nyloflex -PROCESSOR FIII filenyloflex-PROCESSOR F III MACHINE DESCRIPTION Eng. Version 1.1 Page 4 /...

nyloflex®-PROCESSOR FIII

TECHNICAL MANUAL

nyloflex-PROCESSOR F III TABLE OF CONTENTS

Eng. Version 1.1 / 60

MACHINE DESCRIPTION: Manufacturer’s address:..............................................................................3 Range of application:...................................................................................3 Maximum capacity of the unit:.....................................................................3 Principle description: ...................................................................................3 Safety Warnings: .........................................................................................4

PRE-INSTALLATION:

Technical data : ...........................................................................................5 Crate dimensions: .......................................................................................5 Floor space requirement: ............................................................................5 Connection Location:...................................................................................5 Accessories needed for the connections:....................................................6

INSTALLATION:

Unpacking: ..................................................................................................7 Parts supplied with the machine :................................................................7 Connections: ...............................................................................................8

TECHNICAL MANUAL:

Washout brushes pressure adjustment: ....................................................10 Restricted access screen: .........................................................................13 Solid content measurement device : .........................................................17 Solvent replenishment:..............................................................................18 Machine setup : .........................................................................................19 Plates counter : .........................................................................................25 Alarm History :...........................................................................................27 Alarm Setup: .............................................................................................28 Service alarm : ..........................................................................................29 Solvent diagram: .......................................................................................30 Troubleshooting: .......................................................................................31 Positions of the sensors in the machine: ...................................................34 Sensor Malfunctions:.................................................................................35 Maintenance Guide: ..................................................................................39 Spare parts list ..........................................................................................41 Electrical scheme: .....................................................................................50 CE CERTIFICATE:....................................................................................60

nyloflex-PROCESSOR F III MACHINE DESCRIPTION


Manufacturer’s address: AZ Srl "Il Girasole" - Palazzo Donatello 8/07 20084 Lacchiarella (MI) Italy Range of application: This unit is part of a full range designed for treatment of flexographic printing plates. This range includes exposure, processor, dryer and light finisher. The nyloflex®-PROCESSOR F III is a unit designed to wash out solvent washable printing plates. All other steps of the process are carried out on the other components of the range. Maximum capacity of the unit: Number of plates: 3

Minimum plate size: A4

Maximum plate size: 40 x 48 inches 1020 x 1200 mm

Warning: This unit is designed to work with solvent and has been tested with conventional product. Always ask your dealer before trying to change the type of solvent. This may result in major damages and safety issues. This machine has not been designed as an explosion proof unit. Principle description:

• This unit is designed to wash and clean printing plates after the exposure process. • The machine is divided into major sections:

o Input table and control panel: Allow the operator to place the plate into the machine and select the correct parameters to process it.

o Washout section: Designed to provide high quality and even washing out of the plates.

o Cleaning section: Designed to ensure the cleaning and the wiping of the plate. o Exit section.

The machine is operated via a specific control panel which ensures a very easy handling.

nyloflex-PROCESSOR F III MACHINE DESCRIPTION


CRIPTION

Eng. Version 1.1 Page 4 / 60

Safety Warnings:Safety Warnings:

To use this unit safely, it is essential that operator and maintenance people follow thesafety instructions and safety precautions and warnings specified in the manuals. The unit is equipped with emergency switches which allow the operator to stop themachine in case of an emergency. These emergency switches cut off the power supply of the entire machine. Make sure that the risk or the problem has been eliminated before restoring the power onthe unit. To release the emergency switches, turn clockwise. The unit then has to be re-startedfollowing the “Initial Operation”- procedure. Safety Interlocks For the safety of operators, interlocks exist for the following:

• Opening of the top covers during operation, • Overheating • Safety Level Switches

nyloflex-PROCESSOR F III PRE INSTALLATION

Technical data : Dimensions (w x l x h) : 1 820 x 3 120 x 1 100 mm Net Weight : 910 Kg Compressed air supply: 6 bar minimum Exhaust: 600 m³/h minimum Noise Emission: < 70 dB (A)

400V 3Ph / N / PE 50/60Hz 6,5 KW 10 A Power supply :

230V 3Ph / PE 50/60Hz 6,5 KW 16 A

Note : It is possible to dismantle a part of the exit section of the machine in order to reduce the length to 1950 mm to solve specific handling issues.

Crate dimensions:

• Please ensure that the dimensions of the crate match the facilities of your site: door dimensions, soil bearing values …

W: 2 000 mm. L: 3 150 mm H: 1 430 mm. Gross weight 1 350 Kg

Floor space requirement:

• Please ensure there will be sufficient space around the machine for safe use as well as easy access for maintenance. 1.5 meter free space is needed in front of and on the back of the machine to give an easy access. On both sides of the unit 750 mm are required to allow the access.

Connection Location:

• All the connection points are located on the rear side of the machine. • The solvent connections are located on the left and the rear side of the unit. • The compressed air supply connection is located underneath the left side of the exit

table. • The electrical power supply as well as the two connections to the external solvent level

sensors are located underneath the right side of the exit table.


nyloflex-PROCESSOR F III PRE INSTALLATION


Accessories needed for the connections: Compressed air supply: Hose, diameter 6 mm Exhaust : Hose, diameter 120 mm

5 x 6 mm² cable for the 400V configuration Power supply : 4 x 6 mm² cable for the 230V configuration

Solvent : Hose, solvent resistant, diameter 20 mm

nyloflex-PROCESSOR F III INSTALLATION


Upon receipt of your machine please check with the carrier the status of the crate. Notify him of any damage you see on the crate. Before starting to unpack the unit, make sure you have all required tools ready to hand. Unpacking: Warning: For safety reasons, please wear appropriate protective clothing (gloves, glasses, and safety shoes) while unpacking.

• Start by removing the top section of the crate. • Remove the sides one by one. • The machine is now resting on the base of the crate. • Remove all blocking pieces of wood. • Use the appropriate forklift to lift the unit and get it to its installation location. Take care

that the forks are long enough to lift the machine without causing damage. • Ensure there is sufficient space around the machine (see Pre-installation section). • Remove all protection from the unit (do not use sharp tools to prevent damages). • No special anchorage is needed for this unit. The unit will rest only on its feet. • Align the machine precisely by means of a spirit level. The alignment is made by using

the adjustable feet..

Parts supplied with the machine : Items : Qty : Pin bar 3 Hose diameter 120 mm 3 m Locking collars (diameter 120 mm) 2 Panel key 1 Filter key 1 High level used solvent sensor 1 Plug and cable for used solvent sensor 1 Low level fresh solvent sensor 1 Plug and cable for fresh solvent sensor 1 Used solvent barrel adapter 1 Fresh solvent barrel adapter 1 Solvent hoses (diameter 20 mm) with fittings 2 x 3 m Towel 1 Fixation bar for towel 1 Catch Tray 1 Set of fuses 1 Tube for compressed air 3 m Punch device 1 Front cover handle 1 Exit tray 1 Verify that all parts are with the machine.

nyloflex-PROCESSOR F III INSTALLATION


Connections:

All necessary connections have to be carried out in accordance with the rules and regulations of the installation country.

Electrical connection :

• Connections such as electrical power supply have to be carried out by certified personnel.

• It is recommended to use a ground fault circuit breaker as well as a lockout type power switch for the electrical connection.

• Before switching the machine on, measure the voltage on the main switch of the machine and make sure that it matches the value on the identification plate which is fixed on the back of the unit.

Exhaust blower connection:

• Connect all the exhaust hoses to the appropriate location (directly to the outside or to the building exhaust installation). Ensure the airflow is correct.

Compressed air connection:

• Connect the compressed air line to the unit. Solvent connection:

• Connect the solvent lines to the correct points. • Connect the solvent level sensors (high level used solvent and low level fresh solvent)

to the correct plugs.

Filling the heater/cooler tank: • Open the panel located on the left side of the unit. • Remove the cover of the heater/cooler tank. • Prepare 3 litres of a solution based on 70% of de-mineralized water (or distilled water),

30% of ethylene glycol and some drops of algaecide (anti-foam action). • Fill the tank to the maximum. • After operating the unit for a couple of minutes, it may be necessary to check the level

of the heater/cooler tank again and to add solution to reach the correct level. Note: This operation has to be made with the machine switched OFF. WARNING: PRIOR TO USE THE MACHINE IT IS REQUIRED TO CHECK THE WASHOUT BRUSHES PRESSURE. PLEASE REFER TO THE DEDICATED SECTION IN THE TECHNICAL MANUAL FOR DETAILED PROCEDURE.

nyloflex-PROCESSOR F III

Technical Manual Eng. Version 1.1 / 60

TECHNICAL MANUAL


Adjustment of the pressure of the washout brushes: The check-up and adjustment of the pressure of the washout brushes is made by a measurement of parallelism between the brush frame and the washout table. The measurements have to be carried out on the 4 corners of the frame by means of a depth gage (long enough to measure 250mm).

DEPTH GAGE

Measuring points:

The measured distance must be adjusted to 245mm at the four corners. This corresponds to 1mm pressure between the brushes and the washout table. In order to achieve this adjustment, the electrical components plate located in the electrical box of the machine (right side) has to be opened to get access to some locking screws. BEFORE MEASURING: Make sure the bristles of the brushes are soft. If not, use the manual functions to put solvent on the brushes in order to have an easy adjustment of the required pressure. Technical Manual Eng. Version 1.1 / 60


To adjust the rear end of the brush frame (back of the machine):

1. Remove the 3 screws which fix the electrical component plate and open it (the electrical plate is mounted on hinges).


2. At this point, loosen the 2 screws “A” (DO NOT REMOVE THEM COMPLETELY) on the right side and the 2 screws “A” on the left side of the machine as indicated in the following pictures:

A A

3. It is now possible to adjust the position of the brush frame by turning the screw “B” up

or down as shown in the following picture.

B

4. When the brush frame position is correct (245mm) tighten the screws “A” on both sides of the machine in order to lock the brush frame, close the electrical plate.


To adjust the front end of the brush frame (entrance side):

1. Loosen the screws “A” (DO NOT REMOVE THEM COMPLETELY) and adjust the position of the brush frame by turning the screws “B”.

A

B

2. When the brush frame position is correct (245mm) tighten the screws “A”.

When all 4 corners are adjusted to 245mm the machine is ready for use.


nyloflex-PROCESSOR F III TECHNICAL MANUAL


MANUAL

Technical Manual Eng. Version 1.1 Page 13 / 60

Restricted access screen:Restricted access screen: To access the restricted screens, passwords are required from the configuration screen:

1969 13091006

Access to plate counter screen.

Access to machine setup

screen.

1966

Access to alarm History.

2121

Access to alarm setup

screen.

Access to manual function

screen.



88889999

2000300030015000

Activate (9999) or deactivate (8888) the solid content

measurement device.

Change the size of the machine as well as its

type.



MANUAL


Manual functions : Manual functions : Warning: all available functions in this section should be accessed by trained and skilled personnel only. Bad manipulation in this section may result in poor plate quality, damage to the machine or safety risks. Depending on the configuration of the solid content measurement device (refer to the “Solid content measurement device”)) two kinds of manual functions screens can be displayed after the input of the specific password (1969). • Manual functions screen with the solid content

measurement activated: The solid content measurement device is displayed.

• Manual functions screen with the solid content

measurement deactivated: The solid content measurement device is not displayed.

• To start the desired function, simply press its graphic symbol on the screen. One press on

the touch screen starts the function, a second press stops it. Note conerning the pumps : It is not possible to start the pump if the associated solenoid valves have not been opened previously. This is to prevent over pressure and high temperature in the pump itself (no circulation of solvent). If the solenoid valves are closed with the pump running, the pump will stop automatically.



late production.

MANUAL


late production.

• It is possible to run the transport chain forwards or

backwards by pressing the desired direction. • It is possible to run the transport chain forwards or

backwards by pressing the desired direction. • To change the speed of the transport chain, press the

speed display and enter the new value. The new value is used only in the manual function and does not affect the speed parameters stored for p

• To change the speed of the transport chain, press the speed display and enter the new value. The new value is used only in the manual function and does not affect the speed parameters stored for p

Warning: Mind, that running the transport chain backwards may cause some damage to the machine if no attention is paid to the position of the transport bar.


Solid content measurement device : Warning: all available functions in this section should be accessed by trained and skilled personnel only. Bad manipulation in this section may result in poor plate quality, damage to the machine or safety risks. To activate or deactivate the solid content measurement device, simply enter the dedicated password. Depending on the chosen password, a different screen will be displayed.


8888 9999

Deactivates the solid contentmeasurement device. The “%MAX” parameter is notdisplayed anymore.

Activates the solid contentmeasurement device. The “%MAX” parameter isdisplayed.



Solvent replenishment: Two different methods of solvent replenishment are available on the machine depending on the configuration of the solid content measurement device. • If the solid content measurement device is activated: The replenishment is made automatically depending on the result of the measurement. It is possible to define the quantity of fresh solvent to be filled into the machine when the solid% gets too high, as well as the time in between two measurements. In case the solid% is too high, washout solvent is removed from the washout tank first and then replaced by fresh solvent. • If the solid content measurement device is deactivated: The replenishment is based on the calculation made by the computer. It depends on the plate length measured by the machine, the relief depth, plate width and replenishment factor, which have to be entered by the operator. It is possible to define a value for the replenishment, the quantity of fresh solvent to be filled into the machine and the dosage intervals of fresh solvent. In case the needed quantity of fresh solvent exceeds a specific threshold, washout solvent is removed from the washout tank first and then replaced by fresh solvent.


Machine setup : Warning: all available functions in this section should be accessed by trained and skilled personnel only. Entry of wrong settings in this section may result in poor plate quality, damage to the machine or safety risks.


Access to machine setup screen.

1309

OR



MANUAL


Speed Scaling : Speed Scaling : The parameters configure the speed of the transport chain. It is possible to modify the speed of the chain by adjusting these parameters in order to have the speed corresponding to the

” & “C” must remain at 13 & 255

arameter “D” corresponds to high speed.

Scaling :

display. Parameters “Arespectively. Parameter “B” corresponds to low speed. P %

when solid content measurement is ctivated.

figure the solid content easurement device.

• he value

• e value “D” read by the sensor (high % value).

Used onlya The parameters conm

“A” is the % value corresponding to t“B” read by the sensor (low % value). “C” is the % value corresponding to th

Note : “D” must be higher than “B”. Note : “C” must be higher than “A” .

Interval time:

• time between two measurements of the solid content in the washout solvent.

•

% Replenishment volume: defines the quantity of fresh solvent to be filled into the machine when the solid content exceeds the threshold.



MANUAL


Replenishment:Replenishment: Applies only when the solid content measurement device is deactivated. • Replenishment rate: defines the needed

quantity of solvent per square meter of plate and mm of relief depth. Used by the PLC to calculate the needed fresh solvent per plate.

• Replenishment volume: defines the quantity

of fresh solvent to be filled into the machine with each supply.

• Every: defines the time delay between two

supplies of fresh solvent into the machine. Cleaning cycle with SW OFF: The parameters define the length of time for each individual cleaning step when the machine is switched off via the touch screen. • EL2 EL7: length of time in which the cleaning

and wiping brushes are supplied with fresh solvent.

• EL6: length of time in which the washout

brushes are supplied with fresh solvent. Throughout this time the brushes are rotating.



MANUAL


Cleaning cycle with SW ON:Cleaning cycle with SW ON: The parameters define the length of time for each individual cleaning step when the machine is switched ON. • EL2 EL7 : length of time in which the

cleaning and wiping brushes are supplied with fresh solvent.

• Delay: delay to start the rotation of the

cleaning and wiping brushes. • M4: rotation time of the wiping and cleaning

brushes. • P3 : length of time in which the washout

brushes are supplied with fresh solvent. • Delay: delay to start the rotation of the

washout brushes. • M2: rotation time of the washout brushes. Cleaning cycle after plate end: The parameters define the length of time of each individual cleaning step performed right after the end of wiping a plate. This cleaning cycle serves the purpose of cleaning the brushes prior to making the next plate. • EL7: length of time in which the wiping brushes

are supplied with fresh solvent. • M4: rotation time of the wiping brushes. • EL2: length of time in which the cleaning and

reverse side cleaning brushes are supplied with fresh solvent.

• M2: rotation time of the cleaning brushes.


Chain stop mode:


The parameters define the transport chain stop mode of the machine. Press “YES” or “NO” on the touch screen to change stop mode. • If “YES” is selected, the transport chain will stop

after the defined time when a plate is at the end of the machine and a second one is in process. This is, to prevent the second plate to jam into the first one.

• If “NO” is selected, the chain will not stop even

if a second plate is in process inside the machine. Without any action from the operator the second plate will jam into the first one.

Pumps calibration: The parameters define the time needed for the fresh solvent and the draining pumps to pump 1 litre of solvent. These parameters may have to be adjusted if the solvent lines affect the solvent flow of the pump or if different pumps are used (e.g. when the pump of the distillation unit is used to supply the fresh solvent). Temperature: The parameters define the different temperature thresholds: • To start the cooling of the solvent. • To define the solvent temperature alarm. • To define the maximum temperature of the

water. • To define the water temperature alarm.



MANUAL


Number of pins between plates:Number of pins between plates: defines the number of transport chain pins between two plates. Distance between two chain pulses : defines the distance in between two pulses of the transport chain encoder. Draining on WO tank high level: defines the draining time when the washout solvent reaches the high level sensor. This is, to prevent the pump from continuously switching ON and OFF. Plate length sensor timer: defines the timer for the plate length sensor. It prevents the plate length detection to stop in case of a short switching OFF of the sensor. Plate input timer: defines the time for the plate detection during the plate input. If no plate has been detected after this time the on-going cycle is cancelled. Washout section length: used to calculate the washout time from the washout speed and vice versa. Process counter values: Define all the different positions of the process in number of pulses. By adjusting these values the start or stop of a specific function like washout, cleaning, wiping can be shifted. Factory settings: When both keys are pressed simultaneously, all parameters of the machine configuration and set-up are reset to the factory settings.



MANUAL


Plates counter : Plates counter :

Access to plate counter screen

1006

On this screen two different kinds of information are available:

The plate counter : Two different counters are available: • The “processed plates” counter displays the number of plates which have

been processed in the unit. This counter can only be reset to zero with a special software.

• The “Between two services” counter displays the number of plates produced since the last reset of the counter. To reset it, simply press the reset key for few seconds. It is recommended to reset this counter with any maintenance made on the machine.



Additionally to the plate counters, records of the operating hours of the major components of the machine are available. For some of these components the number of performed cycles are also available.



MANUAL


Alarm History :Alarm History :

The list shows a record of all alarms which ever occu

Access to Alarm history

1966

rred on the machine. It displays the type f alarm as well as the date and time of the record.

o



MANUAL


Alarm Setup:Alarm Setup: • By simply pressing the ON/OFF key, it is possible

to activate or deactivate the alarm on a specific component.

• Prior to activating the alarm, the value of the alarm is required to be defined. The maximum operating hours have to be set as well as the number of cycles for specific components like solenoid valves.

• The alarm is set off when the actual operating hours (or number of cycles) exceed the value defined in these screens.

The last screen defines the alarm referring to the different type of maintenance services required on the machine. This is dependent on the number of plates produced with the machine.

Access to Alarm setup screen

2121



MANUAL


Service alarm : Service alarm :

Access to plate counter screen

1006

On the maintenance screen, also some service alarms may be displayed, i.e. an alarm to perform the service A or B, or an alarm referring to the life time of a specific component of the machine. The components alarms are listed by categories and allow the direct access to the concerned screen by simply pressing the respective alarm key. Regarding the service alarms please refer to the “Maintenance guide” section of the technical manual. To reset this type of alarm, a specific password is needed. Please contact your distributor for receipt of the correct password.

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Solvent diagram:

Solvent diagram:


Troubleshooting: This section helps you to identify the cause of a problem. The troubleshooting is sorted by the type of problems which may occur on the machine. The machine does not switch ON:

Check all emergency stops and release them if necessary by turning them anti-clockwise. Check if the main switch located on the back of the machine is in the ON position. Check the electrical power supply of the machine. Verify, that the safety thermostat C2 is not tripped OFF.

The display shows “System Initializing”:

Check the cable in between the display and the PLC.

The cycle does not want to start when “start” is pressed:

Verify, that the compressed air supply is OK. Wait until the chain finds the init position to enter the transport bar. If not working

after a certain time, check the function of sensor S1. Verify, that the entrance cover is closed. Check the function of sensor S2. Verify, that all solvent levels are OK (check the status of the LED on the control

panel).

The brushes do not start at the correct position:

Check the function of sensor EM1.

The brushes stop too soon:

The plate length sensor S3 is not working properly: It is not detecting the complete length of the plate. Clean the sensor, adjust it and check its function.



The brushes stop too late or not at all:

The plate length sensor S3 is not working properly: It is not detecting the end of the plate and, therefore, keeps the brushes moving constantly. Clean and adjust the sensor and check its function. Clean the reflector located underneath the sensor. Check the function of sensor EM1.

The transport bar pushers come back too soon (before the end of the plate):

The plate length sensor S3 is not working properly: It is not detecting the complete length of the plate.

The solvent is not cooled down or heated:

Verify, that the correct graphic symbols are in the ON-position on the dynamic synoptic screen, indicating the heating or cooling of the solvent. Verify, that the water level is OK. Check the sensor L2. Verify, that the water circulation pump is working. Check the water flow by looking into the water tank. Verify, that there is no excessive deposit on the coil inside the solvent tank which is

preventing a temperature exchange by creating sort of an insulation. Drain the tank and clean the coil.

The solvent heating does not stop or the solvent temperature is too high:

Verify, that the temperature sensor C1 is well engaged in its fitting. If it is not, the sensor reads the temperature of the air instead of the solvent.

The transport bar pushers do not come back:

The plate length sensor S3 is not working properly: It is not detecting the end of the plate and constantly remains in the ON-position. Clean the reflector located underneath the plate length sensor. Clean and adjust the sensor and check its function. Check compressed air supply.



There is no indication when the plate reaches the end of the machine:

The sensor S4 is not working properly. Adjust it and check its function.

There is a noise when the transport bar is underneath the washout brushes:

The drive chain of the washout brushes may be loose. Check the tightness of the drive chain. Adjust, if necessary.




MANUAL


Positions of the sensors in the machine:Positions of the sensors in the machine:

L2 & L5 & C2

C3L1 & C1

S5

S3 S4

EM1 & S1

S2 L3 & L4 are the two solvent level sensors fitted on the external tanks.


Sensor Malfunctions: The following tables indicate the problems which could occur in case of a defective sensor or its bad adjustment as well as the corrective measures. Malfunction of the sensor S1 – encoder for the chain position:

• Transport bar pushers do not work. • Transport bar pushers do not

synchronise with the transport chain.

The sensor S1 is not working or it is not adjusted correctly; To check its function look whether the LED’s are switching from OFF to ON when the mark on the disk passes the sensor. To bring the transport bar pushers into the

correct position, loosen the screws of the disk and change the position to get a good synchronisation. If not working, the sensor must be replaced.

Malfunction of the sensor S2 – entrance cover sensor:

The front cover sensor is not working properly.

• The plate does not get pulled inside the machine when start is pressed.

Adjust it by moving it nearer to the cover frame when this is closed.

If not working, the sensor must be replaced.

Malfunction of the sensor S3 – plate length sensor:

• Washout brushes or cleaning brushes stop too late.

• Washout brushes or cleaning brushes stop too soon.

The sensor S3 is not measuring the correct length of the plate. Adjust it by using the setting screw or by changing the position of the sensor. Clean the reflector located underneath the

sensor. • Transport bar pushers do not come

back. • Transport bar pushers come back

too soon.

Malfunction of the sensor S4 – plate has reached the end of the machine:


• No alarm when the transport bar has reached the sensor S4 at the end of the machine.

The sensor S4 is not detecting the transport bar. Adjust it by moving it closer to the transport bar. If not working, the sensor must be replaced.



Malfunction of the sensor S5 – top cover sensor:

• The cycle does not start. The top covers are not properly closed or the sensor S5 is not working properly. Adjust it by moving it closer to the cover

frame.

Malfunction of the sensor EM1:

The encoder EM1 located at the back of the transport chain motor is not working properly.

• The washout or cleaning brushes start too late.

. Adjust it to get the correct sequence on

both LED’s : OFF-OFF ON-OFF ON-ON OFF-ON If not working, the sensor must be replaced.

Malfunction of the sensor L1 – water level in the heater/cooler circuit:

• The alarm on the dynamic synoptic screen is ON.


• The heating and cooling does not work.

• The water circulation pump does not

work.

Check the function of the sensor by moving it manually. The alarm on the dynamic synoptic screen must go from ON to OFF. Verify, that the water level is correct. Verify, that the temperature of the solvent is

not equal to the temperature selected (using the dynamic synoptic screen). If not working, the sensor must be replaced.


Malfunction of the sensor L2 – washout solvent high and low level:

Check the function of the sensor by moving it manually. The alarm on the dynamic synoptic screen must go from ON to OFF.

• The alarm on the dynamic synoptic screen is ON, even though the water level in the tank is correct.

Verify, that the solvent level is correct. • The alarm on the dynamic synoptic screen is OFF, even though the water level in the tank is incorrect.

• The heating and cooling does not work.


• The water circulation pump does not work.

Malfunction of the sensor L3 – used solvent high level:


• The alarm on the dynamic synoptic screen is ON, even though the solvent level in the external tank is correct. Verify, that the solvent level is correct.

If not working, the sensor must be replaced.• The alarm on the dynamic synoptic screen is OFF, even though the solvent level in the external tank is incorrect.

Malfunction of the sensor L4 – fresh solvent level sensor (reserve & low level):


• The alarm on the dynamic synoptic screen is ON, even though the solvent level in the external tank is correct. Verify, that the solvent level is correct.

• The alarm on the dynamic synoptic screen is OFF, even though the solvent level in the external tank is incorrect.




Malfunction of the sensor L5 – washout solvent safety high level:

The solvent is not heated up or cooled down:

• The alarm on the dynamic synoptic screen is ON, even though the solvent in the tank is correct.

Verify, that the sensor is not stuck with polymer. Check the function of the sensor by moving

it manually. The alarm on the dynamic synoptic screen must go from ON to OFF. If not working, the sensor must be replaced.

• The correct graphic symbols are in the ON-position on the dynamic synoptic screen indicating the heating up or cooling down of the solvent.

Check the sensor L2. Verify, that the circulation pump is working. Verify, that the water flow is correct by

looking into the water tank. Verify, that the coil in the solvent tank does

not have excessive deposit of polymer or black carbon on it. If it does, this deposit creates an insulation preventing the temperature exchange. Drain the tank and clean the coil.




Maintenance Guide:

Action : Daily inspection :

Monthly inspection

3 monthly inspection :

Check the function of the top cover sensor. Yes Yes Yes Check the function of the emergency

switches. Yes Yes Yes

Check the solvent levels inside the machine and external tanks.

Yes Yes Yes

Check all connections for leaks : Compressed air Solvent Exhaust air

Yes Yes Yes

Clean the reflector located underneath the plate length sensor S3.

Yes Yes

Clean the plate length sensor S3 using soft towel and glass cleaner. Check and adjust it, if necessary.

Yes Yes

Check the function of the cover switches S2 and S5

Yes Yes

Clean the washout solvent filter. Yes Yes Yes Check the machine for leaks of solvent or

water. Yes Yes

Check the timing of the fresh solvent pulses on the cleaning brush.

Yes Yes

Check the function of and clean the solvent level sensors L2, L3 and L4.

Yes

Check the function of the water level sensor L1.

Yes

Check the drive chain for tightness and adjust, if necessary.

Yes

Check the drive chain for parallelism and adjust, if necessary.

Yes

Check the drive chain for the washout brushes for tightness and adjust, if necessary.

Yes

Drain the washout tank completely and clean tank, coil and temperature probes.

Yes Yes

Open the frame of the washout brushes, check the round brushes and exchange them, if necessary.

Yes

Remove the top cover and doctor blade behind the wiping brush and check the top wiping brush and the reverse side cleaning brush. If dirty, clean them with fresh solvent. If impossible to clean or damaged,

exchange the respective brush.

Yes

Open the washout brushes frame and clean the pressure rollers. Verify, that the ball bearings are OK.

Yes



Clean the solvent divider tubes of the

washout brushes, if necessary. Yes

Check the divider tubes of the washout circulation and the fresh solvent and clean, if necessary.

Yes

Check parallelism of the brushes with the base plate.

Yes

Run and check all functions separately using the manual mode.

Yes

Change the exit towel. Yes Check the synchronisation of the pin bar

pushers and the drive chain. Adjust encoder S1, if necessary.

Yes

Check the start and stop of the brushes and divider tubes. Refer to troubleshooting section to sort out problem.

Yes

Check all motors and gear boxes. Yes Check ball bearings. Yes Tighten the sprockets of the washout

brushes. Yes

Tighten the locking collars of the lateral movement crank.

Yes

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Spare parts listSpare parts list


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032


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REFERENCE : DESIGNATION: 0-BA-003 FRESH SOLVENT LEVEL SENSOR (COMPLETE) 0-BA-004 DIRTY SOLVENT LEVEL SENSOR (COMPLETE) 0-BA-032 SOLVENT LEVEL SENSOR (LOW + HIGH) 0-BA-036 SOLVENT LEVEL SENSOR (SAFETY HIGH LEVEL) 2-349-203 TRANSPORT BAR FRAME 1-XK-122 SATINLESS STEEL RACK FOR 13 PINS 2-XK-101 DRILL FOR PUNCH 2-XK-102 PIN FOR TRANSPORT BAR 2-XK-105 ENCODER DISC Dia 12 5-AC-021 ROUND BRUSHES 2-349-080 5-AC-022 ROUND BRUSHES 2-349-081 5-AC-023 ROUND BRUSHES 2-349-082 5-BA-001 BALL BEARING 626 Dia 6 5-BA-002 BALL BEARING 608 Dia 8 5-BA-003 BALL BEARING 6200 Dia 10 5-BA-004 BALL BEARING 6201 Dia 12 5-BA-005 BALL BEARING 6203 Dia 17 5-BA-006 BALL BEARING 6204 Dia 20 5-BB-101 BALL BEARING ON FLANGE UFL 25mm 5-BC-002 ROD BIG END JAS 17mm 5-BC-012 ROD BIG END JAS 25mm 5-BD-004 LINEAR BEARING TK25 5-CD-017 O RING VITON 2,63 x 3,63 5-CD-039 O RING VITON V3118 5-CD-040 O RING VITON V3100 5-CE-032 IDLER SPROCKET 1/2 3/16 Z10 M8 5-CE-033 IDLER SPROCKET 3/8 Z15 Dia 10 5-CF-001 CHAIN FASTENER 3/8 x 7/32 5-CF-013 CHAIN FASTENER DOUBLE 1/2 5-CF-022 CHAIN SEGMENT 1/2 5/16 23 LINKS 5-CF-032 CHAIN SEGMENT 3/8 41 LINKS 5-CF-033 CHAIN SEGMENT 3/8 247 LINKS 5-CH-003 BALL 10mm 5-DB-003 HANDLE 624 5-DC-002 HINGE NICKELED 40x50 5-DC-006 HINGE R625/CR 5-DD-215 LEXAN FOR PLATE ENTRANCE F3N 5-DD-216 LEXAN FOR WASHOUT COVER F3N 5-DD-217 LEAXN FOR PLATE EXIT COVER F3N 5-DE-013 GAS SPRING D19X585-N250 094943 5-DE-022 GAS SPRING D15X365-N200-082686 5-DE-058 GAS SPRING D15X226,5-N100 082414 5-DE-069 GAS SPRING D22X585-N1000 084972 5-DF-002 SPRING 2000-PK 5-DF-025 SPRING T31970 5-DF-028 SPRING D11970 5-DF-029 SPRING 32240 5-DH-006 PIEDINO ORIENTABILE M 16 5-DH-009 THREADED BLOCK M16 50x50mm 5-DM-003 SHOCK ABSORBER 15x15 M4 M/M 5-DM-004 SHOCK ABSORBER M6 5-DP-002 PANEL LOCKER (TRIANGLE SHAPE) 5-DP-003 KEY FOR PANEL LOCKER (TRIANGLE SHAPE) 5-FA-009 TUBE POLYETHILENE 16/20



REFERENCE : DESIGNATION: 5-FA-019 TUBE TEFLON 10 x 8 mm 5-FA-021 TUBE POLYURETHANE 4x6 5-FA-026 TUBE ARMAFLEX D15mm 5-FA-027 HOSE D140mm 5-FA-032 TUBE TEFLON 6 x 4 mm 5-FA-037 TUBE POLYPAL 5-FB-004 TUBE BRASS 16 x 20 5-FB-005 TUBE BRASS 7 x 10 5-FB-007 TUBE BRASS 28 x 24 6-AA-023 ENCODER SENSOR PNP 6-GA-008 TEMPERATURE PROBE PT100 HEL 705-T-0-12-00 6-GA-027 INDUCTIV SENSOR M12 6-GA-028 OPTICAL SENSOR M12 6-GA-032 INDUCTIV SENSOR M8 6-GA-033 CONNECTOR M12 4P 90° 5m 6-GA-036 PRESSURE SENSOR 0-1 BAR 7-DA-002 AIR CYLINDER 60N2A032A20 S01 7-DA-035 AIR CYLINDER 27U2A50010 7-DB-001 PUSH BUTTON PNEUMATIC 358-976 7-DB-003 SOLENOID VALVE 358-015-02 CAMOZZI 7-DB-005 COIL G7J 230V 7-DB-006 AIR REGULATOR 7-DB-010 AIR FILTER 7-DB-052 COIL A73 24V 7-DB-053 CONNECTOR FOR COIL A/77 A/73 7-DB-107 PRESSURE GAUGE Dia43 P:0-12 7-FA-006 HAND VALVE 3/4 F/F 7-FA-011 HAND VALVE 1/4 F/F 7-FA-019 CHECK VALVE F/F 1/4 STAINLESS STEEL 4890 13 13 7-FA-020 CHECK VALVE F/F 1" STAINLESS STEEL 4890 34 34 7-FA-021 CHECK VALVE F/F 3/4 STAINLESS STEEL 4890 27 27 7-FA-022 SOLENOID VALVE PNEUMATIC 3/4 4222 20 27 20 7-HA-004 LOCKING COLLAR 30-45mm 7-HA-006 LOCKING COLLAR 70-90mm 7-HA-009 LOCKING COLLAR 10-16mm 7-HA-010 LOCKING COLLAR 122-142mm 9-AA-028 ALARM LAMP 9-BA-014 TRANSFORMATOR 230/230 350W 9-CA-006 CONTACTOR 22.22.8.230 9-CA-020 PHASE CONTROLLER 9-CA-026 CONTACTOR 44529024 9-CA-028 SOCKET FOR CONTACTOR TYPE 44 9-CA-030 CONTACTOR 40528230 9-CB-003 EMERGENCY STOP BUTTON 9-CB-008 MAIN SWITCH BRETTER 9-CB-010 CONTACT NC-CGP9B01VN BRETER 9-CB-012 CONTACT NO - BRETER CGP9B10VN 9-CB-026 BALL FOR LEVEL SENSOR 9-CB-029 EMERGENCY STOP LABEL 9-CB-037 STAINLESS STEEL BALL FOR LEVEL SENSOR 9-CB-039 PUSH BUTTON ON/OFF 9-CB-040 PUSH BUTTON LAMP SOCKET 9-CB-042 NEON LAMP 230V 1.2W 9-CD-001 THERMOSTAT 06-100°C 100176 9-CE-002 LEVEL SENSOR LEM 6CNA 9-CE-007 CONNECTOR FOR SOLVENT LEVEL SENSOR



REFERENCE : DESIGNATION: 9-CF-016 COIL 230V NADI (3/4, 1/2, 1/4) 9-CF-017 SOLENOID VALVE TEFLON SEAL 3/4 9-CF-018 SOLENOID VALVE TEFLON SEAL 1/2 9-CF-019 SOLENOID VALVE TEFLON SEAL 1/4 9-CG-008 PLC 36E/24S 9-CG-009 EXTENSION MODULE : 2xPT100 + 1 ANALOG OUTPUT 9-CG-010 POWER SUPPLY 230/24VDC 50W 9-CG-013 TOUDH SCREEN (320x240) 9-CG-015 EXTENSION MODULE : 2IN + 1 OUT ANALOG 9-CG-101 CIRCUIT BREAKER 0,7-1A 9-CG-102 CIRCUIT BREAKER 1,8-2,5A 9-CG-103 CIRCUIT BREAKER 2,8-4A 9-CG-104 ADDITIONAL CONTACT 1NO 1NF 9-CG-201 CONTACTOR TETRA 11KW 9-CG-202 ADDITIONAL CONTACT 1NF 9-CG-204 CONTACTOR 9A 3NF+1NO 230VAC 9-CG-301 FREQUENCY CONTROLLER 0,55KW 9-CG-302 EMC FILTER FRO FREQUENCY CONTROLLER 9-DA-022 HEATING RESISTOR 1500W 9-DB-001 BLOWER PAPST DA 120 230V 9-DB-003 GRID FOR BLOWER DA 120 9-DB-019 BLOWER AXC250 230V 9-DB-020 FIXATION BRACKET FOR AXC250 9-EA-013 FUSE HOLDER VIMEX 32A 2P 9-EA-014 FUSE 10x38 1A AM 9-EA-015 FUSE 10x38 2A AM 9-EA-016 FUSE 10x38 4A AM 9-EA-017 FUSE 10x38 6A AM 9-EA-026 FUSE 10x38 2A GG 9-EA-027 FUSE 10x38 4A GG 9-EA-029 FUSE 10x38 8A GG 9-EA-030 FUSE 10x38 10A GG 9-EB-079 BUZZER 230V AC 9-EB-086 TERMINAL BLOCK ENTRELEC M4/6 GROUND 9-EB-087 TERMINAL BLOCK ENTRELEC M4/6 9-EB-090 TERMINAL BLOCK ENTRELEC M6/8 GROUND 9-EB-091 TERMINAL BLOCK ENTRELEC M6/8 9-EB-092 FLANGE FOR ENTRELEC M6/8 9-EC-006 CONNECTOR COIL+LEVEL SENSOR FEMALE 9-EC-007 CONNECTOR 2P 5372ST M 9-EC-008 CONNECTOR 3P 5373ST M 9-EC-009 CONNECTOR 2P 5372PV F 9-EC-010 CONNECTOR 3P 5373PV F 9-EC-013 CONNECTOR AMP 3P M 1-480700-0 9-EC-014 CONNECTOR AMP 3P F 1-480701-0 9-FB-005 PUMP H2O SIMACO KN34 9-FC-031 GEAR PUMP GVR 50L (SEAL XM XM 2 ZM) 9-FC-032 GEAR PUMP GVR 20L (SEAL XM XM 2 ZM) 9-FC-034 DOSING GEAR PUMP 9-GA-014 MOTOR 0,25KW 4P B14 230/400V 9-GB-005 GEARBOX MVF 30/P 1:30 GR:63 B14 9-GB-010 GEARBOX MVF44/P 1:100 9-GB-012 GEARBOX DOUBLE B14 44/P 1/28 071B14 + 30/P 1/40 063 (1/1120) 9-GB-018 GEARBOX MVF44/P 1:20 9-GB-027 COUNTER REACTION ARM VF 30/44 9-HA-010 COOLING GROUP 230/50/60 TIP B

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Electrical scheme:

Electrical scheme:


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CE CERTIFICATE:

EEC Declaration of Conformity Manufacturer's Name: AZ srl Address: “Il Girasole” - Palazzo Donatello 8/07 20084 – Lacchiarella (MI), Italy Tel.: +39 02 900 90 180 – Fax: +39 02 900 90 149

The manufacturer declares that the equipment here below mentioned has been designed and manufactured according to the EEC safety and health standards.

Product Name: nyloflex-Processor FIII Serial Number: Year of Production: EEC Directive: 98/037 EEC for machines II A 73/023 EEC for low voltage 89/336 EEC for electromagnetic conformity Standards Applied: EN 292/1 EN 292/2 EN 60204/1 Noise Emission: < 70 dB (A)

Signature:

Riccardo de Caria (Managing Director)


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