What if...?. In 1995 KIPP Academy Houston KIPP Academy New York.
KIPP 200 IDS Pad Printer Machine Operation Manual
48
INTERNATIONAL KIPP 200 IDS Pad Printer Machine Operation Manual Serial No.: with SCMIC setup
Transcript of KIPP 200 IDS Pad Printer Machine Operation Manual
INTERNATIONAL
KIPP 200 IDS Pad PrinterMachine Operation Manual
Serial No.:with SCMIC setup
Content
Section Page
Introduction _______________________________________________ 1Installation: Mechanical Part________________________________________ 2.1 Electrical Part _________________________________________ 2.2 Pneumatic Part ________________________________________ 2.3Machine Setup: Ink Cup Installation __________________________________ 3.1-3.3 Ink Cup Removal ____________________________________ 3.4-3.5 Printing Pad Setup _____________________________________ 3.6 Pad Clean Tape Setup __________________________________ 3.7 Pad In/Out Cushion Adjustment __________________________ 3.8 Pad Stop Position for Pad Clean Adjustment _______________ 3.9 Ink Cup Platform Adjustment ___________________________ 3.10 Worktable Adjustment _________________________________ 3.11Control Feature: Front Control Panel ____________________________________ 4.1 Pneumatic Control Panel ________________________________ 4.2Control Sequence ____________________________________ 5.1-5.10Sensor Layout ________________________________________ 6.1-6.2IO Assignment _____________________________________________ 7Electrical Circuit Diagram _______________________________ 8.1-8.5Pneumatic Circuit Diagram ___________________________________ 9Maintenance ________________________________________ 10.1-10.5Spare Parts List: Electrical Spare Parts List __________________________ 11.1-11.2 Mechanical Spare Parts List ______________________________ 12 Pneumatic Spare Parts List _________________________ 13.1-13.2
INTRODUCTION
Warning!
Electrical Warning!
Warning - Danger of Fire!
Warning - Danger of hands being crushed while working on pneumatic elements!
Warning - Do not smoke while working on the machine!
Symbol to identify earth ground terminals.
The following manual will familiarize you with the setup, use and maintenance of your printer. Please note that the diagrams shown within this manual are not to scale, and may not show all details.We would like to draw your special attention to the following notes:
WARNINGIt is the operator’s responsibility to comply with the following safety instructions to prevent any personal injury.1. Please disconnect the main power supply before attempting any machine maintenance. Foot-switch or side doors is to stop machine for adjustment only.2. The air pressure must be released before attending to any service inside the machine or any moving accessories.3. Always use the emergency stop switch to stop the machine in an emergency. The foot switch is used for normal operations only.4. Guards CANNOT be removed when machine is in operation.
We have used the followings signs to show special dangerous situations:
1
2.1
InstallationMechanical Part:Machine Standing Horizontal Adjustment:Place machine on fl at place. If not, you need to adjust machine foot levers to adjust machine level:
1. Place level scale on ink cup platform of machine to survey machine horizontal.2. Release upper screw nut of foot lever.3. Turning foot lever supporter up or down to adjust supporting level.4. Tighten upper screw nut to fi x supporter position.
Remark:- Machine should be located where is • with good ventilation • not damp and wet • without combustible and corrosive gases- Machine should be kept away from the wall at least 600mm, facilitate operation of the control panel and servicing purpose.- Machine should have at least 600mm space with any other equipment.
Foot Lever
Supporter
Upper Screw Nut
Ground
2.2
InstallationElectrical Part:
8-way connector(CN2)
6-way connector(CN3)
5-way connector (CN1)
DRE Digital Shuttle
- Plug in the main power cable with correct power plug to main power connector. Machine is suitable for 230V 50/60Hz.Note: The ground lead of power plug must be wired correctly.
WARNING
- The ground lead of power plug must be wired correctly.
- All external fl exible cables should be run in conduits as not to present a tripping hazard.
6-way connector (CN3)
8-way connector (CN2)
5-way connector (CN1)
- Connect 5-way, 6-way and 8-way connectors from machine stand to DRE shuttle.
ON
OFF
Printer Rear Control Panel (RHS of printer)
Main Power Cable
Main Power Switch
Buzzer
(cables from machine stand)
Installation
Pneumatic Part:
- Connect the compressed air line to machine main service unit. (Please use only clean and dry air)
- Set pressure of main service unit for machine operation to 5-6 bar.
pressure gauge
adjust knob
compressed air inlet
Service Unit for Whole Printer(at the rear of machine body)
2.3
Machine SetupInk Cup lnstallation:
2. Cover ink cup by thin steel plate upside down as right diagram. Remark: The image side of plate cover faces ink cup.
3. Insert ink cup setup unit into thin steel plate with ink cup and then turn it upside down.
ink cup setup unit insert setup unit into thin steel plate turn upside down
4. Move ink cup holder to back side. Release ink cup holder swing arm locks and lift up swing arm.
swing arm locks
swing arm
3.1
1. Press REMOVE INK CUP function key in Printer Setup - 2 screen once to move the ink cup stroke back. Keep pad at the front. The key will be highlighted.
Printer Setup - 2
1
Machine SetupInk Cup lnstallation:
6. While slide ink cup setup unit out, put hand on ink cup top to stay it on plate. Buckle front hole of steel plate with front registration pin of ink cup platform.
7. Push ink cup against the internal back side of the ink cup holder. Then pull down the swing arm and tighten swing arm locks.
8. Release bleeding screw of ink cup.
bleeding screw
3.2
front registration pin
swing arm locks
5. Place ink cup setup unit with ink cup and steel plate on ink cup platform. Buckle rear hole of steel plate with rear registration pin of platform.
rear registration pin
Machine SetupInk Cup lnstallation:
3.3
9. Use allen key to adjust ink cup holder pad position. (This step apply for fi rst setup of new ink cup holder)
ink cup holder pad
10. Press REMOVE INK CUP key again to return ink cup stroke outward.
Printer Setup - 2
10
Machine SetupInk Cup Removal:
2. Tighten ink cup bleeding screw.
bleeding screw
3. Release swing arm locks of ink cup holder and lift up swing arm.
4. Lift up the front side of thin steel plate. Insert ink cup setup unit between ink cup platform and thin steel plate. Push it forward to against rear registration pin. Remove the thin steel plate and ink cup with ink cup setup unit.
3.4
swing arm locks
1. Press REMOVE INK CUP function key in Printer Setup - 2 screen once to move the ink cup stroke back. Keep pad at the front. The key will be highlighted.
Printer Setup - 2
1
Machine SetupInk Cup Removal:
6. Hold the ink cup, turn ink cup over and then remove ink cup setup unit and thin steel plate.
7. Clean the ink cup ring and then cover it well.
8. Use thinner to clean the thin steel plate. Apply grease on its surface and store it in plastic bag to prevent oxidation.
3.5
5. Press REMOVE INK CUP key again to return ink cup stroke outward.
Printer Setup - 2
5
Machine SetupPrinting Pad Setup:
1. Fasten printing pad to pad mounting by 4 screws.
pad mounting
2. Loosen Y-axis locking screw of pad holer assemby. Insert assembly onto pad Y-slide of printer. Tighten Y-axis locking screw to fix the position.
pad Y-slide
Completed Setup
Spare:
Y-axis locking screw
X-axis locking screw
Pad Holder Assembly
3.6
3.7
Machine SetupPad Clean Tape Setup:
pad clean tape platform
rotor
tape roll
tape roll mount
tape roll
Steps:
1. Insert empty core of tape roll onto the mount with rotor.
2. Insert new tape roll onto the mount without rotor.
3. Pull tape from the new tape roll and through the pad clean tape platform. The sticky side of tape faces upward.
4. Stick the tape onto the empty core.
Pad In/Out Cushion Adjustment:Cushion of pad cylinder needs to be adjusted when 2 occasions occurred.a. Carriage moves at high speed and creates bang at both ends (should close cushion).b. Carriage becomes very slow at 10 mm from both ends and creates vibration (should open cushion).Use very short handle screw driver, turn clockwise to close; counter-clockwise to open cushion.
2 cushion screws
3.8
Machine Setup
3.9
Machine Setup
lock knob
Machine RHS
Machine LHS
1. Loosen slider lock knob on the right hand side of machine head.2. Slide lock knob left or right to adjust pad stop position over the tape clean platform.Remark:- move to the left: pad stops further to the front.- move to the right: pad stop further to the back.3. Tighten slider lock knob to fi x position.
Note: There is another slider lock knob on the left hand side of machine. The position of this slider determines when machine power should be cut off automatically in case pad fails to stop over the tape clean platform (sensor failure). It is recommended to leave it in the current position.
Pad stop position over the tape clean platform can be adjusted by moving the slider knob accordingly:
Pad stop position for tape clean adjustment
Machine SetupInk Cup Platform Adjustment:
1. Loosen both locks at the front and back of ink cup platform.2. Turn both adjustment knobs (at the back) in the same direction for in-out adjustment or in opposite direction for angle adjustment.3. Fasten both locks.
3.10
In-out and angle:
back
lock
lock
adj. knobs
front
Machine SetupWorktable Adjustment:
Up/DownLock Handle
Angle Lock Screw
Angle Screw Knobs
X-Axis Lock Handle
Angle Lock Screw
Y-Axis Lock Handle
Handwheel
X-Axis Adjustment:1. Release X-axis lock handle.2. Screw X-axis screw knob to adjust X-axis position.3. Lock X-axis lock handle to fi x X-axis position.
Angle Adjustment:1. Release two angle lock screws and two angle screw knobs.2. a. Turn Left: Loosen left angle screw knob and tighten right angle screw knob. b. Turn Right: Loosen right angle screw knob and tighten left angle screw knob.3. After adjustment, tighten two angle screw knobs and two angle lock screws to lock the position.
Y-Axis Adjustment:1. Release Y-axis lock handle.2. Screw Y-axis screw knob to adjust Y-axis position.3. Lock Y-axis lock handle to lock Y-axis position.
Up / Down Adjustment:1. Release three Up/Dn lock handles.2. Turn the handwheel to adjust up/down position.3. Lock three Up/Dn lock handles to lock up/down position.
3.11
X-Axis Screw Knob
Y-Axis Screw Knob
Left Right
Front Control Panel: Control Feature
4.1
1. Display: Control machine and adjust printing function. (Display feature detail please refer to Control Feature: Touch Screen section)
2. Emergency Stop Switch: to cut main power and air in an emergency.
3. +/- Key: to increase or decrease paramter value, e.g. pad stroke depths.
1
32
Control Feature
4.2
Pneumatic Control Panel:
(RHS of printer)
521 6
1. Pad stroke downward speed control knob: a fl ow regulator to control downward speed of pad stroke.
2. Pad stroke upward speed control knob: a fl ow regulator to control upward speed of pad stroke.
3. Carriage forward speed control knob: a fl ow regulator to control forward speed of pad carriage.
4. Carriage backward speed control knob: a fl ow regulator to control backward speed of pad carriage.
5. Platform forward speed control knob: a fl ow regulator to control forward speed of ink cup platform.
6. Platform backward speed control knob: a fl ow regulator to control backward speed of ink cup platform.
Note: 6 speed control knobs are turning clockwise to decrease speed or anti-clockwise to increase.
3 4
Machine Start Up:
1. Turn on Main Power Switch at the rear of machine stand. 2. Release Emergency Stop Switch.3. The first time machine is activated a pasword must be entered. Ask your local dealer for more info.4. Press START key to start machine.
Machine resumes and screen enters manual mode.
Control Sequence
1
Front Control PanelPrinter Rear Control Panel
5.1
2
43
Control Sequence
A. Printer status and message display bar - shows printing status and error message.B. Cycle Counter displayC. Pad Stroke Setting KeyD. DRE Shuttle Position KeyE. Timer KeyF. Start / Stop Key - Activates a cycle in auto printing mode and manual mode. - In auto printing mode, the key becomes “ STOP ” to stop printer during a cycle.G. Pad Clean Key - Press key once to move pad to pad clean position in manual mode. - Press key once again to perform pad cleaning and return pad to the front.H. Pad Up Down Key - Activates pad up/down motion in manual mode.I. Pad In Out Key - Activates pad in/out motion in manual mode. J. MORE Key - Enters DRE setup-1 screen.K. Index Key - Advances digital shuttle to the print stations in manual mode.
Main Screen (Manual Mode):
A
ED
JC
B
H I KF G
5.2
5.3
DRE Shuttle Stations Selection
DRE Shuttle Loading Station Selection
Control Sequence
1. On the main screen, press/hold the “MORE” Key until “DRE Setup-1” screen appears.2. Press “Station Select” key to enter new screen.3. Press a station key to select (becomes highlighted) or deselect related station.4. Press “EXIT” key to return to the main screen.
1. On the main screen, press/hold the “MORE” Key until “DRE Setup-1” screen appears.2. Press “Load Position” key to enter new screen.3. Press a station key to select the loading position, “LOAD” apears on key. Choose between Home, 1st, 2nd, 3rd and 4th stations.4. Press “EXIT” key to return to the main screen.
Select/deselect print stations (up to 6 available).
1 2 3 2 3 4
Cycle group-1 Cycle group-2
print stations
images/pads
2
2
3
4
4
3
1
1
5.4
Setting DRE Shuttle Printing Stations
Control Sequence
1. Press the “Index” Key repeatedly to select a printing position. Index key moves between preselected stations (1-6 available). 2. Press “DRE Shuttle Position” Key once to activate setting function.3. Press “+/-” Key on front control panel to change value.
orwithout moving the shuttle
1. On the main screen, press/hold the “DRE Shuttle Position” Key until a new screen appears.2. Select a DRE station by pressing related “P1-P6” key.3. Input value then press “ENT” key.4. Press “EXIT” to return to the main screen.
1
3
3
1
2
3
2
Setting DRE Shuttle Speed
1
2
1. On the main screen, press/hold the “MORE” Key until DRE Setup-1 screen appears.2. Press “DRE Shuttle forward” or “DRE Shuttle backward” key.3. Press “+/-” Key on front control panel to change percentage.4. Press “EXIT” key to return to the main screen.
5.5
4
1
Pad Stroke Adjustment
for Printing1. Stop pad carriage at the front by pressing Pad In/out Key.2. Press Index Key to select desired printing station.3. Press Pad Stroke Setting Key once to activate the setting function. The key will be highlighted.4. Press +/- Key on front control panel to change stroke depth. 2
for Inking1. Stop pad carriage at the back by pressing Pad In/out Key.2. Press Pad Stroke Setting Key once to activate the setting function. The key will be highlighted.3. Press +/- Key on front control panel to change stroke depth.
3
1
3
2
Control Sequence
Delay before Ink:Pad pauses above plate for a preset time before moving down for inking.
1. From the main screen, press/hold the “Timer” key until the “Time Setup” screen appears.2. Press/Select a time delay of your choice.3. Press “+/-” switch to increase or reduce delay.4. Press EXIT to return to the main printing screen.
3
Delay before Print:Pad pauses above product for a preset time before moving down for printing.
Cycle Auto Restart Delay:Allows to preset a time delay for product unload-load. Cycle restarts automatically once time delay has elapsed. For auto cycle mode printing ONLY.
Setting Delay before Ink/Print, Dwell for Ink/Print, Cycle Auto Restart
Dwell for inking:Pad dwells on the cliché’s surface for a preset time.
Control Sequence
5.6
1 2
Dwell for printing:Pad dwells on the product’s surface for a preset time delay. Setting avail-able for up to six prints as followed:
1 1 2 2 3 3 4 4
1 2 3 4 5 6
Cycle group-1 Cycle group-2
ink
dwell for printavailable
Printing Mode Selection:
Print Cycle Selection:
Pad Clean Rotor Setting:Allows to set a number of rotations to unroll a clean piece of tape clean.
1. From the main screen, press/hold the “Pad Stroke” key until the “Printer Setup-1” screen appears.2. Press the "Next" key.3. Press the "Pad Clean Rotor Key”.4. Press +/- key to set a number of rotation.
Control Sequence
4
5.7
1. From the main screen, press/hold the “Pad Stroke” key until the “Printer Setup-1” screen appears.2. Press the “Print Mode” key repeatedly to select either single cycle mode or auto cycle mode. Single Cycle Mode: Step on foot switch once to start one printing cycle. Auto Cycle Mode: Press Start key to start continuous printing cycle.3. Press EXIT to return to the main printing screen.
1. From the main screen, press/hold the “Pad Stroke” key until the “Printer Setup-1” screen appears.2. Press the “Print Cycle” key of 1st group and 2nd group repeatedly to select single cycle or double cycle print. Single Cycle Printing: Executes [one ink - one print] per cycle Double Cycle Printing: Executes [one ink - one print]x2 per cycle3. Press EXIT to return to the main printing screen.
1
1
1
2
2 2
3
3
2
3
Control Sequence
5.8
Cycle Counter Reset:
Moving Ink Cup In or Out:
1. From the main screen, press/hold the “Pad Stroke” key until the “Printer Setup-1” screen appears.2. Press the "Next" key.3. Press/hold the "RESET” key untill 00000 is displayed.4. Press EXIT to return to the main printing screen.
1. From the main screen, press/hold the “Pad Stroke” key until the “Printer Setup-1” screen appears.2. Press the "Next" key.3. Press "Remove Ink Cup” key to move ink cups in or out.4. Press EXIT to return to the main printing screen.
Move ink cup in or out when setting up machine with plates and cups.
1
1
2
2
3
4
4
3
Control Sequence
5.9
Printing:
Auto Cycle Mode:Before running this mode, it is necessary to set the printing function to “AUTO cycle” mode. Refer to the “Printing mode selection” section.1. In manual mode, turn off any highlighted manual keys.2. Press the “START” key once to execute continuous printing.3. The START key becomes the STOP key and is used for stopping Auto Cycle Mode printing and entering Manual Mode.
Manual Mode:1. Press any manual key (key will be highlighted).2. Press the “START” key to enter manual mode and execute related function.
Single Cycle Mode:Before running this mode, it is necessary to set the printing function to “ SINGLE cycle” mode. Refer to the “Printing mode selection” section.1. In manual mode, turn off any highlighted manual keys.2. Press the “START” key once to enter "SINGLE cycle" mode.3. Press the foot switch once to activate one print cycle.4. Press “STOP” Key to stop cycle.
23
2
24
1
1
1
3
1. Foot switch: Press the emergency stop switch to cut off the main power and air supply of machine in the event of an emergency. Release switch by turning its mushroom head clockwise.
Foot switch
2. Emergency Stop Switch: Press the foot switch to stop machine movement. Press the START key on the touch screen panel to restart.
A lubrication warning will appear every 30,000 cycles. If machine requires a password, please contact your local dealer.
1. Activate the lubrication pump ON and OFF.2. Input password (Optional).3. Press OK.
Emergency Stop Switch
3. Side door: When a side door is opened all movable parts will stop immediately. All manual function keys and START key won't be responsive. Close the side doors then press the START key once to restart. Side
doors
Control SequenceStop and Restart:
Lubrication Warning:
5.10
Sensor LayoutPrinter:
6.1
X001 X004X005 X007X000------ Pad stroke optical ruler sensor (PS2).X001------ Pad stroke home optical sensor (PS1).X004------ Pad carriage home micro switch (PS5).X005------ Pad carriage actuated micro switch (PS6).X007------ Ink cup stroke home micro switch.X010------ Middle pad clean sensor. X000
X040
X016
X015
X006
X006------ Ink cup stroke home micro switch (PS7). X015------ Left side door sensor (SR2). X016------ Right side door sensor (SR4).
X040------ Oil pump handle sensor.
X010
Sensor LayoutShuttle:
X024 X023 X027
X023------ DRE shuttle home sensor (MS1). X024------ DRE shuttle far limit sensor (MS2). X027------ DRE shuttle registration home sensor.
6.2
IO Assignment
7
INPUTS (FX1N-60MT MASTER PLC) OUTPUTS (FX1N-60MT MASTER PLC)X000 Pad stroke optical ruler sensor (PS2) Y000 DRE shuttle servo pulse signalX001 Pad stroke home optical sensor (PS1) Y001 Pad clean tape rotor solenoidX002 +/- key (-) Y002 DRE shuttle motor direction signalX003 +/- key (+) Y003 Spare outputX004 Pad carriage home micro switch (PS5) Y004 DRE shuttle servo driver SON signalX005 Pad carriage actuated micro switch (PS6) Y005 Spare outputX006 Ink cup stroke home micro switch (PS7) Y006 BuzzerX007 Middle pad clean sensor Y007 Spare output
X010 Middle pad clean stop protect sensor Y010 Main air solenoidX011 Spare input Y011 Pad stroke up/down solenoidX012 Spare input Y012 Ink cup carriage in/out solenoidX013 Spare input Y013 Pad carrage in/out solenoidX014 Spare input Y014 Middle stop of pad clean solenoidX015 Left safety side door sensor (SD2) Y015 Pad stroke dwell solenoidX016 Right safety side door sensor (SD4) Y016 Pad clean lock cyclinder solenoidX017 Foot switch Y017 Spare output
X020 15 ways connector pin 5 confi guration Y020 Spare outputX021 15 ways connector pin 4 confi guration Y021 Spare outputX022 15 ways connector pin 3 confi guration Y022 Extend pad stroke solenoid 1X023 DRE shuttle home sensor (MS1) Y023 Extend pad stroke solenoid 2X024 DRE shuttle far limit sensor (MS2) Y024 Extend pad stroke solenoid 3X025 DRE shuttle servo driver ready OK signal Y025 Extend pad stroke solenoid 4X026 Spare input Y026 Spare outputX027 DRE shuttle registration home sensor Y027 Spare output
X030 Spare inputX031 Spare inputX032 Spare inputX033 Spare inputX034 Spare inputX035 Spare inputX036 Spare inputX037 Spare input
X040 Oil pump hander sensorX041 Spare inputX042 Spare inputX043 Spare input
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X00
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Pad stroke home optical sensor (PS1)
X00
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006 Ink cup stroke home micro switch (PS7)
X00
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005 Pad carriage actuated micro switch (PS6)
Pad carriage home micro switch (PS5)
X01
7 Foot switch
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12
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Fan2
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4
Pad stroke dwell solenoid
Y01
5Y
006 Buzzer
Y01
3
e
Y02
3
e
Y02
4
e
Y02
5
LAB
EL
KE
NT
PA
RT
NO
.LA
BE
LK
EN
T P
AR
T N
O.
LAB
EL
KE
NT
PA
RT
NO
.
PV
A-0
70P
VA
-070
OLE
NO
ID C
OIL
FFa
n
KS
P3-
EC
-000
Fan
8.1.7
8.1.7
- +1
12
1 2
1 2
1 2
1 2
1 2
1 2
1 2
e
Y02
2
1 2
1 2
P lock cyclinder
Y01
6
1 2
Main air solenoid
Y01
0
1 2
carriage in/out
Pad clean tape rotor solenoid
Y00
1
1 22
KP
200
KP
200
SIN
GLE
SIN
GLE
SIN
GLE
12
34
56
78
12
34
56
78
A B C D FE
A B C D FE
8.4
MIT
SU
BIS
HI
FX1N
-60M
T
MP
OS
-EC
-120
PLC
AN
D T
OU
CH
PA
NE
L LA
YO
UT
0 V
SA
NM
OY
ION
AC
SE
RV
O S
YS
TEM
SR
SA
NY
O D
EN
KI
RS
1A01
AA
MO
OE▲
▼W
R/
▼
T S R t r DL1
DL2 P RB
1
RB
2
C N A C N B C N C
P C C N 1 C N 2
W V U
CH
AR
GE
PO
WE
R
P50
B07
040H
XS
00
EN
CO
DE
R C
AB
LE
PO
WE
R C
AB
LE
RS
1A01
AA
SE
RV
OS
D1
MR
1
E
R2
ES2 0V0V
24V
MP
OS
-EC
-110
Touc
h sc
reen
12
34
56
78
12
34
56
78
A B C D FE
A B C D FE
8.5
9
HGL-1/4B(KP200-PFR-010.01)
ASC200-08(KP150-PFR-011)
ASC200-08(KP150-PFR-011)
ASC200-08(KP150-PFR-011)
ASC200-08(KP150-PFR-011)
ASL6-01(EX-PFR-011.01)
ASL6-01(EX-PFR-011.01)
ASL6-01(EX-PFR-011.01)
PC
F-06
-G01
CD
C(1
5-P
FT-3
30)
Pne
umat
ic C
ircui
t Dia
gram
VT-3
07-5
G-0
2(1
5-P
VA
-120
)(Y
016)
PA
D C
LEA
N L
OC
K
CY
LIN
DE
AE
VC
-25-
10-I-
P(H
VA
150-
PC
Y-0
50)
VT-
307-
5G-0
2(1
5-P
VA
-120
)(Y
014)
MFH
-5-1
/8-B
(15-
PV
A-0
90)
(Y02
3)
MFH
-5-1
/8-B
(15-
PV
A-0
90)
(Y02
4)
MFH
-5-1
/8-B
(15-
PV
A-0
90)
(Y02
5)
PA
D S
TRO
KE
CY
LIN
DE
R
PA
D C
AR
RIA
GE
C
YLI
ND
ER
IND
EP
EN
DE
NT
INK
CU
P
STR
OK
E C
YLI
ND
ER
ASL6-M5B(10-PFR-011.01)
PA
D C
LEA
N R
OTO
R
CY
LIN
DE
AE
VC
-25-
10-I-
P(H
VA
150-
PC
Y-0
50)
VT-3
07-5
G-0
2(1
5-P
VA
-120
)(Y
001)
10.1
MaintenanceSafety instructions for doing maintenance:• Electrical and pneumatic energy sources must be cut off from machine before doing maintenance. Complete separation of power plug from socket and air hose from compressed air line by mean of lever or quick connector coupling is mandatory to prevent injuries caused by unexpected energizing or start up of machines.• Only an authorized electrician is allowed to access the control of machine.• Do not wear loose or hanging clothes or jewelers.• Do not clean machine with high pressure compressed air.
Daily inspection:• Compressed air supply pressure for machine is higher than 5.5bar and stable. Pressure for air blower is kept in 1-2bar.• Compressed air supply must be clear of water and oil. • Drain water from bowl of service unit if there is deposited water.• Electricity supply is kept in 220V AC and stable.• Earth line is connected properly.• No cables and air hoses lay on working fl oor. • Check whether buzzer sound is normal.• Check whether printing pad surface is damaged. It needs to be replaced whenever its surface is scratched. Finishing of pad surface begins degrading after 5000 cycles used. Usual life of printing pad is 20000 cycles or longer.• Check whether ink cup ring edge is chipped. Recommended to do reconditioning per 2 days or 4 shifts. If ring edge is widen than 0.25mm, the ring needs to be regrinded. • Check whether printing plate surface was worn out or scratched. Maximum life of aluminum plate is 50000 cycles and that of thin steel plate is 100000 cycles.
Maintenance after each printing job or working day:• Release water from service unit. (See page 10.4 "Discharge Water from Service Unit" for details)• Unload ink cups from printing plates. Cover ink cups by polymer plate covers after cleaning.• Clean ink on printing plates with thinner. Coated plates with grease to avoid oxidisation.• Clean ink on pads with thinner. Store pads in cool place. Never put pads into any plastic bag.• Keep ink cup platforms clean.• Apply grease to easy-rusty parts and areas.
10.2
MaintenanceWeekly maintenance:• Do daily maintenance as usual.• Clean machine cabinet and inside with mild cleaning solvent.• Check the overall operation of machine.• Check whether there is air leakage from pneumatic devices and connections.• Check whether there are visible damages of cables, air hoses and mechanisms.• Check whether all movable parts move smoothly, without abnormal sound.• Check visually whether any electrical and pneumatic connectors are loosed.• Check sensors position and sensitivity adjustments.• Check and clean the sensor lenses.• Check and tighten if any screws are loosed by vibration from machine movement.• Lubricate machine movable parts as indicated. (See page 10.3 "Lubrication" for details)
Monthly maintenance:• Do daily and weekly maintenance as usual.• Check fi lter of anti-dust blower.• Check cables and connectors of servo motors.• Check condition of ball screws and guide rails.• Check fuses of all devices.• Check function of all emergency switches.
10.3
MaintenanceThere are some regular maintenance works to keep printer in smooth operation.
1. Lubrication:Weekly lubricate machine parts by injecting grease into grease nipples indicated in the following pictures.a. Grease nipples of pad carriage. b. Grease nipples of shafts of ink cup stroke. c. grease ball screw bearing system of DRE shuttle by pressing oil pump handle.
c
b
lubrication remind screen
handle
piston handle grease container
injection handle nozzle
Operation of Grease Pump:Fit nozzle onto grease nipple and then press injection handle to inject grease.Remark:- When piston handle is retracted into container completely, the pump is needed to refill. (See page 10.5 for details)
Remark:It is recommended to apply Kent grease (DP-0047) for parts a b and e.
Remark:If DRE shuttle has not been lubricated by oil pump for running over 20000 print cycles, a lubrication remind screen will be shown on touch screen panel when machine is powered on and system resume completed. Press oil pump handle once, then Press OK key to return manual screen.
a
OK
Maintenance
10.4
2. Scale Ruler Cleaning:Please weekly clean the scale ruler up.
scale ruler
Main Service Unit(at the rear of machine body)
Service Unit For Air Blower(at the rear of machine body)
4. Discharge Water from Service Unit:If there is water inside bowl of service unit, discharge the water everyday.
discharg water from here
3. Refill Oil Pump:a. fi t nozzle of grease gun to refi ll inlet of oil pump.b. press handle of grease gun to inject grease into oil pump.
Handle
Nozzle
Grease pump Refi ll inlet
Remark:If there is excessive water drained into the bowl, a fi lter/dryer should be considered and installed upstream at the back of air compressor to extract moisture and other contaminants.
5. Press release button to release piston handle lock.
release button
MaintenanceRefill of Grease for Grease Pump:- When piston handle retracted into container completely, it is time to refi ll grease into the pump.
1. Open grease pump.grease container
injection handle
2. Dig top opening of pump body into grease container.
3. Pull piston handle out. Grease will be sucked inside the pump body.
piston handle
4. Cover the grease pump.
10.5
Electrical Spare Parts List15-EC-131Proximity sensorTL-Q5MC1
15-EC-420Emergency Stop SwitchYW1B-V4E01R
15-EC-590Micro switchVX-5-1A3
15IDS-EC-000Main power switch194E-E25-1753-6N
AN10-EC-620Optical sensorEE-SX672
AN15-EC-300Servo motorP50B07040HXS
DRE70-EC-022Pad carriage servo motor driverRS1A01AA
EM-EC-040Switching power supply24VDC 2.7A
HVA90-EC-001+/- switch
KP150-EC-A990Foot switch
KSD130-EC-000Metal resistor47OHM/50W
KSDTT-EC-100.012 Poles fuse holder
KSDTT-EC-111Fuse 10X38mm4A 500V
KSDTT-EC-112Fuse 10X38mm10A 500V
KSDTT-EC-15118A/220V ContactorLC1-D18M7C
KSP3-EC-000Fan(4 1/2INCH) DC24V
MPOS-EC-040BuzzerB11S3240 24VDC
MPOS-EC-100PLCFX1N-60MT
11.1
Electrical Spare Parts ListMPOS-EC-1104.2" mono touch-screen DISPLAY
MPOS-EC-120Cable for F900GOT & FX2N(LENGTH 3M)
11.2
Mechanical Spare Parts List15-GIC-A021Dia. 130mm flat ceramicmagnetic ink cup
15-ICT-A022150mmx300mm polymerplate & thin plate support plate(for dia.130mm ink cup)
15-MB-120Rubber ringI.D.27mm X O.D.38mmX L.3mm
15-PC-6800.7mm Optics scale(1.5X20X177.7mm)
21-MB-131Gray sponge(53X72X85mm)
CMIC-A051.11Ink cup set up unit(for dia.120~130 ink cup)
ICH-A006.04130mm swing arm inkcupholder ass'y
KP200-ICT-A0604 Colors ink cup platformassembly
KP200-PA-A030104mm pad mounting plate
KP200-SC-094Left side door(30X600X690mm)
KP200-SC-104Right side door(30X600X690mm)
KP200-SC-115Back safety cover(6X149.5X668mm)
KP200-SC-122Front safety cover(6X296.5X648mm)
MT-815Grease pump(BULK 400C.C)
MT-871Manual grease pump(YGL-T08 800 C.C.)
12
Pneumatic Spare Parts List10-PFT-020Fitting (GCK-1/4-PK-4KU)
15-PFT-020Fitting (CK-1/4-PK-6KU)
15-PFT-060Fitting (GCK-1/8-PK-6-KU)
15-PFT-150Fitting (GCK-1/4-PK-6-KU)
15-PFT-280T-connector (T-6-4-6)
15-PFT-311Quick connector coupling(SPC06-G01 CDC)
15-PFT-330Quick connector coupling(PCF-06-G01)
15-PVA-060Solenoid valve(MFHE-3-1/4-B)
15-PVA-090Solenoid Valve(MFH-5-1/8-B)
15-PVA-1203/2 Single solenoid valvePT 1/4(VT-307-5G-02)
20-PFT-010Fitting(GCK-3/8-PK-9-KU)
20-PFT-020Fitting(CK-3/8-PK-9-KU)
20-PFT-030Straight male connector(CK-1/4-PK-9-KU)
20-PFT-080M6 straight grease nipple
20-PSL-010U-1/8 silencer
21-PSU-020.01R1/8 blade pressure gauge(QY-40Z)
22-PSU-010Filter regulator(AW30-02+AR30P-270AS)
C12L-PCY-012.01Independent ink cup strokecylinder(DSBA-F-50-160-CA)
13.1
Pneumatic Spare Parts ListC4-PFT-020Fitting(T-PK-4)
EX-171.01Extend pad cylinder(64.5X71X88.5mm)
EX-PFR-011.01Flow regulator(ASL6-01)
HVA150-PCY-050Pad clean (middle stop)cylinder(AEVC-25-10-I-P)
KP150-PFR-011Flow regulator(ASC200-08)
KP200-PCY-020Pad carriage cylinder(L-CG1BA32-300)
KP200-PCY-050.02Pad stroke cylinder(DSBA-F-100-100-CA)
KP200-PFR-010.01NON-Retune valveHGL-1/4B
KP200-PFR-0203/8" Flow regulator(ASC300-10)
KP200-PVA-0101/4" solenoid valve(VQZ3121-5GB-02F)
13.2
