USER MANUAL release 2.

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IMPORTANT NOTE

NEVER EJECT CARDS WITH THE COMMAND ON THE PANEL AS LONG AS THE INITIAL PRESSURE BELOW IS NOT SET. - IN ORDER TO PREVENT ELECTRICAL DAMAGES DURING THE STARTING OF THE MACHINE THE FUSES ARE RETIRED OF THE GENERAL CONNECTOR AND THE HYDRAULIC PRESSURE IS VOLUNTARILY SET TOO LOW. - TO START THE MACHINE : . PLACE TWO FUSES 10 A IN THE GENERAL CONNECTOR, . SWITCH 10 TIMES THE MACHINE ON/OFF, . PLACE A 800 microns LAMINATED SHEET IN THE UNIT AND SWITCH THE MACHINE ON. SCREW THE HYDRAULIC PRESSURE SCREW BY TURN PER TURN UNTIL THE SHEET IS CUT. . WHEN THE SETTING IS COMPLETE, DONT FORGET TO LOCK THE NUTS ON THE PRESSURE SCREW.

Vis de pression Ecrous

Pressure screw

Nuts

NOTE IMPORTANTE

NE JAMAIS EJECTER DES CARTES AVEC LA COMMANDE DU PANEL TANT QUE LE REGLAGE INITIAL DE PRESSION CI DESSOUS N'EST PAS REALISE. - POUR DES RAISONS DE PROTECTION ELECTRIQUE LES FUSIBLES SONT ENLEVES DE LA PRISE GENERALE DALIMENTATION ET LA PRESSION HYDRAULIQUE DE FONCTIONNEMENT EST REDUITE . - POUR PROCEDER AU DEMARRAGE : . INSTALLER DEUX FUSIBLES 10 A DANS LA PRISE, . FAIRE PLUSIEURS CYCLES DE DEMARRAGE A VIDE, . PLACER UNE FEUILLE DE PVC LAMINEE DE 800 microns DANS LA MACHINE ET FAIRE UN CYCLE DE DEMARRAGE. VISSER LA VIS DE REGLAGE DE PRESSION DU GROUPE HYDRAULIQUE TOUR PAR TOUR JUSQU'A CE QUE LA COUPE SOIT OBTENUE. . A LA FIN DU REGLAGE, NE PAS OUBLIER DE SERRER LECROU ET LE CONTRE ECROU DE LA VIS DE REGLAGE DE PRESSION.

TABLE Of Contents

SECTION 1

GENERAL PRESENTATION ...

3 3 6

1. 1 Punchcard PRO: field of applications 1. 2 Technical Specifications 1. 3 Main parts description

SECTION 2

INSTALLATION ...
8 8 10

2. 1 Reception and control before unpacking 2. 2 Requested area around the Punchcard PRO 2. 3 Starting the Punchcard PRO

SECTION 3

FUNCTIONS ASSOCIATED WITH EACH MODE

12
12 12 13 14 14 16

3. 1 Descriptin of the three user modes: 3.1.1 Automatic mode WITH Crop Marks: 3.1.2: Automatic mode WITHOUT Crop Marks 3.1.3 Manual settings mode 3. 2 Standard templates informations 3. 3 Printing troubles Deformation during lamination and Sheet diecutting :

SECTION 4

TECHNICAL SETTINGS

17
17 18 18 20 21 21 22 23 24 25 26 26

4. 1 Settings of the sheet introduction : 4. 2 Adjustment of the optical fiber : 4.2.1 Optical fiber : 4.2.2 Amplifier : 4. 3 Calibration of the optical fiber electronic device 4.3.1 Triggering value determination : 4.3.2 Displayed value of the amplifier : 4.3.3 Programmation of VS : 4.3.4 L mode and D mode : 4.3.5 Amplifier sensiblity adjustment : 4. 4 Settings optimisation : 4. 5 Ejection speed settings :

SECTION 5

MAINTENANCE - RECOMMANDATIONS

30
30 30 32 32 35

5. 1 Terms of warranty : 5. 2 Maintenance recommandations plan : 5. 3 Recommandations : 5. 4 Using a Punchcard Pro in technical mode : 5. 5 Ajustement of lower position of the toll :

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SECTION 1

GENERAL PRESENTATION

1. 1 Punchcard PRO field of applications: The Punchcard PRO has been designed for the die cutting of ISO standard cards (54 x 85.5 ), printed on sheets of 311 mm. These sheets can be either paper or plastic, printed or not, with a gauge betweeen 210 and 800 microns. The die Tool is built with 3 male/female dies, which means that the cards are cut 3 up.

The punchcard PRO can work in 3 different modes : -

Automatic Mode without crop mark optical detection > die-cutting white card Automatic Mode with crop mark optical detection > die-cutting printed cards Manuel Mode > used for settings Technical Mode >

1. 2 Technical Specifications

Die cutting format ISO standard - 85,5 X 54 mm Other die cutting shapes on demand. Possible Substrates Paper from 250 g/ m2 PVC, Polyester, plastics from 210 to 800 microns. Teslin. Supported sheet size Printed or white sheets of a width between 300 and 320 mm. Card stock and ejection Eject the cards with electronique remote control 3 cards holder of 300 cards ( 900 cards) and die cut cycle accounting Page 3

Die cutting speed 8000 ISO cards per hour when using 21 up cards 457 mm length sheets. Manual feeding Die cutting positionning Horizontaly by adjustable mechanical guides. Verticaly by optical fibre detection. Life Time 4 000 000 ISO cards in Teslin and 10 000 000 of ISO cards 800 microns for the other substrates. Die cutting tools exchangeable and resharpenable. Electrical network required Single phase with hearth 230 VAC - 50 Hz Electrical consumption 1,5 KW Weight and size Without packaging 79,5 cm X 72 cm X 127 cm (Width. X length. X high.) 9 224 Kg With packaging: 161 cm X 91 cm X 152 cm Width. X length. X high.) 314 Kg Hydraulic station 2 L Tank Die cutting pressure between 20 and 50 bars Gears pump with oil filter Double direction valve with speed regulation for ejection system

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Page 5

1. 3 Main parts description

2 Figure 1

4 5

Figure 2

Page 6

10

16

11

12

2 Figure 3

13

14

15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Card holder Manual roll gear Bottom frame Feet General power plug Wheels for transport Oil gauge Entry guides Wheels for transport Optical amplifier card ejection lever Die cutting cycle accounter Entry sensor Light Emergency stop Modes selection button Page 7

SECTION 2

INSTALLATION

2. 1 Arrival Parts control: The packaging of the Punchcard PRO is made of a wooden palette, a triple thickness Cardboard box, and 4 metal fixations. The following parts must be included inside each palette: The Punchcard Pro, 2 handles and a screw for dies replacement, A pack of 6 10 Amps fusers, The starting procedure, The instructional CD The users manual The Technical manual A 220 VAC power cable.

In case of visible damage on any of these parts, or in case something is missing, please proceed with standard reclamation procedures with the transporter on the delivery bill, and to your dealer by mail in the requested lead time Before putting the PunchCard Pro on the floor, remove the metal brackets using a flat 19mm key.

CONSIDERING THE WEIGHT OF THE PUNCHCARD PRO, SEVERAL PEOPLE WILL BE REQUESTED.

Please keep the packaging for future transportation 2. 2 Requested area around the Punchcard PRO

The working place must allow a free circulation around the machine. A bin is recommended to receive the die cut skeletons. It is imperative that the PunchCard Pro is level, using the four feet and a 24mm flat key.

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Free area.

Carbage.

The plug for the power cord is located on the rear of the machine, under the on/off switch. A PROPER GROUND CONNECTION IS ABSOLUTELY REQUESTED.
Switch on/off.

Fuses holder

Main power plug.

Serial port for link with automatic feeding system

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2. 3 Starting the Punchcard PRO THE MACHINE IS DELIVERED WITH A STARTING NOTICE STICKED ON THE PUNCHCARD PACKAGING. IT WILL ALLOWS YOU TO SET THE PRESSURE REQUESTED FOR CARDS WITH A THICKNESS OF 800 OR LESS (*) DIECUTTING. THIS PROCADURE MUST ABSOLUTELY BE FOLLOWED DURING THE FIRST START OF THE MACHINE, OR AFTER ALL MACHINE DEPLACEMENT.

(*) The die cutting pressure is adjustable and directly proportional to pump speed, which itself depend from the tension of the electrical network. In order to protect the equipment, the pressure is volontarly bring down before delivery, and must be adjsut during installation. Starting procedure of the machine Level the machine, Install 2 10 Amps fuses in the general power plug, Plug the electrical cable, Place the function mode button (n 16) in MANUAL position and ensure that the emergency button is not engaged.

16

Position a laminated PVC sheet of 800 microns thickness in the diecutting tool by using the manual roller gear n 2, Switch on the main power. The pump will start, and the cycle will make an initialisation cycle (up and down). In the first try, the sheet WILL NOT be die cut.

BE CAREFULL : NEVER ACTIVATE THE EJECTION BUTTON IF THE SHEET IS NOT CUT. THIS WILL BRAKE THE EJECTION MECHANISM. Page 10

Switch of the machine or activate the emergency button. Increase the hydraulic pressure by turning the adjsutment screw on the hydraulic groupe of half a turn and make a second try.

Tightening nut

Thightening nut

Adjustment screw If the PVC sheet is not diecutted, redo the procedure since the 3 cards are diecutted. Once achieved, tighten the 2 nuts. Switch off the machine, move hte sheet forward and check the settings. The Cards must be diecutted and lift up into the female parts of the die cutting tool. If the cards are correctly cutted, you can use the ejection button to lift up the cards.

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SECTION 3

FUNCTIONS ASSOCIATED TO EACH MODE

The Punchcard PRO can work in 4 different automatic modes Automatic Mode without crop mark optical detection > Die cut white cards Automatic Mode with crop mark optical detection > Manual Mode > used for settings before production Technical mode> Diecutting tool amplification and hydraulic trigger settings.

The First three mode are accessible by the user with button n 16, the last one is only accesssible to a qualified maintenance operator. 3. 1 Description of the three user modes : 3.1.1 Automatical diecutting with crop mark detection: In that mode, the diecutting position in the vertical way is define by a printed black spot. Each time a crop mark will be detected by the optical sensor, a diecutting cycle will be initiated. In that mode, a final diecutting cycle is initiated after the end of each sheet. The length of the sheet and the number of diecutting cycle per sheet are not limitated. Technical margin must be respected see chapter 3.2 Exemple : on a 311 mm X 457 mm sheet with 7 lignes of 3 cards, 8 cutting cycle will be executed. When the n 16 button is in OPTICAL DETECTION mode, the full diecutting cycle for one sheet will be the next one: a a green led and an orange led are alighten on the optical amplifier. b A soon as a sheet is bring at the roller entry, it is detected and taken away. The orange ligth switch off. c the sheet will stop when the first spot will be detected, the orange light will switch on again. d The male die cutting tools will go up for the die cutting of the first row of cards e The rollers will run again up to die cut the next raw of cards approximately 57mm after, and the die cutting process will happen again 7 times. f - After the last cut is complete, the rollers will run for a while to eject the skeleton and the male die will go up and down one last time. g The accounting system increased each time a die cutting cycle occurs (3 cards). h - As soon as the rollers stop, a second sheet can be inserted.

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The card holder can handle approximatively 3 colomnus of 300 cards 800 , which means approx. 40 sheets 21 up. To eject the cards, first put the mode button in MANUAL position., than press on the ejection button. The columns of cards will rise from approx 12 cm. Once the cards have been removed from the card holders, press once more on the ejection button to bring back down the lifting system.

Leds - amplifier

Ejection button

Accounter

Accounter Reset Button 3.1.2 Automatical diecutting without crop marks: In this mode, the position of the die cutting is fixed, determinated by the programmation. Since a sheet is detected and that it is possible to do a die cutting cycle, it will be done, what ever the sheet length is. Exemple : on a 311 mm X 457 mm sheet with 7 lignes of 3 cards, 7 diecutting cycle will happen. When the button n 16 is in position WHITES CARDS position, a full cycle is the next one: a A green and orange light on the optical fiber electronic are switch on b As soon as the user puts the sheet to those rollers, they will take it. The orange light on the optical fiber electronic device will then switch off. c The first die cutting process will happen approximately at 80mm of the top edge of the sheet the orange light will switch on again. d The male die will go up to cut the first row of 3 cards e The rollers will run again up to die cut the next raw of cards approximately 57mm after, and the die cutting process will happen again 7 times. f - After the last cut is complete, the rollers will run for a while to eject the skeleton g The accounting system increased each time a die cutting cycle occurs (3 cards). Page 13

3.1.3 Manual settings mode : The setting below can be made a Horizontal positionning of the sheet and skew. b Optical fibre replacement and calibration. c Ejection speed settings. d Diecutting tool amplitude settings.

3. 2 Standard templates :

A CD is delivered with the machine that contains 4 standard templates: File name gabarit punch 300 2006.pdf gabarit punch 760 2006.pdf punch 300 2006.qxd punch 760 2006.qxd Content PDF template to print and die cut 300 cards PDF template to print and die cut 760 cards Quark Xpress template to print and die cut 300 cards Quark Xpress template to print and die cut 760 cards

The distances between the rows are slightly different from one template to another to compensate the deformation during the laminating process to obtain 760:

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Sheet edge.

2mm full bleed mark

Iso format size.

Mark to align with the die cutting tool

-R1

Spots.

R1

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What ever is the type of template used, next informations must be noticed : Spots must be on the right side when the machine is with manual feed. In that case, the optical fiber is on the right side. Spots must be on the left side when the machine is with automatic feed. In that case, the optical fiber is on the left side. Top and bottom die cutting crop mark corresponding to die cutting shape are used to check the skew during feeding. Use the right one in case of manual feed and the left one in case of automatic feed. The red shape noticed Iso format size is positioned in comparaison with the top of the black crop mark.

In order to avoid losing time with settings, it is better to always print off of the same template, and with a consistent positioning on the sheet. 3. 3 Printing troubles Deformations during lamination sheet diecutting: Notice that the final default notice on the card is the sum of the default due to printing of each side, lamination and diecutting. Next indications can be given on each phases:

See next table:

Phase

Prcautions

Printing

- Check that sheet are correctly diecutted before printing - Check centering and sckew of both front and back during printing, - For the front side and the back side check if the horizontal and the vertical positions of the cards are the same. - Check if the printing quality and density for all colors are correct.

Lamination

- Ensure that front, back, middle core and overlay are correctly registered together. - The side that will be used as reference for diecutting must be the one positionned near from the edge of the plates. - To get the best results, the face with the higest coverage must be diecutted face down. - The lamination parameters must be set so that the lamination will be correct while avoiding too much deformations.

Diecutting

- Check skew and horizontal positionning of the cards. - Cut the pages with the front side in contact with the paper guides - On the first sheet, check manually that all the spots are correctly detect by the optical fiber.

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SECTION 4

TECHNICAL SETTINGS

4. 1 Settings of the sheet introduction:

Blocking screw Right mobile guide

Central fixed Guide

Left mobile guide

In order to adjust sheet introduction, refer to R1 and R2 crop marks printed on the templates. Proceeding this way will allows you to ensure the perpendicularity of the cards rows comprativly to the die cutting side edge. If deformations during lamination are too much important, the crop marks may not be correctly detected.

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4. 2 Mechanical adjustment of the optical fiber:

MONTAGE DE LA FIBRE DANS LE SUPPORT ALUMINIUM

FIBRE

SUPPORT

LENTILLE

H COMPRIS ENTRE 25,5 ET 26,5 mm

An adjustment in the position of the optical fiber may be needed to center the die cutting on the full bleed image. The optical detection ystem of the Punchcard pro is composed of: - A double optical fiber and a lens installed on the diecutting tools, - An electronical amplifier. 4.2.1 Optical Fiber :
Magasi

Tool. Optical fiber bloc screw

Optical fiber

Optical fiber Optical fiber locking screw. Lens

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MONTAGE DE LA FIBRE DANS LE SUPPORT ALUMINIUM

FIBRE

SUPPORT

LENTILLE

H COMPRIS ENTRE 25,5 ET 26,5 mm

This optical fiber is maintained by a 3mm headless screw on the aluminum optical fiber bolc. If the distance H is superior to 26,5 mm, the lens will be definitivly broken during the first start. If the distance H is less than 25,5 mm, the lens will be less precise and stable. By unscrewing the locking screw of the optical fiber bloc, the vertical positionning of the diecutting in the full bleed can be adjust..
Locking screw

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4.2.2 Optical signal amplifier :

ReceptiveFibre Cover

Emiting Fibre

Amplifier adaptator

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Sensibility green Led

Button 2 panel Button 1

3 positions switch Status orange Led The optical system is based on 2 fibers (one emitting, one recepting), a lens, 2 plugs and an optical signal amplifier. The emetting fiber will send a ligth signal on a flat surface, perpendicular to it, and the recepting fiber will bring back the refracted light on the surface. The lens will focus the light signal. The plugs will positionned correctly the 2 fibers in the amplifier. The amplifier will transform the light signal in an electrical one, which will then be used by the electronical board of the machine. Depending from external conditions (light, colors of the substrates, dust, lens dirtyness, scolors of the spots), imprecisions in te diecutting position may happen. Most of the time, a calibration will be necessary, and enough to solve the issue. The amplifier may rarely lose its values, which will also request a calibration.

4. 3 Optical signal amplifier calibration:

The electronic device is an amplifier that will, depending from the value read, start the die cutting process. The calibration consists of deciding and saving the best detected value to start the die cutting cycle. 4.3.1 How to determine the triggering value : Put the mode button in Manual settings (Middle) Pass a sheet with crop marks through the rollers and check that each time a crop mark is under the optical fiber, the orange light of the amplifier switches on. Then note all the values display on the screen of the optical fiber device, as it is shown underneath.

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Status of the sheet No paper White Crop mark 1 White Crop mark 2 White Crop mark 3 White Crop mark 4 White Crop mark 5 White Crop mark 6 White Spot noir 7 White

Led orange

Led verte

Valeur lue 170

Valeur lue

580 220 620 230 640 210 620 220 640 210 650 240 630 220 640

580 is the minimum value during white detection, called VB. 240 is the maximum value during crop marks detection, called VN. The triggering value, called VS must be approximately in the middle of those 2 values. In the above example, VS = 410. 4.3.2 Information about the values displayed on the amplifier The minimum difference between VN and VB must be at least of 200. The maximum value displayed is 1023. This value should appear only if the optical fiber is not mechanically correctly set. The field experience shows that The values white should be between 500 and 900, The values crop marks should be between 100 and 300.

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4.3.3 How to program VS :

Steps

Displays

1 Mode Button in Manual settings.

D 8- 173

2 Place the selector in position SELECT.

D 8- SELE

3 Press on button 1 until S is displayed instead of T.

D 8- SELE

4 Place the selector in position MODE. The figure 8 blinks.

D 8 173

5 Press one time on button 2, so that the figure 1 blinks.

D 8 1 73

6 Press on button 1, until the figure 1 is replaced by the figure 4.

D 8 4 73

7 Press one time on button 2, so that the figure 7 blinks.

D 8 473

8 Press on button 1, until the figure 7 is replaced by the figure 1.

D 8 413

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9 Press one time on button 2, so that the figure 3 blinks.

D 8 41 3

10 Press on button 1, until the figure 3 is replaced by the figure 0.

D 8 41 0

11 Place the selector in RUN position.

D 8- 173

4.3.4 How to change L mode on D mode : The letter D (dark) signifies that the values crop marks will be used to trigger the die cutting process (normal way of working). In case of de-programmation of the amplifier, the letter L (light) may replace D. The die cutting process will then start on the white values. Follows the next steps to find back the D value on the display:

Steps

Display

1 Mode button in Manual settings position.

L 8- 173

2 Place the selector in position SELECT.

SELE

3 Press on time on button 2 to replace the letter L by D.

D SELE

4 - Place the selector in position RUN.

D 8- 173

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4.3.5 Change amplifier sensibility : Amplifier sensibility can be adjust from 1 to 8 (8 for the strongest). This value is indicated by the first figure on the right side of the D letter. For exemple, to go from 7 to 8 value, proceed as follow:

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4. 4 Notes and settings optimisations: Before proceeding to a new calibration, remove dust from the diecutting tools by blowing dry air, and ensure that the 2 optical fibers are correctly inserted in there holes; the emetting dow aand the receptive up (the receptive has got a white stripe on it. It may sometimes be necessary to cut the optical fiber. In that case, only a proper cutting tool must be used ( delivered with the fiber itself. It is forbidden to cut it with cutter, cissors or knife, it will damage the fiber on several cetimeter length. If an amplifier sensibility adjustment is necessary, the values will be different than the one previously obtain. A new triggering value adjustment will be necessary. In order to obtain a good calibration, what is important is to obtain that the values of white area versus black stops will be really differents. It can commonly be observe that the change of values between a white and a black area is not immediate. Commonly, by changing from few decades the programmed triggering value, the diecutting positionning can be sligtlhy adjust comparatively to the template, and therefore limitate the possible fluctuation. 4. 5 Cards ejection speed setting: On this model, the cards ejection is hydraulic. The operator can activate up or down movement from the ejection jack with the button n11.

BE CAREFULL : pressure is set to diecut cards of max 800 thickness. If the cards are thicker, there is a risk that the cards will not be diecut correctly and therefor stand in the skeleton. IN THAT CASE, OR IN ANY CASE WHERE THE CARDS ARE NOT CUT CORRECTLY, DO NOT TRY TO EJECT THE CARDS, IT WILL BRAKE THE JACK.

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In normal working, it is possible to set the speed of the cards ejection. To adjust the speed when going down, we adjust the quantity of oil that gets out from the bottom oil chamber of the jack. To adjust the speed when going up, we adjust the quantity of oil that gets out from the up oil chamber of the jack. Generaly speeking, it is better to have a going movement a bit faster than the going down one.

Ejectors

Fixed die

Page too much thick

Slotted optical switchs

Ejector axis Ejection jack Horizontal bar

Up hose

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Down / Ejection Down / Cut

Up / Cut

Adjustable stop For cutting jack

Up / Ejection

EV1 Down Cut RD3 Up / Ejection adjustable speed

EV4 Up / Ejection RD4 Down / Ejection adjustable speed

EV2 Up / Cut

EV3 Down / Ejection

Manometer

Insulation valve

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To do an speed adjustment, proceed as follow : Remove the black plastic protective lid,

Un tighten the locking screw with a 10mm Flat key.

Tighten the Chc screw with a flat 5 mm key to reduce the speed or untighten it to increase the speed,

Retighten the locking nut and place back the lid Page 29

SECTION 5

MAINTENANCE TROUBLESHOOTING

5. 1 Warranty limitations : DIE CUTTING OF SHEETS OF MORE THAN 800 THICKNESS IS STRICTLY FORBIDDEN, AND THE DAMAGES CAUSES TO THE MACHINE DURING SUCH AN OPERATION WILL NOT BE COVER BY THE WARRANTY THE UTILIZATION OF CERTAIN TOOLS OR OBJECTS COULD DAMAGE, BEYOND REPAIRS, CERTAIN PARTS OF THE EQUIPMENT (SUCH AS BUT NOT LIMITED TO: CUTTERS, SCISSORS, SCREW DRIVERS, SHARP OBJECTS), ESPECIALLY WHEN IN CONTACT WITH THE DIE CUTTING MATRIX. ONLY MGI OR A FACTORY AUTHORIZED/CERTIFIED DIE CUTTING TOOL COMPANY IS AUTHORIZED TO PROVIDE THE RE-SHARPENING SERVICE FOR THE DIE CUTTING TOOLS IN NO EVENT SHALL M.G.I. USA, INC. BE LIABLE FOR ANY IMPROPER USE OF THE EQUIPMENT AND ALL THE COST OF REPAIRING OR REPLACING THE ALLEGED DEFECTIVE PART(S) SHALL BE BORNE BY THE PURCHASER. PURCHASER WAIVES THE RIGHT TO CLAIM OR RECOVER ANY SPECIAL DAMAGES, DIRECT OR INDIRECT INCLUDING WITHOUT RESTRICTION, CONSEQUENTIAL OR INCIDENTAL DAMAGES, THE LOSS OF PROFITS, EARNINGS, INCOME OR REVENUE TO PURCHASER, LOSS OF USE OF PURCHASER'S EQUIPMENT 5. 2 Maintenance map and recommandations:

The maintenance map underneath will ensure the correct working of the machine during its lifetime. All maintenance operations that must be done are detailed underneath.

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MAINTENANCE MAP - PUNCHCARD PRO

action Dust cleaning Monthly weekly Monthly Depending dirtiness Once a year Once or twice a year depending from use alcool UNIL OPAL - HFM 46 (*) HIFI MGI Cartridge hydrolub greaser mechanic grease Dry compressed air Dust cleaning greasing Dust cleaning Replacement Replacement alcool - essence F timing Advised liquid Forbidden liquid acetone Water Oil acetone See underneath All other material

parts

4 driving rollers

Diecutting tool

Diecutting tool guiding columns (*)

Painted cover

Hydraulic oil

Filter cartridge

(*) Advised oil standard Warm country Cold country (*)

use

UNIL OPAL HFM 46

UNIL OPAL HFM 68

UNIL OPAL HFM 32

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5. 3 Troubleshooting:

Trouble

Cause(s)
a) Amplifier sensibility is too high,

Actions
a) Reduce sensibility from 1 point and rebuilt a calibration. b) Readjust higher diecutting tool position the

1 Values detected on white area on amplifier are allways equal to 1023.

b) The clamp is too low.

2 The between VB and VN is under 100.

a) The optical lens is dirty or an optical a) Dmonter le bloc porte fiber is not correctly connected to fibre et nettoyer la lentille difference the amplifier, et reconnecter les fibres . b) The clamp is too high. b) Readjust lower the diecutting tool position

a) If thickness is within the a) The Hydraulic pressure is too low or specifications, increase the the sheets are too thick. pressure. 3 After diecutting, the

cards stay stick on the skeleton.

b) The male die cutting tool does not go b) Readjust the lower positon up enough in the female one. of the diecutting tool.

4 when using thin sheets, the sheet stick on a) The clamp is too high. the diecutting tool.

a) Readjust lower the diecutting tool position

5. 4 Punchcard utilisation in technical mode:

A special connector is given with the machine that allows to swop the machine in technical mode. This mode allows to move the die cutting tools and ejection system manualy, with no interaction of the program. This will be necessary to proceed to tool settings (down position, latitude, ejection system speed) To start the machine in technical mode, proceed as follow :

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 Technical mode connector

- Step 1 :
Switch off the machine and remove the right painted cover (over electrical component) (6 screw to untight and 2 to remove)

- Step 2 :
Unplugg the wire (*) link to J17 connecor of the daughter board. Plug J17 on the technical mode connector.

(*) This wire link the board to the mode button in normal fonction.

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- Step 3 :
Switch on the machine and check that the red and green leds are on Remove the techncial mode connector from J17 plug back the original cable

- Step 4 : HOW TO USE TECHNICAL MODE

Optical detection position: Hydraulic pump start command and possibility to start the diecutting hydraulic jack. UP : Selection of hydraulic Jack going up. White cards position: Hydraulic pump start command and possibility to start the ejection hydraulic jack.

DOWN : Selection of hydraulic Jack going down.

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The technical pode will be reset back to normal mode by switching on and off the machine 5. 5 Setting the diecutting tool down position:

Step 1 :
- dismantle the rear painted guide (6 screws to be removed). - Dismantle the down painted cover (2 screws to be removed).

Step 2 :
- with a 24 mm spanner, remove the protective screw placed under the hydraulic jack.

Step 3 :
- Untighten the stopping screw to Lower the down die cutting tool position, Or - Thighten the stopping screw to raise the down die cutting tool position, 1 complete rotation = 1mm Page 35

Step 4 :
- Switch on the machine, let the initialisation cycle happen then swithc it off. - Reassembly the protective screw. Do not forget to place back the rubber seal.

Step 5 :
CORRECT THE DOWN SWITCH POSITION - Untight the locking screw of the right angle bracket. - Put the bracket down till it trigger the switch. - Tighten the screw again.

Step 6 :
- Put back on place the 2 painted covers.

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La modification de la position basse de l'outil peut galement se faire en agissant directement sous le bloc mobile de l'outil de coupe. Dans ce cas procdez comme ci dessous :

Step 1 :
- dismantle the rear painted guide (6 screws to be removed).

Step 2 :
- With a 24 mm spanner, untighten the nut 1. - With a 24 mm spanner, turn the hydraulic jack anti-Clock wise to Screw 1 lower the down position of the tool, Or - With a 24 mm spanner, turn the hydraulic jack Clock wise to raise the down position of the tool, 1 complete rotation = 1mm - retighten the nut 1.

Jack

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Step 5 :
CORRECT THE DOWN SWITCH POSITION - Untight the locking screw of the right angle bracket. - Put the bracket down till it trigger the switch. - Tighten the screw again.

Step 6 :
- Put back on place the painted cover.

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4.2.2 KEYENCE Amplifier : From the UF7-33160 serial number, the model of the optical amplifier has changed. This new model (KEYENCE) allows the operator to achieve a calibration more easily than on the former model. Apart from the calibration method of the amplifier, the rest of the optic chain doesn't present any difference; which mean: - Integration of the optic fiber in the tool, - Positioning of the fiber and interchangeability.

To conduct an automatic calibration easily as indicated here over, it is necessary: - To place a white zone under the optical fiber, - To push during three seconds the button set and to maintain it press, - To moce forward the sheet with the manual button to make pass all black spot under the fiber, - To continue to move to position it on the white zone situated after the last spotlight and finally to loosen the button set. The calibration is finished then.

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Page_40

If the calibration is achieved correctly, the led is lit every time that a black spot is read by the optical fiber. If the working of the led is reversed it is necessary to pass the amplifier in the mode : DARK ONE (d one) as indicated here under.

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