04-Operation Manual English ab 1004 2011 3003 - Flexo
Contents
1. Plates torn from frame Wrong program selected with too high brush pressure Enter the correct program Plate not properly fastened If plate is visible Select program 20 manually press input sensors press Start and remove plate from machine Bar is crooked Correct chain tension at output Error message on the display Motor disruption Motor safety switch or fuse is out Safety thermostat Solvent temperature is too high Check cooling Emergency cut off Emergency cut off switch is activated Release emergency cut off Check Sensor the 3 sensors are shown as symbols green OK red error Sensor input dirty or defective Clean or replace sensor Check viscosity meter filter Filter dirty Clean filter Air pressure absent or is too low Turn on compresses are or determine the cause Check viscosity meter Viscosity meter plunger is dirty Clean viscosity meter Sensors are not being activated Check sensor position correct as needed Operation Manual smart English 1004 2011 3003 Page 7 smart Processor Operation Manual page 8 6 Operation 6 1 Starting the machine The main switch of the machine must be turned on Press button I start control is activated and the display becomes visible the machine is now ready for operation production can begin after reaching the set solvent temperature 6 2 The o2. Page 10 Screen 4 Screen 2 Screen 3 TOR 030 6 33 100 2 2 Screen 1 Base screen Screen 1 changing screens by pressing the menu fields Plate menu Service Language Information on the current plate and the machine data is show in the lower fields Plate type TDR 030 Solid matter content 4 0 Relief depth 2 5mm Solvent temperature 32 C Wash time 7 6 min Transport speed 125 mm min Plate thickness 3 7mm Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 11 Screen 1 Screen 2 1 Screen 2 2 CU PON A Screen 2 TDR 030 6 33 100 2 2 Plate menu Screen 2 Changing screens by pressing the menu fields Change Accept Changing plates by pressing the circular position fields 1 7 Use the arrow keys to change to other plates 8 21 Select the plate the selected plate will be highlighted Accepting the plate by pressing the position field Accept Changing plate values by pressing the position field Change Screen 2 2 appears automatically changing plate values Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual page 12 Screen 1 Screen 4 Screen 2 GU PONT wa E TOR 030 409 t 25mm 32 Service menu Screen 3 0 Use the vertical arrow keys to move the cursor to the point on the menu Use the horizontal arrow keys to change the value Settings Cleaning time 0 1 t
3. of an additional fan Good room ventilation must be ensured For machines using per and FLEXosoL the following applies check per and FLEXosoL concentration with Drager tubes Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 21 9 Information for emergencies 9 1 Type of fire extinguishing equipment to use All conventional fire extinguishers can be used see solvent safety data sheet 9 2 Notes for rescue In case of solvent contact with the skin or eyes proceed according to the safety requirements of the solvent manufacturer Operation Manual smart English 1004 2011 3003
4. 6 language Deutsch English Francais N Espa ol N Italiano f accept preduction select plates Settings y language rinse solid content solvent temperature solvent p gt tank 0 2 sek 3 0 32 C Flexosol Fill Empty 0808 99 operating hours 00050 Filling Emptying ATTENTION this menu point may not be called up during plate production as the both functions operate independently of the float switch fresh solvent tank empty old solvent tank full controlled current process will be interrupted Service emptying filling the tank Screen 3 2 Use the vertical arrow keys to move the cursor to the menu point Tank Both buttons Fill and Empty will appear automatically By pressing the fill button fresh solvent is pumped into the re flush tank until it spills over into the main tank this process will run automatically until the main tank reaches the minimum wash level or the fill button is activated again During the active phase the word fill is light blue By pressing the empty button the main tank is emptied this process will run automatically until the minimal wash level is reached or the empty button is activated again During the active phase the word empty is light blue Further activation only so long as the empty button is pressed Plate transport pumps and brushes movements will be turned off Op
5. ate input 2 new plate different plate type step 1 select plate menu cf Menu guide Screen 1 step 2 select plate type cf Menu guide Screen 2 step 3 accept plate now the message appears on the display Plate in process accept new plate anyway and the sensor fields Yes No Stand by step 4 press the sensor field stand by the message will disappear Now the transport bar with the new plate can be fed in cf Plate input step 5 press the sensor field Start on the display Now Stand by blinks over the input symbol up until preceding plate has left the washing area The machine automatically makes the adjustments for the new plate and the plate is pulled in cf Washing pre drying and removing plate Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 19 6 5 Drum to drum operation Drum to drum operation is controlled by the drum level switches Gauge Description Measures to take Switch contact FS drum empty Message in display and acoustic Change fresh solvent drum plate production signal can continue OS drum full Message in display and acoustic Do not introduce any new plates plate signal pumping out is no longer production must stop possible Main switch to OFF position Change old solvent drum continue plate production FS Fresh solvent OS Old solvent 6 6 Tank t
6. e dried At the same time the relief side can air dry The plates must be dried post exposed light finished before being used in the printing machine Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 6 4 Safety 4 1 Safety measures when working at the machine Avoid skin contact with the solvent In all work carried out at the machine when opened protective glasses and gloves are to be worn possibly use skin protective cream When filling and emptying with hoses and pails protective gloves and face protection possibly with separate air supply are to be worn Ensure adequate ventilation of the room If solvent comes in contact with the eyes rinse immediately with lots of water For other problems it is advised to see a doctor 4 2 Notes on the use of personal protective equipment Avoid skin contact with the solvent For all work protective glasses and gloves are to be worn possibly use skin protective cream 4 3 Information on residue risks avoiding hazards When filling and emptying with hoses and pails protective gloves and face protection possibly with a separate air supply are to be worn Ensure adequate ventilation of the room 4 4 Environmental protection When operating the machinery it must be kept in mind that the solvent poses a risk to the water supply It is not allowed to reach the waste water system or the ground Under the machine are safety catch tanks sent a
7. eration Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 17 6 3 Manually filling the machine internal tank cf menu guide Screen 3 2 The fresh solvent drum is full the dirty solvent drum is empty Both drums and float switches are connected to the machine The fresh solvent pump and the suction lines must first be bled and filled with fresh solvent Danger of dry operation For filling the tank the main switch must be set to on The display is turned on The input table and tank covering must be removed so that visual contact with the level switches exists Now select the lower point tank on the display service Two buttons will appear automatically fill and empty Activate the fill button Now the tank will be filled automatically until the float switch reaches wash level cf menu guide Screen 3 2 In normal operation the filling of solvent takes place automatically Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual page 18 6 4 Plate production preparation input washing out pre drying and removal Plate preparation The plate must be fastened to the transport bar with the polymer side up For the machine to recognize the plate the plate plates must be positioned so that at least one of the 3 photo sensors B3 B7 B8 middle right left located at input level is covered by the plate plates The photo sensors will identify the length of the plate plat
8. es and will control the other processes of the machine cleaning shut down and release for entry of next plate Input of plate first please select the appropriate plate type from the display Lay the transport bar with the plate in the plate feed area push forward parallel up to the stop The transport bar will fall approx 10 mm and will rest in the input feeder At the same time 2 sensors located over the input B5 B6 will identify the correct input of the transport bar and will release the start menu on the display The plate can now no longer be corrected Washing pre drying and removing the plate Activate the sensor field Start on the display The transport bar will be pneumatically lowered The transport bar will be fed to the transport chain and pulled in At the same time a small red indicator H2 will turn on The plate transport through the machine and is automatically washed out cleaned on both sides and pre dried until the sensor B2 plate outlet is reached It will give an acoustic signal The message plate at output will appear on the display The transport bar along with the plate can be taken out of the machine The acoustic signal ceases as soon as the plate is removed As soon as the indicator H2 goes out the plate input is pneumatically raised again Now a new bar and plate can be introduced At this point there are 2 possibilities 1 new plate same plate type Can be input directly cf pl
9. long as standard equipment These are able take up the entire volume of solvent Disposal Dirty solvent can be recycled through distillation Otherwise it is regarded as hazardous waste with the waste key no 55326 Solvent soaked cleaning rags are to be disposed of as hazardous waste Residue from distillation equipment is to be disposed of as hazardous waste according to the waste key no 59703 Information on hazardous waste disposal is given by the environmental ministry the workplace oversight authority district administrative office among others Consult local agencies Operation Manual smart English 1004 2011 3003 smart Processor Operation M anual 5 Information on the operation of the machine 5 5 Improper usage The machine may only be operated with solvents approved by the manufacturer 5 6 Instructions for recognizing and eliminating errors Problem Cause Measure to take Plate is not washed out cleanly Wrong program selected Select correct program Wash out speed too fast Lower wash out speed Solvent not properly heated Solvent too contaminated Refresh solvent Too little solvent in system Fill up solvent Brush distance too great Correct brush distance Solvent temperature is too high Cooling failure Test cooling Plates are not pulled in Compressed air is absent or is too low Turn on compressed air or determine the cause
10. lushing zone where they are cleaned with fresh solvent Before the plates leave the washing area of the machine the cleaning agent is removed from both sides with the aid of round brushes and fresh solvent and the plate is thus cleaned After leaving the washing area the plates go through the pre drying section where they are ventilated on the upper side and pre dried on the under side by means of a plush coating on a rotating shaft The plates leave the machine dry to the touch Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 5 1 4 Description of the Process The speed at which the plates go through can be preset and can be adapted to the individual plate types After the plate is exposed it is first perforated with the pneumatic perforating punch The plate is fastened to the transport bar with the polymer side facing up and is fed into the input where is enters the transport system and passes through the following sections Wash out section Six flat brushes transverse to each other and contra rotating round brushes wash out the non polymerized non exposed parts of the plate The solvent reaches the brushes directly via brush holders and boreholes Cleaning section Cleaning takes place through contra rotating round brushes moistened with fresh solvent clearing the plate of washout solution Plate exit section At the exit section the plate is pulled over a rotating plush surface and pr
11. missible ambient conditions 3 5 Connecting to the power supply preparation for putting into operation first filling Service Manual 10 3 6 Principles for putting into service Service Manual 11 iD ervice Manual 11 12 3 7 Checking for correct operation 3 8 Requirements for use in a potentially explosive atmosphere ervice Manual 4 Safety 4 1 Safety measures when working at the machine 4 2 Notes on the use of personal protective equipment 4 3 Information on residue risks avoiding hazards oon Dm OD N 4 4 Environmental protection Operation Manual smart English 1004 2011 3003 smart Processor 5 Information on the operation on the machine 5 1 Description of the functions of all individual components 5 2 Measuring solid matter content and solvent heating 5 3 Description of adjustment and replacement work 5 4 Basic information about the washing brushes 5 5 Improper usage 5 6 Instructions for recognizing and eliminating errors 6 Operation 6 1 Starting the machine 6 2 The operations field 6 3 Manually filling the internal tank 6 4 Plate production 6 5 Drum to drum operation 6 6 Tank to tank operation with distillation 7 Instructions for equipment maintenance 7 1 Type and frequency of inspections operator 7 2 Instructions for maintenance work 7 3 Type and frequency of maintenance work service 7 4 Address of DuPont Operation Manual Page 3 Service Manual 14 16 Service Manual 17 Adj
12. o 0 5 seconds ca 0 2 seconds Solid matter content 1 0 to 9 9 ca 4 Solvent temoperature 20 C 40 C depending on solvent Solvent Flexosol Optisol Per LM 1 3 Tank see Screen 3 2 If a value has been changed the question will automatically appear Accept changed data Yes saves changed values No keeps the old value Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 13 Screen 3 Screen 2 Screen 1 40 sn 25mm 32 creen 4 Language menu Screen 4 0 In this screen the language can be changed Select the language with the arrow keys and press the Accept button The user interface language will automatically change to the selected language Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 14 Screen 2 4 Screen 2 1 Screen 2 i Plate in machine Accept new plate TDR 030 1 6 33 100 2 2 no l Stand by Screen 2 Plate values Screen 2 2 In this screen the plate values can be changed Click on menu field Selected menu field will have a highlighted background Change the value with the arrow keys The following changes are possible Position no sets the position number of the plate menu Name see Screen 2 3 Plate thickness Relief depth Wash time or transport speed values are changed analogously The value shown in the highlighted field abo
13. o tank operation with distillation If the machine is operated with the tank to tank version the sensors have the same function as in the drum to drum version If the message FS drum empty or OS drum full appears on the display the levels in the tanks must be checked and acted on accordingly Important The sensors delivered as standard float switches must not be used in EX rooms Please consult with DuPont beforehand Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 20 7 Information for equipment maintenance 7 1 Type and frequency of inspections operator daily every every 2 quarter Service plan Smart Processor menwa __fp ff ff _ e filter sock tank strainer brush adjustment pump gaskets brush wipers sprockets brush bearings fiter electrical box ventilator ee ee E a ventilation fan a eae De eae ae fee P check and if necessary act R clean T replace 7 2 Instructions for maintenance work Turn off main switch Maintenance work that is not listed in the servicing plan may only be carried out by a service technician or with prior consultation with the manufacturer Generally service work should take place if possible early Monday before the start of work The machine is ventilated then and a minimal disturbance is taken into account Before and during the service work the internal area of the machine is ventilated with the help
14. peration field see Menu guide smart pages 10 16 Screens 1 to 4 choose language Screen 4 0 program plates Screen 2 2 2 3 program flush time Screen 3 2 pre select solid material content Screen 3 2 determine solvent temperature Screen 3 2 determine solvent Screen 3 2 Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual page 9 The operation field touch screen settings Base screen production Screen 1 select plate menu select service select language start plate production start plate production in stand by mode start after interruption error messages Plate menu selection of plate types Screen 2 selection of plate types 1 21 selection of plate types in stand by mode changing plate settings Screen 2 2 changing relief depth changing plate thickness changing wash out speed changing plate name Screen 2 3 entering changes in data Screen 2 4 Operation machine settings Screen 3 changing the cleaning time changing the concentration of solid materials changing the solvent temperature changing the solvent select production select plate menu select language taking on changes in data Screen 3 1 filling tank Screen 3 2 emptying tank Language language choice Screen 4 German English French Spanish Italian Select production Select plate menu Select service Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual
15. smart Processor Operation Manual DuPont Cyrel Cyrel smart Processor Operation MANUAL subject to technical changes 1004ff 201 1ff 3003ff smart Processor Operation Manual customer Kunde Client Intergraf Hungary Order Nr DDE 07430 com No SP 3011 A 6044 Kom Nr No de com year of manufacture 09 2001 operating of voltage 400V 50Hz Baujahr Betriebsspannung Ann e de fabrication Tension de fonctionnement KieselstraRe 9 Rolf f GmbH 56357 Miehlen SCH AN Tel 49 6772 3393 Fax 49 6772 2053 Typ Smart XXL Processor KOM Nr SP 3011 Baujahr 09 01 Volt 3 N 400 V Hz 50 kW 7 Nennstrom 16 A Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual Page 2 Contents 1 About the machine Page 1 1 Address of manufacturer 1 2 Type of equipment 1 3 Description of operation 4 1 4 Description of the process 5 1 5 Designation of jobs 1 6 Data on noise emissions 1 7 Information on ventilation and fumes 1 8 Electrical supply Service Manual 7 1 9 Information specific to machinery materials 2 Transporting and setting up the machine 2 1 Unloading Service Manual 8 2 2 Transporting Service Manual 8 2 3 Setting up and aligning 2 4 Foundations 3 Bringing the machine into service 3 1 Requirements for fixing and anchoring 3 2 Conditions for insrallation 3 3 Space requirement for operation servicing and maintenance ep i lt e ervice Manual 3 4 Per
16. ustments 3 N Adjustments 4 7 7 8 16 17 18 19 19 2 N YW Oo o Service Manual 3 7 Service Manual 3 8 Safety related information for removing the machine from service and dismantling 9 Information for emergency situations 9 1 Type of fire extinguishing equipment to be used 9 2 Notes for rescue 10 Technical data and plans Delivery list Loading plan Pre loading plan Set up plan space requirements transport plan Specifications technical data Flow plan Liquid conduits and switching points for the level gauges Pneumatics plan Electrical wiring plan Operation Manual smart English 1004 2011 3003 Service Manual 33 21 21 Service Manual 35 Service Manual 36 37 Service Manual 38 Service Manual 39 Service Manual 40 Service Manual 41 Service Manual 42 55 smart Processor Operation Manual Page 4 1 About the machine 1 3 Description of operation The washing system serves to automatically wash flexographic printing plates of all types in conjunction with one exposure unit one dryer one light finisher The plates are illuminated in a UV light source polymerizing the image parts that will print later The plates run horizontally through the processing section of the machine where they are washed out with help of oscillating flat brushes and round brushes The washing agent a tempered solvent is used that is fed continuously to the brushes After washing the plates go though a f
17. ve the brush symbol is the distance brushes to the level of the bottom plate this value is reached by Plate thickness minus Relief depth max 4 mm If a value has been changed the question comes up Accept changed data Yes accepts the changed value No keeps the other value Operation Manual smart English 1004 2011 3003 smart Processor Operation Manual page 15 Screen 2 4 Screen 2 1 Screen 2 2 Plate in machine IN Accept changed data Accept new plate yes no stand by ELS 030 Plate value Name Screen 2 3 selecting the menu field name will give it a highlighted background At the same time an alphanumerical character map with a cursor will appear Use the arrow keys to change the position of the cursor By pressing transfer the number or figure under the cursor will be transferred to the menu field name Pressing the menu field again or another menu field will make the character map disappear automatically screen 2 2 Operation Manual smart English 1004 2011 3003 Screen 1 f production selet plates settings ii language Cyrel plate typ TDR 030 4 0 relief depht 2 5 mm C 2 7 6min 125mm min 3 7mm smart Processor i Screen2 takeover change PLS 030 5 TDR 067 2 pis osr TDR 112 3 PLS 112 7 TDR 045 4 PTS Screen 3 2 Operation Manual Screen 4 production T select plates settings i Page 1
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