3.5.3.1 Unwinding types .................................................... 3.5.4 Feeding assembly ....................................................... 3.5.5 Alignment control system ............................................. 3.5.5.1 Transversal alignment (X axis) ................................. 3.5.5.2 Longitudinal alignment (Y axis) ................................ 3.5.6 Longitudinal slitting system (Y axis) .............................. 3.5.7 Transversal slitting system (X Axis) ............................... 3.6 Overall dimensions .........................................................

Operation and Maintenance Manual – Rev.00/2012 Page IV

10 11 12 12 12 13 13 14 14 14 15 16 18 19 20 22 23 26 29

4.1 4.2 4.3 4.4 4.5 4.5.1 4.5.2 4.5.3 4.6 4.7 4.8

General safety precautions .............................................. Definitions ..................................................................... General safety precautions .............................................. Hazards arising from non-compliance with safety rules ....... Accident prevention symbols ............................................ Dangers ..................................................................... Prohibitions ................................................................ Obligations ................................................................. Safety devices ............................................................... Safety provisions to be carried out by the user company ....................................................................... Residual Risks ................................................................

CHAPTER 5. 5.1 5.2

32 32 33 34 34 35 36 36 38 39 39

TRANSPORT ............................................. 41

General rules ................................................................. 42 Transport modality ......................................................... 43

CHAPTER 6. 6.1 6.2 6.2.1 6.3 6.4 6.5 6.6 6.7 6.8

SAFETY .................................................... 31

INSTALLATION ........................................ 45

Leveling ........................................................................ Connections ................................................................... Electric connection ...................................................... Pneumatic connection ..................................................... Permissible environmental conditions ................................ Device calibration and setting .......................................... Noise Level .................................................................... Storage ......................................................................... Scrapping ......................................................................

CHAPTER 7.

46 47 47 48 48 49 49 49 49

DRIVES AND CONTROLS .......................... 51

7.1 Control panel ................................................................. Main User Menu ....................................................................... 7.1.1 Setting a feeding length ............................................... 7.1.2 Storing a feeding length ..............................................

Operation and Maintenance Manual – Rev.00/2012 Page V

52 53 55 56

Automatic Cutter - XL Series

CHAPTER 4.

Automatic Cutter - XL Series

7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9 7.1.10 7.1.11

Scan of a cut mark (transversal) ................................... Storing a cut mark ...................................................... Job in a combined length / mark mode .......................... Storing a cut mark and a length (for TJOL only) .............. Recalling a memory channel ......................................... Setting the cutting of multiple copies ............................. Double transversal slitting ............................................ Setting the longitudinal alignment control system ........... Adjusting the transversal cutting speed .........................

CHAPTER 8.

OPERATION ............................................. 63

8.1 8.2 8.3 8.4 8.5 8.6

Switching the machine on................................................ Loading the reel (machine version with unwinder) .............. Threading the web material ............................................. Loading single sheets ...................................................... Panel settings ................................................................ Positioning of the longitudinal alignment control sensors (Y axis) ......................................................................... 8.6.1 Manual mode .............................................................. 8.6.2 Automatic mode.......................................................... 8.7 Positioning of the longitudinal slitting stations .................... 8.8 Starting production ......................................................... 8.9 Semi-automatic mode operation....................................... 8.10 Operator position ........................................................... 8.11 Prohibitions for injury prevention ......................................

CHAPTER 9.

56 58 58 59 59 60 61 61 62

64 64 67 67 68 69 69 70 70 73 73 74 74

MAINTENANCE ......................................... 76

9.1 Maintenance safety warnings ........................................... 9.2 Routine Maintenance ...................................................... 9.2.1 Cleaning and lubrication ............................................... 9.2.2 Checks and verifications............................................... 9.2.2.1 Checking compressed air filter (FR assembly) ............ 9.2.2.2 Checking tension of transmission belts ...................... 9.3 Extraordinary maintenance .............................................. 9.3.1 First operation ............................................................ 9.3.2 Subsequent operations ................................................

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77 78 78 84 84 85 86 86 88

CHAPTER 10. CALIBRATIONS ........................................ 90 91 91 92 93 94 95 96 98

CHAPTER 11. TROUBLESHOOTING............................... 100 11.1 11.2

Cutting bent web materials ............................................. 101 Common problems ........................................................ 103

Operation and Maintenance Manual – Rev.00/2012 Page VII

Automatic Cutter - XL Series

10.1 Calibration menu map (control panel) ............................... 10.1.1 Card A/1 .................................................................... 10.1.2 Card A/2 .................................................................... 10.1.3 Card A/3 .................................................................... 10.1.4 Card A/4 .................................................................... 10.1.5 Card A/5 .................................................................... 10.1.6 Setting the distance between transversal slitting and sensors (offset) .......................................................... 10.1.7 Disabling the transversal slitting ...................................

Automatic Cutter - XL Series

Operation and Maintenance Manual – Rev.00/2012 Page VIII

INTRODUCTION

Operation and Maintenance Manual – Rev.00/2012 Page 1

Automatic Cutter - XL Series

CHAPTER 1.

1.1

Introduction

This manual provides all the necessary information for machine operation and maintenance. Perfect functioning and long life of the machine depend on proper maintenance and operating care. This machine underwent rigorous testing prior to leaving the manufacturing plant; nevertheless, upon delivery, check that the machine did not, during transport, suffer structural damages that could impair its functions and safety.

Chapter 1 - Introduction

This instruction manual is to be regarded as an inseparable part of the machine and must accompany it until such time as the machine is demolished. The graphic elements in the manual (photographs and/or drawings) are an integration of the descriptive parts and have the purpose of making the system understood. Sometimes they may not be as built. 1.2

General rules

For easy reference, the notes of particular importance are highlighted as follows: NOTE: Notes marked with a caution sign (as seen here) are particularly important for safety and must be strictly complied with by anyone operating the machine. NOTE: Notes marked with this sign (as seen here) are useful to ensure full working capacity and optimal machine performance or they are aimed to focus the reader's attention on a specific point. The information drafted herein is in accordance with reference standard CE 2006/42; all technical details presented cover exclusively the machine in question. WARNING: Keep a copy of the manual in a location that is accessible to all staff in charge of machine operation and maintenance. Keep a second copy in the archives, ready for use in case the first copy is damaged or lost. Fotoba recommends having at least two copies of the manual readily available at all times; if this is not the case, please request an additional copy. The technical information herein is a property of Fotoba and is to be considered of confidential nature. Reproduction, even partial, of its content, text and illustrations is lawfully prohibited.

Operation and Maintenance Manual – Rev.00/2012 Page 2



It is compulsory to limit one’s actions to what is within one’s knowledge. If any doubts or uncertainties should arise, please contact Fotoba's technical department or request a service call;



The machine may be used only by skilled personnel, duly trained on the operations to be performed;



It is strictly forbidden to make any unauthorized changes or modifications. Failure to observe this rule releases Fotoba from any responsibility for any damages and/or malfunctions.

Operation and Maintenance Manual – Rev.00/2012 Page 3

Chapter 1 - Introduction

WARNING: The following rules shall be complied with by anyone operating the machine:

Chapter 1 - Introduction

Operation and Maintenance Manual – Rev.00/2012 Page 4

CE CERTIFICATION

Operation and Maintenance Manual – Rev.00/2012 Page 5

Automatic Cutter - XL Series

CHAPTER 2.

Compliance Statement

2.1

THE MANUFACTURER Fotoba s.r.l.

Chapter 2 - Ce Certification

Company

Via G. Marconi,101

13854

Address

ZIP

Quaregna

Biella (Italy)

Town

Province and Nation

STATES THAT THE FOLLOWING MACHINE Automatic Slitter-Rewinder

XL

Description

Model

Serial Number

Year of manufacture

Cutting of flexible web materials having a thickness up to 0.8 mm Expected use

COMPLIES WITH THE FOLLOWING DIRECTIVES 

European Parliament and Council Directive 2006/42/CE of the 17th May 2006, covering machines, and amending directive 95/16/CE.



European Parliament and Council Directive 2004/108/CE of the 15th December 2004, covering Electromagnetic Compatibility, and resolving lawful conformance by the Member States to it.



European Parliament and Council Directive 2006/95/CE of the 12th December 2006 relative to electrical material to be used within given voltage limits, and resolving lawful conformance by the Member States to it.



European Council Directive 97/23/CE dated 29.05.97 (covering Pressure Vessels).

Operation and Maintenance Manual – Rev.00/2012 Page 6

Reference to following harmonized standards: EN 14121-1(2007); EN12100-1(2005); EN 12100-2(2005); EN 602041(2006). AND AUTHORIZES

TO ISSUE THE LEGALLY BINDING TECHNICAL FILE FOR THE SUBJECT MACHINE Should changes be brought to the subject machine without our prior authorization, this statement becomes null and void.

Place, date

The Manufacturer

Operation and Maintenance Manual – Rev.00/2012 Page 7

Chapter 2 - Ce Certification

Engineer Mr. Simone Favari, Via Risorgimento n.24, 27050 Casei Gerola (Pavia), Italy

Chapter 2 - Ce Certification

Operation and Maintenance Manual – Rev.00/2012 Page 8

GENERAL INFORMATION

Operation and Maintenance Manual – Rev.00/2012 Page 9

Automatic Cutter - XL Series

CHAPTER 3.

Chapter 3 - General Information

3.1

Manufacturer data

Manufacturer :

Fotoba International s.r.l.

Address :

Via G. Marconi, 101 13854 Quaregna (BI) - Italy

Phone :

+39 015 925344

Fax :

+39 015 925346

E-Mail:

[email protected]

Internet:

www.fotoba.com

Operation and Maintenance Manual – Rev.00/2012 Page 10

Machine Identification Label

Chapter 3 - General Information

3.2

CE Label

Operation and Maintenance Manual – Rev.00/2012 Page 11

3.3

Machine Description

Chapter 3 - General Information

AUTOMATIC CUTTER FOR DIGITAL PRINTS

3.3.1

Web materials to be handled

The machine can handle flexible web materials with a maximum thickness of 0.8 mm (0.030 in.). Compatible web materials include: polycarbonates, laminated and encapsulated media, photographic paper, banners, vinyl, adhesive materials, PVC, materials for inkjet prints, graphic arts film, duratrans. 3.3.2

Width of the web material

The web material width range is dependent upon the model: Maximum width

Minimum width

cm (in)

cm (in)

TJOL

190 (75)

101 (40)

XL 190

190 (75)

110 (43)

XL 250

260 (102)

110 (43)

XL 320

330 (130)

110 (43)

Model

Operation and Maintenance Manual – Rev.00/2012 Page 12

3.3.3

Intended work

 Unwinding of the web material from the reel (if the machine is equipped with an unwinder);  Feeding of the input web material to the slitting area;  Automatic transversal slitting (as the cut marks pass by);  Support of input web material to the external sheet collecting table. 3.4

General technical specifications



Maximum forward feeding speed of the web material: 18 m/min;



Maximum diameter of the unwinding reel (for machines equipped with an unwinder): 24 cm (10'')



Job settings in inches or centimeters;



Scan and storage of varying types of cut marks (by means of 8 different memory channels);



Web material forward feeding precision ±1 mm (±0.04”);



2 single standard longitudinal slitting stations;



Optional longitudinal double slitting stations (fixed at 8 mm);



Pair of single longitudinal slitting stations for a double slitting from 9 mm onwards;



Automatic control system of transverse (X axis) and longitudinal (Y axis) alignment;



Maximum feed programmable up to 25.4 m;



Double slitting programmable up to 99 mm;



Self-sharpening blades of the slitting assembly;



Electric power supply: 115/230 V a.c. (plus earthing);



Electric power absorption: 250 W;



Microprocessor for function handling;



Machine parts moved by stepper motors;



Electric cabinet built-in to the machine.

Operation and Maintenance Manual – Rev.00/2012 Page 13

Chapter 3 - General Information

 Longitudinal slitting of the web material during forward feeding;

3.5

Machine description

3.5.1

Unwinder

The unwinder is standard on XL 250 and XL 320 models and is optional on the TJOL version.

Chapter 3 - General Information

The assembly consists of low inertia rollers completely supporting the reel allowing it to rotate during unwinding. 3.5.2

Unwinder XL 250 - 320 The speed of the unwinding reel is controlled by Orings which increase the reel rotation friction for maintaining the web tension.

Operation and Maintenance Manual – Rev.00/2012 Page 14

TJOL Unwinder (Optional)

The unwinder is equipped with a clutch to slow down the reel rotation (principle of operation similar to that of the O rings on the unwinder of machine models XL 250 and XL 320).

Operation and Maintenance Manual – Rev.00/2012 Page 15

Chapter 3 - General Information

3.5.3

3.5.3.1

Unwinding types

Three different unwinding configurations can be chosen according to the production's requirements:

Chapter 3 - General Information

With guide flanges

The transverse movement of the unwinding reel is prevented by removable guide flanges, which are placed on the side blocks.

The side blocks can be moved transversally in order to suit the width of the reel.

With chucks

The mechanical expansion chucks are inserted at both ends of the core and rotate with it during the unwinding of the reel.

The unwinder is provided with a clutch which slows down the reel rotation (principle of operation similar to the O-rings of the unwinder for machine models XL 250 and XL 320).

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With reel supports with 5'' cores

The supports structure.

are

fixed

to

the

machine

Two rubber rollers are mounted on each support, to sustain the excesses of the core.

Operation and Maintenance Manual – Rev.00/2012 Page 17

Chapter 3 - General Information

Special supports (optional) can be used for reels with 5'' cores.

Chapter 3 - General Information

3.5.4

Feeding assembly

The assembly consists of a series of transport rollers driven by a stepper motor on which a pressure assembly constituted by idle rolls operates. The pressure exerted by the pressure rollers on the transport rollers determines the feeding of the web material forward toward the slitting zone.

The pressure assembly is manually lifted by means of levers (one on each side).

The movement of the pressure assembly is actuated by means of a pair of pneumatic cylinders which are controlled by a pedal (this is optional on models TJOL and XL 190, of series XL 250 and XL 320).

NOTE: the pressure on the transport rollers is caused by the sheer weight of the pressure assembly.

Operation and Maintenance Manual – Rev.00/2012 Page 18

3.5.5

Alignment control system

The machine is equipped with two alignment control systems: transverse (X axis) and longitudinal (Y axis).

The standard Fotoba cut mark is constituted by two black stripes on a white background, with a width of 2 mm and with a space of 2 mm between them; the distance from the edges of the image must be 4 mm. If the cut marks fall within these parameters, the alignment control system is able to work very precisely, even if the mark definition is not ideal.

Y

X Printing with transversal cut marks (X axis) and longitudinal cut marks (Y axis)

Operation and Maintenance Manual – Rev.00/2012 Page 19

Chapter 3 - General Information

The operation of the system depends on the cut marks printed on the web material.

NOTE: the blue arrow indicates the feeding direction of the web material.

Chapter 3 - General Information

NOTE: The external longitudinal cut mark can also consist of a single black stripe, 2 mm wide, with a minimum distance of 1 mm from the image edges. The distance from the edges of the web material must be between 1 and 13 cm. 3.5.5.1

Transversal alignment (X axis) The transversal cut mark is detected by two optical sensors positioned on the pressure assembly; if the sensors do not detect the mark passing by at the same time due to the printing being misaligned, the system automatically moves the cutting system (both the slitting and transversal cut-off system) in order to make in any case a cut which is parallel to the print.

Transversal misalignment detection (X axis)

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Operation and Maintenance Manual – Rev.00/2012 Page 21

Chapter 3 - General Information

Correction of the transversal alignment control system (X axis)

Chapter 3 - General Information

3.5.5.2

Longitudinal alignment (Y axis)

The optical sensors of the longitudinal alignment control system detect the mark or the edge of the web material during forward feeding.

In case of misalignment between longitudinal cuts and longitudinal cut marks are misaligned, the longitudinal slitting assembly is moved transversally to correct the error (up to ±3 cm).

Correction of the longitudinal alignment control system If the distance between the cut mark and the edge of the web material is greater than 13 cm (or if the cut mark is not present), the sensor must be positioned along the edge of the web material.

Operation and Maintenance Manual – Rev.00/2012 Page 22

Longitudinal slitting system (Y axis)

The longitudinal slitting system consists of a series of single or double slitting stations, with transversal movement; each of them consists of a series of web material transport rollers (1) and one or two pairs of circular blades (5). The circular blades and the lower transport rollers are rotated by means of a shaft (4) driven by its own step motor. NOTE: lower blades and rollers can only rotate in the same direction as the feeding of the web material; counter-rotation is prevented by a 'free wheel' system. Each slitting station is equipped with a feeding guide for the web material (6) and a reference mark (7) indicating the correct working position for the station. The newly cut web material is supported by plates (8) which keep it flat until it reaches the external collecting table.

Single cuts

Double cuts

Operation and Maintenance Manual – Rev.00/2012 Page 23

Chapter 3 - General Information

3.5.6

Chapter 3 - General Information

According to the width of the longitudinal trim the following can be used: A

Single slitting stations (to trim or to trim copies which are joined).

B

Double slitting stations, to slit copies which are not joined, 8 mm wide, two pairs of blades (5).

C

Coupled narrow single slitting stations, that is a pair of narrow slitting stations placed one beside the other.

Slitting stations: single (A), double (B) and single narrow (C)

Parts of the longitudinal slitting system

Operation and Maintenance Manual – Rev.00/2012 Page 24

The end of the shaft on the other side of the controlling end rests on a support which must be removed in order to insert and extract the slitting stations.

Transversal movement of the longitudinal slitting system Moreover, the whole cutting system is rotated angularly by the action of the transversal alignment control system (paragraph 3.5.5.1).

Angular movement of the slitting system

Operation and Maintenance Manual – Rev.00/2012 Page 25

Chapter 3 - General Information

The longitudinal slitting system is moved transversally by the action of the longitudinal alignment control system (paragraph 3.5.5.2).

Chapter 3 - General Information

3.5.7

Transversal slitting system (X Axis)

The transversal slitting system consists of two pairs of in-line circular blades: two upper blades (1) and two lower blades (2); the system is moved by means of a toothed belt (3) controlled by its own stepper motor.

When the transversal cut mark is in the slitting position, the web material is stopped and the transversal slitting system moves toward the opposite side of the machine, cutting the web material along its entire width.

Operation and Maintenance Manual – Rev.00/2012 Page 26

Web material blocking belt operation during cutting As already indicated in the previous paragraph, the transversal cut-off assembly is rotated angularly together with the longitudinal slitting assembly by the action of the transversal alignment control system.

Angular rotation of the whole cutting system (view from above)

Operation and Maintenance Manual – Rev.00/2012 Page 27

Chapter 3 - General Information

During the slitting operation the web material is "pinched" by the yellow belt (4) moved into contact by the slitting station (the web material passes between the belt and the structure).

Chapter 3 - General Information

If the job requires the transversal trim of the web material (double slitting): A

The transversal slitting system carries out the first cut after having aligned itself with the mark;

B

The web material is fed forward for a distance equal to the width of the trim (double slitting);

C

The transversal slitting system carries out the second cut;

D

The web material starts moving again. NOTE: A transversal trim can be set between 0.5 and 99 mm with increments of 0.5 mm.

Transversal trim slitting (double slitting)

Operation and Maintenance Manual – Rev.00/2012 Page 28

Overall dimensions

TJOL and XL190 models

H= 2824 mm

XL 250 model

H= 3584 mm

XL 320 model

H= 4284 mm

Operation and Maintenance Manual – Rev.00/2012 Page 29

Chapter 3 - General Information

3.6

Chapter 3 - General Information

Operation and Maintenance Manual – Rev.00/2012 Page 30

SAFETY

Operation and Maintenance Manual – Rev.00/2012 Page 31

Automatic Cutter - XL Series

CHAPTER 4.

4.1

General safety precautions

Pursuant to Legislative Decree 81/2008, the head of safety is obliged to inform the operators of the risks related to use of the machine. Moreover, the employer must provide information and training for the machine operators as prescribed by the current laws. Failure to observe the basic safety rules may cause accidents during machine operation, maintenance or start-up.

Chapter 4 - Safety

Fotoba machine control takes into account all possible circumstances that may create danger. Nevertheless, it is recommended to operate the machine only in accord with what is described in this manual, taking care that additional unexpected risks will not arise. 4.2

Definitions

USER: Person who is authorized to operate the machine (operator or service engineer). OPERATOR: Person or persons assigned to adjustment, routine maintenance and/or cleaning.

machine

operation,

SERVICE ENGINEER: A qualified or specialized person who is duly trained and capable of installing, repairing and performing unscheduled maintenance operations, all of which require thorough knowledge of the machine, particularly its safety devices. WARNING: During special procedures, the presence of an additional operator may be necessary. This is allowed only if that person and the official operator are able to stay in sight of each other. The official operator shall, however, make sure that the assistant operates under safe conditions.

Operation and Maintenance Manual – Rev.00/2012 Page 32

4.3

General safety precautions

The machine must be used exclusively for the work indicated in the technical specifications (section 3.3 and subsequent sections); the use of web materials not intended for the technical specifications is strictly forbidden. Fotoba shall not be held liable for damages arising if the machine and/or its components are used improperly.

WARNING: The following directions are to be strictly complied with: 

Always use appropriate personal safety devices according to the operations carried out;



The machine is not to be run by operators with heart problems or carrying auxiliary equipment for assisted vascular circulation;



Except for the operators, no other persons are to stand in the operating range of the machine;



Machine use is limited to authorized and trained personnel; if any doubts or uncertainties should arise, contact Fotoba and request a service call;



The machine is not to be used in a corrosive and/or explosive environment;



Keep the machine clean;



Keep the floor clean;



Do not use flammable or toxic solvents for cleaning;



In case of fire, only use CO2 extinguishers and never throw water on the machine;



Always keep the instruction manual at hand;



Do not touch electric wires, selector switches, pushbuttons etc. with wet hands;



It is prohibited to remove or try to by-pass the accident prevention devices on the machine and/or in the electric cabinet;



Do not perform any procedure that could compromise machine reliability and /or operator safety;

Operation and Maintenance Manual – Rev.00/2012 Page 33

Chapter 4 - Safety

NOTE: The instruction manual herein must be read and fully understood before machine start-up.



At the beginning of the shift, the operator must check the machine to see whether any changes have occurred that may jeopardize safety, advising the supervisor if such changes are found. NOTE: The information contained in this manual cannot provide absolute protection from all hazards one may be exposed to while operating the machine. They are to be integrated with common sense and experience.

Chapter 4 - Safety

4.4

Hazards arising from non-compliance with safety rules

This machine has been designed to guarantee safety and reliability over time. Nevertheless, operation of the machine that is not in accordance with specifications and/or is carried out by unqualified personnel could result in poor quality of the end product or even injury to the machine operator. Improper or incorrect usage may be, for example: 

Handling web materials of a different thickness and nature than specified;



Using expedients to neutralize protection devices;



Forcing hardware or software commands with objects.

In addition to any recommendations given in this manual, the applicable laws, provisions and rules on safety and accident prevention must be abided by. 4.5

Accident prevention symbols

The machine has been designed and built in accordance with the safety standards in force in the European Union. Potentially dangerous areas for the operator or maintenance engineers are labelled to show the specific type of danger as seen here below. Other signs must be applied in the work area around the machine; when particular operations are being carried out (for example transport, installation or maintenance), additional signs must be put in place. WARNING: Removing the warning labels could jeopardize machine safety. Damaged labels must be substituted by other labels with the same graphic symbol and must be placed in the same position.

Operation and Maintenance Manual – Rev.00/2012 Page 34

Dangers

GENERAL DANGER

DANGER: LIVE EQUIPMENT It warns of the presence of live electric equipment. CUTTING HAZARD It indicates the risk of cutting yourself with especially sharp objects. FALLING OBJECT HAZARD It indicates the risk of falling materials HAND CRUSHING HAZARD It indicates the risk of crushing your hands between machine parts in motion. RISK OF TRIPPING OR STUMBLING It indicates the risk of falling due to tripping over parts of the machine placed on the floor that are particularly low. RISK OF HAND SQUEEZING AND DRAGGING It indicates the risk of getting entangled at moving elements of the machine, with consequent squeezing and shearing.

Operation and Maintenance Manual – Rev.00/2012 Page 35

Chapter 4 - Safety

4.5.1

4.5.2

Prohibitions

DO NOT LUBRICATE OR ADJUST MOVING PARTS

DO NOT LUBRICATE THE MACHINE IF THE GUARD IS NOT FITTED

Chapter 4 - Safety

DO NOT TOUCH LIVE ELECTRIC EQUIPMENT

DON’T USE WATER TO EXTINGUISH FIRES

NEITHER SMOKE NOR USE FREE FLAMES

4.5.3

Obligations PROTECTIVE GLOVES ARE MANDATORY The operator must wear protective gloves, of the type as indicated in the accident prevention regulations. PROTECTIVE FOOTWEAR IS MANDATORY The operator must wear protective footwear, of the type as indicated in the accident prevention regulations. SAFETY CLOTHING IS MANDATORY The operator must wear work clothing, with characteristics in accordance with the accident prevention regulations.

Operation and Maintenance Manual – Rev.00/2012 Page 36

MANDATORY READING OF THIS MANUAL All machine users must perfectly understand how the machine works and be knowledgeable of all the accident prevention requirements imposed in this manual. DISCHARGING PRESSURE IS MANDATORY

ELECTRICAL DISCONNECTION IS MANDATORY Before undertaking maintenance, disconnect the machine from electrical mains.

THE SAFETY RECOMMENDATIONS MANUAL MUST BE COMPLIED WITH

GIVEN

IN

THIS

AN ADDITIONAL SUPERVISING OPERATOR IS MANDATORY During the machine transport operations, in addition to the fork truck or crane operator, there must be another person checking that the transport way is clear of obstacles and that the machine, while being handled, doesn’t strike persons or things. ADEQUATE SLINGING MEANS ARE MANDATORY In machine transport operations, for slinging use only metal chains or nylon belts of adequate strength to sustain the weight of the machinery and its packaging. Independent of warnings, the operator must acquire a deep knowledgeable of the machine and its operation, so that he/she knows and perceives what is to be done and what is to be avoided under various circumstances. Also, machine users must wear snugly fit clothing and must avoid long hair, ties and/or clothing that could become entangled in the machine’s moving parts; furthermore, light coloured or light reflecting clothing must be avoided.

Operation and Maintenance Manual – Rev.00/2012 Page 37

Chapter 4 - Safety

The maintenance engineer must close the main supply valves of a pressure circuit/vessel and discharge the residual pressure before proceeding with maintenance operations.

4.6

Safety devices

The cutting area is designed so as to minimize access to the blade during jobs, compatibly with the operation of the machine.

Chapter 4 - Safety

Each longitudinal slitting station is equipped with a transparent guard preventing contact with cutting parts but allowing for visual checks of the normal operation. (In the case that the machine is equipped with a pedal to lift the pressure assembly) The pedal used to move the pressure assembly is equipped with a safety switch lock which prevents the pressure assembly to be closed accidentally once the pedal has been pressed. Furthermore, the machine is equipped with a photocell protecting the slitting area: if the beam is interrupted all moving parts are stopped. NOTE: The same happens when the pressure assembly is lifted, since the bracket (2) interrupts the light beam of the photocell (1)

Red mushroom-head emergency pushbuttons are located on both sides of the machine. Upon pressing an emergency stop pushbutton all moving parts are arrested in the quickest possible time.

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NOTE: Do not use stop pushbuttons unless a real emergency takes place. Once pressed, an emergency pushbutton is blocked: it must be rotated to unblock it. NOTE: During production the machine can always be stopped by pressing any key on the control panel, as well as with the emergency pushbuttons. Safety provisions to be carried out by the user company NOTE: The user company should assign clear and distinct responsibilities – especially regarding safety – to the machine personnel. The user company should also make sure that this manual is read, understood and complied with by the machine users. Copies of this manual must be easily reachable and readily available for consultation either at the machine and/or at the production manager’s office, or in any other handy place. 4.8

Residual Risks

An accurate risk analysis conducted during machine design has permitted the elimination of most of the risks connected to the conditions of use of the machine. The following residual risks are present with the machine: 

As the machine may not have its own lighting, it must be installed in a place which is appropriately lit pursuant to the law;



Electrical maintenance risk due to the need for operating with live equipment: According to Presidential Decree 547/55, only skilled engineers may carry out work on live equipment, always using double isolation to earth;



As the machine is not designed for operation in an environment with explosive and flammable substances, all risks in this respect should be removed; NOTE: Periodically check safety device performance.

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Chapter 4 - Safety

4.7

Chapter 4 - Safety

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TRANSPORT

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Automatic Cutter - XL Series

CHAPTER 5.

5.1

General rules

Chapter 5 - Transport

NOTE: The machine buyer must check that the floor can sustain the machine weight.

Before handling the machine assemblies always check that the weight is within the capacity of the lifting equipment: Model

TJOL / XL 190

XL 250

XL 320

Net weight [Kg]

210

248

330

Gross Weight [Kg]

395

525

650

288 x70 x 110h

358 x70 x 110h

428 x 70 x 110h

Dimensions [cm]

NOTE: Do not lift weights without first having considered possible obstacles within the range of motion. Make sure that the passage area is free, and that there are no moving objects (loose objects that may fall) on board the machine. NOTE: Personnel involved in moving machine parts must wear suitable personal protection equipment (accident prevention footwear, protective gloves, etc.)

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Transport modality

The machine is delivered to the user company completely packaged. Once it arrives to the building where it will be in operation, remove the cover and sides of the packaging crate. Remove the anchor brackets (1) then insert the forks of a suitable transport machine into the lifting brackets (2), which are adjustable in width. NOTE: Before moving the machine, carry out the following operations: 

Make sure the machine is not tied to the pallet;



Remove parts that can be removed;



Secure all mobile moving;

parts to prevent damage during

If the lifting height of the machine exceeds 50 mm from the floor, maintain a safe distance of at least 2 meters from the machine itself. Lift the machine, transport it to the operating area and lower it with utmost care to the ground. Place the machine in the correct working position and block it with the position brakes (3). NOTE: During this step particular care must be taken to avoid injury to the feet by the machine wheels.

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Chapter 5 - Transport

5.2

Chapter 5 - Transport

Machine transport

NOTE: During the machine positioning, take into consideration the space needed to load and unload the material to be worked on. NOTE: Handling and transport of the machine must be carried out by specialized personnel; no other person must stand in the surrounding area. Failure to comply with the above releases the manufacturer from any and all liability.

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INSTALLATION

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Automatic Cutter - XL Series

CHAPTER 6.

6.1

Leveling

Chapter 6 - Installation

Unlock the knobs (3) and use the knobs (1) to adjust the leveling of the machine, referring to the spirit levels (2). Once the machine is perfectly level, lock the knobs (3).

Machine levelling NOTE: if the machine is moved, before commencing production check the levelling again to ensure correct operation. On the XL320 model, after the machine has been levelled, adjust the central foot so that it is standing without lifting the machine. Prior to moving the machine, lift the central foot and adjust it back to its place afterwards.

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6.2

Connections

6.2.1

Electric connection

The electric cabinet of the machine is located on the side carter. WARNING: corresponds the voltages network and

Check that the voltage shown in the CE label with the current line of the production factory. If do not match do not connect the machine to the contact technical service.

NOTE: Two fuses (3) protect the electric cabinet from possible voltage fluctuations. An auxiliary connection to the earthing line is also present (4).

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Chapter 6 - Installation

Connect the power supply cord (1) to the relative outlet (2) and then to the external network outlet.

6.3

Pneumatic connection

If the machine is equipped with pistons to move the pressure assembly, it is necessary to carry out the pneumatic connection:  Direct the external pneumatic supply (1) to a 8 mm pipe and connect it to the quick-disconnect coupling 1/8”(2).

Chapter 6 - Installation

 Then open the tap (3) to provide the pneumatic supply to the machine.  Check on the pressure gauge (5) that the pneumatic supply pressure is 2.5 bar; if necessary, adjust the regulator (4) to set the correct pressure value.

FR Assembly (Filter / Regulator) 6.4

Permissible environmental conditions

To guarantee correct machine operation: 

Place the structure where it is protected from atmospheric agents;



Maintain the room temperature between 5°C and 40°C;



Maintain relative humidity under 90%;



Maintain a well lit and clean work area.

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6.5

Device calibration and setting

After the machine has been installed, check that all its devices are properly calibrated and ready for use. WARNING: Incorrect calibration of devices may cause serious hazards to the operator. In the event abnormalities are found, contact Fotoba technical service. Noise Level

The machine is built with low noise emitting stepper motors: the level of acoustic pressure created by the machine is estimated to be under 70 db(a). WARNING: Pursuant to Law 277/91 workers who are exposed to sound pressure levels higher than 85 db(a) must protect their ears with personal protection equipment. Workers must therefore be provided with proper protection devices if noise levels in the work environment exceed this limit. 6.7

Storage

Before storing the machine, disconnect it from the power supply and from the pneumatic supply (if present). Remove any foreign part and clean the surfaces. Using a brush, lubricate all mechanical parts. WARNING: Before re-installing the machine, remove the lubricant with an alkali degreaser (sodium hydroxide) using gloves and masks. Group all moving parts and, following the handling instructions (Chapter 5), store the machine in an area with a temperature between 0° and 40°, protected from atmospheric agents, dust and humidity (to this effect use silica gel bags). 6.8

Scrapping

When scrapping the machine, all components are to be delivered to authorized dumps in accordance with the law. Parts made of the same type of material are to be gathered for recycling.

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Chapter 6 - Installation

6.6

Chapter 6 - Installation

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DRIVES AND CONTROLS

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Automatic Cutter - XL Series

CHAPTER 7.

Chapter 7 - Drives And Controls

7.1

Control panel

The machine is equipped with 8 memory channels: each of them can store a cut mark (transversal mark), a slitting length (that is, the length of the web material to be cut) or a combination of both.

NOTE: When a cut mark/length is acquired, it will be automatically stored on channel [1] of the memory (buffer); it will then be possible to transfer it to another channel (see paragraphs 7.1.2 ) to permanently store it to memory.

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Main User Menu

Chapter 7 - Drives And Controls

To access the main menu to select settings press “MENU”, the display will show “Main User Menu” on the first line and “Double Cut Setting“ on the second line. To chose a menu setting, scroll them by the two arrows “ & “ keys and confirm by pressing the “ENTER” key.

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The available settings are: Main User Menu Double Cut setting

Chapter 7 - Drives And Controls

Resync Side Sensor XL – Resync Settings Paper speed setting Cut speed setting Flush paper setting New format setting Cut centering Mark / Length Store Mark / Length recall Manual Length intro Mark cancel request Edge / Cut mark choice Side sensor disable End Order setting

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7.1.1

Setting a feeding length

To set a length:  Press the “MENU” button: the display will show “Main user menu”. Using the  and  arrows select “Manual length intro”; press “ENTER”, the display will show the last measure set “Meters = ##.###” or “Inches = ###.##”.  Press the “Clear” button to reset this measurement (if you want to change it).  Use the keys of the panel as shown in the image, in order to set the required measurement; where the ESC key increments the length in 10m steps, CUT is 1m, Up arrow 10cm and HELP is 1mm steps.  The corresponding keys beneath these on the keypad decrement the length setting in an inversely proportional way. Using a combination of both rows of keys allows setting an exact size, down to a millimetre accuracy. Dam=00/000 m=00/000 dm=00/000 mm=00/000

+ -

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Chapter 7 - Drives And Controls

Alternatively to the automatic transversal slitting (when the transversal mark passes by), a slitting length can be set manually; the maximum length that can be set is 25.4 meters (999.99 inches).

Setting a feeding length  Select the ENTER button to confirm the length setting and activate the parameter set.

Chapter 7 - Drives And Controls

NOTE: To calculate the cutting length, use as a reference the transversal centreline of the marks, or a known point between two consecutive images.

7.1.2

Storing a feeding length

To store a length:  Set the desired length (see paragraph 7.1.1).  Press the “MENU” button: the display will show “Main user menu”. Using the  and  arrows select “Mark / length store”; press “ENTER”, the display will show “Write on mem [1] / Mark=OFF Lgt=ON”.  Using the  and  arrows select the channel were you wish to store the length.  Press the ENTER button. The length has now been stored; to confirm the operation has been carried out, the display will show the message "Accepted" for a few seconds. 7.1.3

Scan of a cut mark (transversal) NOTE: to scan a cut mark, it is necessary that it is preceded by a blank space of at least 10 cm (4'').

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Transversal mark about two centimeters before the pressure assembly  Press and release the Scan button. NOTE: If the marks are printed with UV ink, press the button down until the display shows the message “Scan is now set for UV_INK_ MARK”, then release the button.  The machine carries out the scan, moving the web material back and forward four times. Meanwhile the display shows "Scanning.....", followed by the mark's reading values detected by the optical sensors.  If the scan if completed successfully, the display will show “MARK DETECTED !”. Before starting any production cutting cycle it is recommended to carry out a test to ensure the correct detection of the cut marks on the loaded media. In order to do so, press the Test key once or twice to verify correct recognition of the Mark. If the scan was not successful, the display will show one of the following messages: 

“Fail x white”: one of the sensors failed to detect the black stripes on the mark;



“White too long”: the mark was not detected;



“BW level error L (R)”: one of the cells has detected the mark with a faint black;

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Chapter 7 - Drives And Controls

 Load the media as shown below and, using the  arrow, feed it forward until the transversal mark is about 20 mm (0.8”) before the pressure rollers.



“Nothing to store”: the white area of the mark has not been detected. NOTE: Data relating to this mark are automatically recalled from the memory channel [1] every time the machine is switched on.

Chapter 7 - Drives And Controls

7.1.4

Storing a cut mark

To store a mark:  Scan the mark (see paragraph 7.1.3).  Press the “MENU” button: the display will show “Main user menu”. Using the  and  arrows select “Mark / length store”; press “ENTER”, the display will show “Write on mem [1] / Mark=ON Lgt=OFF”.  Pressing the  and  arrows, select the channel were you wish to store the mark.  Press the ENTER button. The mark has now been stored in the desired channel; to confirm the operation has been carried out, the display will show the message "Accepted" for a short while. 7.1.5

Job in a combined length / mark mode

In this job mode, also called 'blank window', the system first searches for the first transversal mark to determine the first slitting, then moves the web material , deactivating the optical sensors, for almost the entire length set. Now the mark reading is activated: if a mark is detected, the transversal cut is carried out, with an angular correction if necessary; otherwise the transversal slitting is activated when the length of the fed web material is exactly equal to the length that was set, without correction. NOTE: The 'blank window' mode is recommended when the cut mark is not satisfactorily defined and/or has a variable size. In this way, reading errors are avoided and there is no loss of synchronization with the workflow, for in-line slitting systems with a printing system at the origin, where maximum speed printing can sometimes generate a reduction in quality of the cut marks.

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7.1.6

Storing a cut mark and a length (for TJOL only)

To store a cut mark and a length simultaneously:  Scan the cut mark (see paragraph 7.1.3).  Store the mark in a memory channel (see paragraph 7.1.4).  Set the length corresponding to the distance between the centres of two subsequent marks. (see paragraph 7.1.1).  The display will now show: “Meters= ##.### / Mark OK Enter=y (yes)”.  Press ENTER to confirm the selection: the display shows the message “Mark ON Lgt=ON” for a second. NOTE: Before processing the length, the system searches for the first cut mark in order to use it as a starting point for the job. To disable this function, press the button; with the arrows  and  select “Manual Length intro”; press ENTER, and the screen shows “Mark OK ? Enter=Y”; press ENTER. 7.1.7

Recalling a memory channel

 Press the “MENU” button: the display will show “Main user menu”. Using the  and  arrows select “Mark / length recall”; press “ENTER”, the display will show “Read from mem [1]”.  Use the  and  arrows to select the desired channel.  Confirm with the ENTER button. NOTE: Each memory channel shows which slitting mode (mark / length) is active and which is inactive. In this way the values can be checked and modified if necessary.

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Chapter 7 - Drives And Controls

 Store this length in the same memory channel as the cut mark.

Chapter 7 - Drives And Controls

If a mark as well as a length is stored in the selected channel, the display will show “Meters= ##.### / Clr=0 Enter=accept”: 

If you do not want to use the 'blank window' function, press CLEAR to reset the length.



If you want to change the length value, follow the procedure given in paragraph 7.1.1 (except for the first step, which is to be skipped).



If you want to confirm the existing setting, press ENTER: the display will show “Meters= ##.### / Mark = ON ltg = ON” for a few seconds; the channel is now active.



If you need to disable the search for a cut mark, set the correct function in the menu.

If only the length is stored, press ENTER: the display will show “Meters = ##.### / Mark = OFF ltg = ON” for a few seconds. If only the mark is stored, press ENTER: the display will show “Meters = ##.### / Mark = ON ltg = OFF” for a few seconds. 7.1.8

Setting the cutting of multiple copies

 Press the Multi button. The last selection will be displayed as “ Multi set ###”.  By pressing the  and  arrows the number of transversal cuts to be carried out can be set.  Press the ENTER button. The machine is ready to cut the set copies with the selected work mode (length or mark slitting). NOTE: Setting the Multi value to zero, the machine will operate without pause in a continuous cycle. Press “CLEAR” to set the counter to 1 for a single copy.

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7.1.9

Double transversal slitting

During production it is required to remove the transversal cut mark from the finished prints. For this purpose an adjustable double cut width can be set (also see paragraph 3.5.7). NOTE: when the machine is turned on, the last double cut value that was set is automatically recalled.

 Press the “MENU” button: the display will show “Main user menu”. Using the  and  arrows key select “Double cut setting”; press “ENTER”. The display will show “Double cut ##.#” setting.  Using the  and  arrows, select the desired measurement for the double cutting (that is, the width of the transversal trim to be cut). NOTE: Each increase or decrease of the double cutting value obtained with the arrows corresponds to 0.5 mm (0.2”).  Press the ENTER button to confirm the setting.  Pressing the Clear button the value of the double cut returns to 18,0 mm (default setting) The maximum value that can be set for double cutting is 99 mm (3.9''); if this function is set to a value of zero, the machine will carry out a single transversal cut (no media removal). 7.1.10

Setting the longitudinal alignment control system

Set the operating mode of the longitudinal alignment control system (see also paragraph 3.5.5):  Press the “MENU” button: the display will show “Main user menu”. Using the  and  arrows key select “Edge/Cut mark choice”; press “ENTER”. The display will show “Set=Cut-Mark, if the previous job was detecting the cut mark, otherwise “Set=Paper-edge” is displayed if it was detecting the edge of the web material; and then “Up/Down to change”. Press ENTER to confirm the operating mode, otherwise select the desired mode using the  and  arrows, then press ENTER: for about two seconds, “ACCEPTED” is displayed.

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Chapter 7 - Drives And Controls

To change the selection, proceed as follows:

7.1.11

Adjusting the transversal cutting speed

5 different cutting speeds can be selected according to the thickness and rigidity of the web materials to be cut.

Chapter 7 - Drives And Controls

 Press the “MENU” button: the display will show “Main user menu”. Using the  and  arrows key select “Cut speed setting”; press “ENTER”, the display will show “Cut speed is [ ] Up/Dwn to change”.  With the  and  arrows select the desired cutting speed, shown in the field “Cut speed is [ ]” (where [1] = maximum speed, through to [5] = minimum speed).  Confirm the value with the ENTER button. “ACCEPTED” is shown on the display for a few seconds. NOTE: The machine automatically recalls the last selected cutting speed every time it is turned on. During a cutting job the motor moving the transversal slitting system may stop due to an error or media jam. The software will try to restart it at a lower speed; in the event of failure, the warning “**Cut Error** Any key to retry” will appear on the display, and when any key is pressed the message “ENTER = Finish cut” will be displayed: 

By pressing ENTER the system will attempt in any case to complete the transversal slitting.



Pressing Clear the transversal slitting station will return to the starting position (recommended choice, since a problem has arisen).

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OPERATION

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Automatic Cutter - XL Series

CHAPTER 8.

8.1

Switching the machine on

Check the machine at the beginning of a work shift to make sure there is no modifications or abnormalities that may jeopardize safety. If there is, report it to the supervisor. It is necessary both at the beginning and at the end of his/her work shift for the operator to verify that the machine does not present any problems regarding functioning, or noises that may indicate possible mechanical failures.

Chapter 8 - Operation

If oil leaks are found on the floor, stop the machine and inform the maintenance staff. To turn on the machine, press the main switch located on the side carter of the machine.

8.2

Loading the reel (machine version with unwinder)

Position the reel to be unwound on the idle rollers of the unwinder assembly, trying to center it as much as possible on the middle line of the machine. WARNING: Use the appropriate equipment for unloading the reels if their weight exceeds 20 Kg. particular attention must be shown by the operator residual risk of crushing hands between the reel and the machine. If the optional unwinder is used for the TJOL version, the clutch of the reel can be adjusted with the spring brakes assembled under the unwinder rollers, which slow down its rotation.

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loading and Furthermore to avoid the the frame of

A.

Lift one end of the reel;

B.

Insert the chuck fully into the core;

C.

Block the chucks into the core, closing the lever;

D.

Place the reel onto the unwinder rollers;

E.

Put in place the retaining lock ring and lock the retaining knob.

Repeat the procedure for the other end of the reel.

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Chapter 8 - Operation

If the job requires chucks to be used:

Chapter 8 - Operation

If the job requires the use of guide flanges A.

Install the guide flanges onto the side blocks.

B.

Slide the blocks transversally until the are at the same level with the ends of the reel, on both sides.

If the job type requires supports for reels with 5'' cores A.

Fit the supports to the machine frame and adjust their transversal position.

B.

Load the reel, taking care that the excesses of the core are lying on the rollers of the supports, after checking they rotate properly.

WARNING: The arrow indicates direction the reel will unwind

the

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8.3

Threading the web material

Lift the pressure assembly using the levers or the control pedal (if provided); then thread the web material onto the transport rollers, until a flap can be pulled out on the output side.

NOTE: During this operation try to maintain alignment of the web material as much as possible, both transversally and longitudinally. In the event the web material is being unwound from a reel, when the threading is completed rewind the web material so that it is well stretched out in the slitting zone. 8.4

Loading single sheets

Alternatively to operating the machine with web material being unwound from a reel, the machine can also be used to cut single sheets containing multiple images. To use the machine in this mode, it must be positioned downstream from a sufficiently large and stable loading table, where a longitudinal reference guide is placed to align the sheets entering the machine. Automatic alignment tables can also be used, which carry out this operation automatically.

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Chapter 8 - Operation

The web material must reach the slitting area with the printed side up; make sure that it passes under the yellow belt for the transversal cutting (see paragraph 3.5.7).

Chapter 8 - Operation

Finally lower the pressure assembly.

Moving the pressure assembly with a lever / pedal WARNING: Take care not to crush or cut the hands during the movement of the pressure assembly.

8.5

Panel settings

Referring to Chapter 8, carry out all settings for the job from the control panel: 

Length and / or transversal marks cutting;



Multiple cutting copies



Double cutting;



Setting the longitudinal alignment control system (Y axis) (see also paragraph 8.6);



Transversal cutting speed;



Web material feeding speed;



If necessary set the feeding mode without cutting / cutting disabled.

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8.6

Positioning of the sensors (Y axis)

longitudinal

alignment

control

The positioning can take place in two different ways: 8.6.1

Manual mode

Chapter 8 - Operation

After choosing the position of the longitudinal slitting system bar, unscrew the knob of the support bracket of the sensors, and slide it transversally moving the reading point to the first cut mark, or to the edge, starting from right to left.

Moving the longitudinal alignment control system sensors (Y axis) When the sensors are in the correct reading position, the display will show the message “CENTERED!”, and the machine beeps. Confirm the positioning pressing ENTER again; the display will show the “ACCEPTED” message and the beep will stop.

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8.6.2

Automatic mode

In automatic mode, simply press the Multi button and select ENTER twice. In this way neither the transversal positioning of the slitting system bar nor that of the sensors need to be set: the bar moves automatically until the sensors are in the correct reading position for the longitudinal cut mark.

Chapter 8 - Operation

NOTE: Remember that the automatic movement of the bar can decrease the range of the longitudinal correction. 8.7

Positioning of the longitudinal slitting stations

To position the longitudinal slitting stations proceed as follows:  Carry out a transversal cut to eliminate any unwanted (non printed) margin of the web material.  Insert the slitting stations needed for the job into the longitudinal slitting system bar (see paragraph 3.5.6), then position the web material onto the cantilevered end of the bar.

Inserting slitting station and bar support  Move the initial flap of the web material near the slitting stations to facilitate their positioning: 

Automatically: check that the transversal alignment control sensor is activated in mark control mode and is correctly positioned; then press the CUT button and then Enter,



Manually: keep the  and  buttons pressed to feed the web material forward.

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 Move each slitting station transversally to the points where the cutting must be carried out, then lock them into position using the relative knob.

Positioning of slitting stations NOTE: before proceeding to position the longitudinal slitting stations, check that the longitudinal alignment control sensor is correctly positioned (section 8.6).

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Chapter 8 - Operation

NOTE: the reference marks correspond to the cutting line.

Chapter 8 - Operation

 Install the plates to support the web material exiting from the longitudinal slitting area.

Positioning of sustaining plates for the web material WARNING: Trimmings and dust on the floor (created during slitting) create danger of tripping and falling: exercise caution.  Prepare the external collecting table for the cut prints, checking that the plane situated near the slitting area has its same height and a sufficient width.

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8.8

Starting production

To start the work cycle (or to restart after a stop), press the Start button (or the foot switch): the machine starts production, using all previously set parameters. NOTE: It is recommended, before starting the process, to conduct a mark recognition test. if the Auto start function is active the machine starts automatically when the transport zone inlet sensor detects the presence of the material. 

Preset the width of the double cutting (if used);



Recall from memory the type of cut mark which is used on the print.

WARNING: During production do not touch the unwinding roll or the web material.

8.9

Semi-automatic mode operation

Production can be carried out in semi-automatic mode, checking every action of the machine: The buttons  and  move the web material forward and back, whilst the side sensors read the longitudinal mark or the edge of the web material (according to the selected settings). When the image corresponds to the transversal cutting line, it may be misaligned. To carry out a parallel and precise cut, the following options may be selected after pressing the Cut button: 

Use  and , if necessary, to rotate the slitting system and align it to the print.



If necessary press Clear to exit this menu and realign the web material manually.



Press Cut again to carry out the cutting.



Press ENTER to cut and feed the web material forward to the longitudinal slitting zone, automatically repositioning the transversal alignment control sensors.

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Chapter 8 - Operation

NOTE: for using the Auto Start function, it is necessary to:

8.10

Operator position

During the production (machine running), the operator must always remain facing the control panel so as to check principal parameters and the proper functioning of the machine.

Chapter 8 - Operation

WARNING: The operator must check that there are no other persons in the work area before the machine is started or while the machine is running, and that there are no objects which are foreign to the production process. 8.11

Prohibitions for injury prevention

The following operations must be absolutely avoided for the safety of the operator as well any third party who may be in proximity of the machine. WARNING: It is strictly forbidden to: 

put one’s hands in the machine’s range of action;



touch the web material or moving parts of the machine with the hands during production;



execute any maintenance on the machine when it is on and/or running;



operate the machine in the case of inadequate natural or artificial lighting.

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Chapter 8 - Operation Operation and Maintenance Manual – Rev.00/2012 Page 75

MAINTENANCE

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Automatic Cutter - XL Series

CHAPTER 9.

9.1

Maintenance safety warnings

The maintenance operations are to be executed by skilled staff wearing appropriate personal protection equipment (PPE) in accordance with Italian Law 81/08.



The production manager must make certain that the maintenance personnel abides by the required safety guidelines and uses appropriate PPE to ensure safety and that nobody executes servicing tasks which are beyond their own qualification.



Regular maintenance operations must be conducted with the machine stopped, the main switch off and the power supply cord unplugged; furthermore, during maintenance a warning sign, "MAINTENANCE UNDER WAY: DO NOT START" must be displayed.



Before carrying out any maintenance operations on the machine, turn the compressed air supply off (if applicable) and completely discharge the residual air.



If the maintenance engineers have to perform calibrations or checks in a live electric cabinet (power on), the maintenance engineer must post one or more warning signs that show that the cabinet is live and that it is absolutely prohibited to activate any machine command; furthermore the maintenance engineer must wear all personal protection equipment for protection against electric shock.



Access to the electric cabinet is strictly prohibited to unauthorized personnel.



Using spare parts or accessories other than those specified may be hazardous and Fotoba shall not be held liable. All structural elements and components are designed specifically for the type of machine.



Only parts (spare parts/wear and tear parts) provided by Fotoba or by approved retailers of the respective original equipment manufacturers should be used.



In the event of substituting cables, the replacement components must have the same rating and characteristics (manufacturer and model).

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Chapter 9 - Maintenance

THE SAFETY RULES HEREAFTER ARE TO BE FOLLOWED:

Chapter 9 - Maintenance



If safety devices are removed or deactivated for purposes involving repairs, maintenance or for machine set-up, they must be reset upon completion of the work.



After having performed maintenance operations on normal and/or emergency stopping devices, test their operation before restarting the machine.



During maintenance and / or cleaning of the slitting system, wear appropriate protective gloves (compliant to current regulations).



Contrast springs have been fitted to control some movements: the dismantling and reassembling of the springs must be carried out by specialized personnel equipped with protective gloves and goggles.



When fuses of the electric cabinet must be changed, use only fuses with the same load and capacity.

9.2

Routine Maintenance

For the machine to maintain a high performance level, the preventive maintenance plan should be structured as follows. 9.2.1

Cleaning and lubrication WARNING: Lubrication is to be executed properly and with the due frequency. A lack of lubrication involves the risk of excessive friction of mechanical parts, which would increase vibrations and degrade machine performance. WARNING: Maintain a maximum level of cleanness of the machine and of its surrounding area.

The arrows that indicate the areas of the machine to be cleaned use the following graphic symbols: Use isopropyl alcohol. Use low pressure air (NOT COMPRESSED AIR). Use grease. Use PTFE oil (Teflon lubricant).

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Weekly maintenance

Clean the circular blades of the longitudinal slitting stations.

Bi-weekly maintenance

Clean the surface of transport rollers and pressure rollers avoiding oil based products.

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Chapter 9 - Maintenance

Clean the circular blades of the transversal slitting station.

Chapter 9 - Maintenance

Remove any dust from the longitudinal alignment control sensors.

Lubricate all moving parts of the slitting system on both sides of the machine.

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Grease the slider bearings on both sides of the machine, for the movement of the transversal slitting station.

Grease the threaded shaft controlling the angular rotation of the cutting system.

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Chapter 9 - Maintenance

Monthly maintenance

Chapter 9 - Maintenance

Grease all slider bearings for the angular rotation and the transversal displacement of the cutting system; grease also the spring of the yellow belt for transversal cut-off.

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Clean and then lubricate the rail for the sliding of the transversal slitting station.

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Chapter 9 - Maintenance

Clean the protective cover of the transversal alignment control sensors.

9.2.2 Section

Operation

9.2.2.1

Checking compressed air filters

9.2.2.2

Checking tension of transmission belts

9.2.2.1

Chapter 9 - Maintenance

Checks and verifications Hours frequency 1000

2000

X X

Checking compressed air filter (FR assembly)

For machines equipped with a pneumatic circuit: to avoid an early decrease in the performance of some parts of the pneumatic system it is fundamental to periodically check the water level in the collection trap (1) of the FR assembly.

If there is water in the trap (caused by atmospheric humidity in the pneumatic system) it is to be drained:  Close the pneumatic tap (2).  Press the bleed valve (3) NOTE: In humid climates where the trap is filled rather quickly with water, install an air drying system upstream of the pneumatic system line.

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9.2.2.2

Checking tension of transmission belts

Chapter 9 - Maintenance

Transmission belts should be checked periodically for their integrity and tension; belts that are worn or broken at any point must be replaced.

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9.3

Extraordinary maintenance WARNING: Maintenance often involves residual risks: utmost care must be exercised during maintenance.

Chapter 9 - Maintenance

WARNING: Extraordinary maintenance is to be carried out only by authorized maintenance personnel. During test runs, Fotoba technicians have set to optimal values the operating parameters shown in the following charts; before modifying these parameters please contact the Fotoba technical service. 9.3.1

First operation

The following chart shows the values entered into the memory during the final test, to be used as a reference for maintenance.

Main offset. Dbl print setting. White toler. Set. Black toler. Set. Pre white sel.

Cut

Post white sel.

Feed–chk setting.

Slicer spd sel.

Feed delay sel.

En/Disable

Enc. Angle. Angle corr. Lgt. Fineadj. Square corr.

TMA selection. Nonstop srch sel. Blank stripes.

On / Off

Stop / Go

Select Inch/cmt.

Cmt / Inch

On / Off

Enco_sqr set/res.

On / Off

Cut / Ignore Absent / Xtractor select. Mounted

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Only for XL version:

Winder port

On/Off

Slicer motor

Blade work

On/Off

Gap is

1/2 300/500

Firmware version:

Volts :

Hz.: 50/60

Manufactured in year: Checked by:

WARNING: If the motherboard is replaced make sure these values are entered and stored again.

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Chapter 9 - Maintenance

Serial number:

9.3.2

Subsequent operations

Chapter 9 - Maintenance

The following chart shows the values entered into the memory during maintenance, to be used as a reference for subsequent maintenance operations.

Main offset. Dbl print setting. White toler. Set. Black toler. Set. Pre white sel.

Cut

Post white sel.

Feed–chk setting.

Slicer spd sel.

Feed delay sel.

En/Disable

Enc. Angle. Angle corr. Lgt. Fineadj. Square corr.

TMA selection. Nonstop srch sel. Blank stripes.

On / Off

Stop / Go

Select Inch/cmt.

Cmt / Inch

On / Off

Enco_sqr set/res.

On / Off

Cut / Ignore Absent / Xtractor select. Mounted Only for XL version:

Winder port

On/Off

Slicer motor

Blade work

On/Off

Gap is

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1/2 300/500

Firmware version:

Maintenance date:

Revision n.:

Carried out by:

WARNING: If the motherboard is replaced make sure these values are entered and stored again.

Chapter 9 - Maintenance

NOTE: if this chart is filled in, store it together with the manual.

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CALIBRATIONS

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Automatic Cutter - XL Series

CHAPTER 10.

10.1

Calibration menu map (control panel) WARNING: The “Factory set MENU” parameters can be accessed only by maintenance personnel.

calibrate qualified

Card A/1

Chapter 10 - Calibrations

10.1.1

used to Fotoba's

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Card A/2

Chapter 10 - Calibrations

10.1.2

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Card A/3

Chapter 10 - Calibrations

10.1.3

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Card A/4

Chapter 10 - Calibrations

10.1.4

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Card A/5

Chapter 10 - Calibrations

10.1.5

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10.1.6

Setting the distance between transversal slitting and sensors (offset)

The factory setting of the distance between the reading point of the sensors and the transversal slitting point is about 70 mm. This value can have a range of 50-90 mm. To change the selection proceed as follows:  Press the D/Cct button. The display shows the last selection “DCcent mm/0 ###”.

Chapter 10 - Calibrations

 Use the  and  arrows to change the value.  Confirm the change with the Ent. button. To reset the factory setting  Press the D/Cct button: the display will show the last selection “DC center ##.#”.  Press the Clear. button : “DC center ##.#” will appear.  Press ENTER to confirm. NOTE: This value must then be stored as Main Offset in the Factory set MENU, proceeding as follows:  Press the Clear button until the display shows “Factory set MENU”.  Using  select the item “Main offset ##.#” in the display.  Confirm the selection using ENTER: the display will show the previously set value.  Increase or decrease the correction value with the  and  buttons.

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Mark not centred: decrease the correction value

Mark not centred: increase the correction value  Selecting Ent. again the correction is automatically stored.  Press the Clear button to exit the factory setting menu.

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Chapter 10 - Calibrations

Mark centered with regards to double slitting

10.1.7

Disabling the transversal slitting

To disable the transversal slitting, proceed as follows:  Press the Clear button until the display shows “Factory set MENU”.  Using the ““ button select “Special Settings”, press “ENTER”, with the ““ button select “Cut En/Disable”, then disable the selected cut “Cut is Disabled”.

Chapter 10 - Calibrations

 Press Ent.  Pres “Clear” twice to exit the function NOTE: This function does not bypass the longitudinal alignment control system: when the mark passes by (or at the end of the set length), the feeding stops, but the transversal automatic cut is not carried out. When the slitter is turned on again, the function automatically resets to "Cut Enable".

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Chapter 10 - Calibrations Operation and Maintenance Manual – Rev.00/2012 Page 99

TROUBLESHOOTING

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Automatic Cutter - XL Series

CHAPTER 11.

11.1

Cutting bent web materials

Detection of transversal mark As a consequence, the system will detect a simple misalignment and will react by rotating the transversal slitting system. In this way the web material will be wrongly cut (see also paragraph 3.5.5).

Wrong attempt of automatic realignment  Wrong cut

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Chapter 11 - Troubleshooting

If the web material to be cut is bent, the pair of transversal alignment system sensors will detect the horizontal marks in different instants.

Chapter 11 - Troubleshooting

To prevent a wrong action of the transversal slitting system, the operator must place the fulcrum of the arch between the pair of sensors.

Solution: fulcrum of the arch in the correct position In this way the system will not detect any longitudinal misalignment and consequently will not wrongly attempt to correct the slitting.

Correct transversal cut on bent web material Common issues

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11.2

Common problems

The machine functions are controlled by a microprocessor: failure to operate is often due to incorrect settings of job parameters; if abnormal functioning occurs check that the data entered is correct (if possible delete entirely and enter again).

The display is completely OFF

Possible cause and solution Check fuses Check connection to the main supply Check that the Emergency Push Button are in the upper position Check the “Piggy Back” electronic board

The Display is ON (backlight ) ma no message is shown

Contact the technical service for the LCD Board replacement

Pressing the Start nothing happens.

The safety sensor is activated. Check that the field of action of the safety sensor is free. Press again the Start key. Verify that parameter.

the

D/Cut

function

has

a

valid

Verify that the Main Offset function has a valid parameter. (see par. 10.1.6 re. par 9.3.1) The display shows Mark=OFF Lgt=OFF. (see par.7.1.7). Repeat the setting of : Setting of a feeling length (see par.7.1.1) and memorizing .. (par. 7.1.2) Scanning of a cut mark (see par. 7.1.3) and memorizing .. (par. 7.1.4) As soon as the cutter is turned ON the display shows “cut error”

The cutting unit is not positioned in the home position (the optical sensors is not activated by the cutting unit). Follow the sequence as in Note of par. 7.1.11.

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Chapter 11 - Troubleshooting

Problem

The cutting unit is in the home position but the initialisation does not start. Contact the technical service.

Chapter 11 - Troubleshooting

The display shows “cut error”

If the blade stop is due to the thickness or rigidity of the media, reduce the cutting speed. (See par. 7.1.11) If the blade stop is due to a media jam, switch the cutter OFF, remove the jam, turn the cutter ON and start a cut but the sequence Cut and then ENTER keys. If the blade is at a stop in between the two home position, no paper jam is occurred and there are no problems with the thickness of the media, switch the cutter OFF, check that the two home positioning sensors are not having any media or fraction of it in face their eyes. Remove them and switch the cutter ON as per note of par. 7.1.11.

The display shows “enter=finish The safety sensors has been activated. cut” and the cutting unit is at a Check that the field of action of the safety sensor is stop in between the two home free. positions. Press ENTER key to finish the cutting or press Clear to have the cutting unit coming back to the origin of the cut. (Warning: During those two action the safety sensor is not activated). The keyboard emergency stop has been activated (Any key to stop) . Do the required action. Press ENTER key to finish the cutting or press Clear to have the cutting unit coming back to the origin of the cut. (Warning: During those two action the safety sensor is not activated).

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The cutter does not scan the cut mark correctly.

Verify what specified in par. 3.5.5.

When display shows any of the following:

Verify what specified in par. 7.1.3.

Fail x white White to long BW level error Nothing to store

Verify the optical sensors readout (View cells read) with the gray print supplied with the cutter in which back are stated the original factory test values for your machine. ( Verify what specified in par. 10.1.3).

The does not detect the horizontal Verify what specified in par. 3.5.5. cut marks. Verify and eventually increase the cut marks reading tolerance values (see par. 10.1.2) Press the “MENU” key to activate the function (see par. 7.1.7). Repeat the scanning of the mark. Verify what specified in par. 7.1.3. Verify the optical sensors readout (View cells read) with the gray print supplied with the cutter in which back are stated the original factory test values for your machine. ( Verify what specified in par. 10.1.3). If the values are not corresponding, contact the Fotoba technical support . The does not detect the horizontal Function Flush paper active. cut marks. (TJOL version only) The display missed"

shows

“V

mark In case the longitudinal mark is not printed, press twice “Clear”. Proceed temporarily in semiautomatic mode (par. 8.9) until normal condition “Recenter slicers Down/Up=L/R” are obtained. In case the longitudinal mark is there but missed by the sensor, with means of the two arrows keys, move the slicing unit toward left or right until the sensor will detect the mark correctly. An acoustic beep shall start when this will happen. The display will show: “Mark OK? Start=Yes”. Press “Start” to keep cutting or “Clear” to stop the cutter.

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Chapter 11 - Troubleshooting

If the values are not corresponding, contact the Fotoba technical support .

Mark detect failed

The Autostart function cannot be See note par. 8.9. activated (TJOL version only) When switching ON the cutter the centring of the slicing unit is not completed. Contact the Fotoba technical support

Chapter 11 - Troubleshooting

The paper feeding motor starts and The “autostart” photo sensors is not correctly stops intermittently (TJOL version activated by the back of the paper or some images only) are printed in the back of the media. Set the function “Dbl print setting” ON, see par. 10.1.2. The paper advances step by step Left Encoder’s read error. (XL version only) Set off the function “Feed delay sel.”, see par. 10.1.3. Contact the Fotoba technical support. As soon as the cutter is turned ON The cutter needs software reload. the display shows “Download Contact the Fotoba technical support. needed”

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