AFINIA LABEL DLF-Series User manual

USER MANUAL
DLF-Series
Digital Label Finishers
this product is certified:

IMPORTANT: Please keep the original packaging
just in case for a return material. If we will receive the
system in a non-original packaging the warranty will
expire automatically.
IMPORTANT: The latest version of the DLF Se-
ries software is available on our websites,
anialabel.com or anialabel.co.uk

I N D E X
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System requirements
How to install outer discs
How to install the plotter
How to install the cutting plotter
How to install the core holder
How to load and operate with the lamination module
How to set the lamination sensor
How to adjust the clutch
When to adjust the clutch
Load the media into the plotter
How to run the cut test and start a job
How load the matrix remover & slitter
How to load the matrix remover core holder
How to load the rewinder core holder and set the slitter module
How to add or remove blade holder
Metal guide alignment
DLF CUTTING MANAGER
User interface
Advanced options
Error Messages
Black-mark detection
Cutting le specications
Black-mark position into the cutting le and printed artwork
Black-mark position in the media
How to cut blank labels
How to update software
How to restore plotter settings
How and when to reduce the plotter feeding speed
Media path
Ultrasonic sensor calibration
Lamination / matrix remover&slitter modules speed rotation
How to install pressing roller
Adapter for the DLF
How to used the o-ring on the matrix roller
Graphtech maintenance
How to replace the knife
How to replace the slitter blade
How to replace the cutting mat
Troubleshooting

DLF software is compatible with
Windows XP and above;
CPU memory 4GB;
Cutting les: Adobe Illustrator or and
Corel Draw (PDF).
Diagram connectors behind the on-off
panel.
3
With a screwdriver install the outer discs on
the Core Holder for printed roll.
SYSTEM REQUIREMENTS
HOW TO INSTALL OUTER DISC
HOW TO INSTALL THE PLOTTER
Error
SEnSor
ManagEMEnt
donglE uSb
CaMEra uSb
plottEr uSb
uSb to pC
A. Pull the plotter from the packaging and place it on the plate, make sure to push the
rubber feet into the holes.
B. Plug in the machine and switch it on.
A B

1. Click on “Setup DLF-Software 1.0.msi”
and follow the step by step all the points to
complete the installation.
2. Click NEXT 3. Click NEXT
4. Click YES 5. In process
4
HOW TO INSTALL THE CUTTING PLOTTER
6. If required, allow installation of
application by clicking “Yes”
Click Close.
The installation is completed, a DLF
shortcut is displayed on your desktop

Plug in the USB camera and the USB dongle, they will auto-install.
If your computer has already got plugged a camera, it is recommended to disable it,
because probably the cutting manager will ignore the cam on the plotter.
CM Software will generate a folder in the Windows start menu.
If USB dongle is not installed correctly or
un-plugged, the below error will be shown.
5
The grey handle must match with the
grey holder and the black handle with
the black holder.
IMPORTANT: screws must be face
down.
HOW TO INSTALL THE CORE HOLDER
HOW TO LOAD AND OPERATE THE LAMINATION MODULE
IMPORTANT:
If you don’t use the lamination roll
please cover the sensor with the blue
cap.
Just for DLF-220L and DLF-350L models

Load the printed roll and move it against
the roll guide. Tighten the core holder.
Load the lamination roll, move it along
the supply shaft and make it match with
the web.
IMPORTANT: the lamination roll always
needs to be narrower than the web width.
Example: if the web width is 7” then the lamination roll
needs to be lesser than 7” (let’s say ¼ inch on each end).
At this point you can tighten the core
holder.
When the LEDs on the control board
are off, the device works on a manual
feeding.
Move the media through the rollers and
press the FORWARD button. The media
will be loaded through the rollers whereas
if you push the BACKWARD button, the
rollers will roll the media backwards.
6
Load an empty cardboard core onto
the shaft intended for laminate liner
rewinding. Tighten the core holder.
Core Holder No. 1 intended for laminate
use
Core Holder No. 2 intended for laminate
liner use
Core Holder No. 3 intended for printed roll
use
1 2
3

Hold the laminating lm with both hands, pull it underneath the guide roller, center it and
adhere the laminating lm to the web and attach the liner onto cardboard.
!PLEASE LOOK AT THE LAMINATION PATH! (PAGE 21)
While using the knobs, please adjust the
pressure on the rollers in order for the
laminating lm to adhere to the media
and avoid any possible air bubbles.
When the green LED is on, the automatic feeding is activated and operated by the
ultrasonic sensor. When both yellow and green LEDs are on, it indicates the system is in
error mode. The cause is due to the media or laminate roll is not detected or it is run out.
If this is not the cause, please reset the sensor.
Turn the screw on the sensor clockwise
or counterclockwise. This operation has
to be done without lamination in place.
If there is no lamination in place, the
LED will light on.
If there is lamination in place, the LED
will light off.
laMinatE SEnSor
7
HOW TO SET THE LAMINATION SENSOR

Both core holders are clutched
(unpowered), they are the same and
they work independently.
It is possible to adjust the clutch by
screwing or loosing the aluminium
handle.
It is important to keep the media and laminating lm in tension thanks to the clutch
adjusting. If the tension is too tight the roller system will get damaged or if the tension is
too loose, the media will not be laminated properly.
Pull the laminated media underneath the tension arm, than pass it through the aluminium
rollers, the guide can be adjusted preventing the web from rolling.
Press down the handle on the rear of the plotter.
Pull the media through the plotter and keep the media edge aligned to the alignment
points. Just slide, set both pinch rollers close to the media edge.
8
HOW TO ADJUST THE CLUTCH
WHEN TO ADJUST THE CLUTCH
LOAD THE MEDIA INTO THE PLOTTER

While holding down the media in the aligned position pull up the handle on the rear of the
plotter to keep the media loaded.
Press button 2 as requested on plotter’s display.
>> How to run the black-mark mode
User Interface at page 16 might be helpful.
- Open DLF Cutting Manager.
- Press “OPEN PDF” or “OPEN LAST JOB” to load the cutting le.
- Look at the left window where the camera reading preview is shown, press “BACKWARD
MEDIA” or “FORWARD MEDIA” arrows to move the web until the black-mark goes in the
center position of the blue rectangle area.
no yES
- In “DISTANCE BETWEEN BLACKMARKS” box, digit the value relating to the space
between top to top black-mark.
9
HOW TO RUN THE CUT TEST AND START A JOB
IMPORTANT:
WorkingwiththeDLF-220LorDLF-350Lmodels,pleaseopen“ADVANCED
BUTTON”, click on Settings and uncheck Media/Lamination Sensor
option, then save and close the pop up.
- Press “CUT TEST” to check for cut depth. If the liner has been cut, decrease the cutter
pressure value in the cut force box. If label tears, increase the cutter pressure value in the
cut force box.
- Make sure label is aligned with the cut. Through X and Y values, adjust offsets if cut
doesn’t match label.

MovE thE Cutting filE
-y+x
+y-x
cutting
direction
- Once the cut settings are properly set, select “COPY MODE” ON if you desire a preset
quantity of copies or OFF if you desire unlimited copies until the media roll is nished.
- Set the black-mark size” in “BLACK-MARK MODE” area.
- Press “START”.
IMPORTANT:
Whenever you lower and rise the lever while you are in black-mark
mode, wait until the plotter head has moved to the right.
>> How to run the blank mode
-Press “OPEN PDF” or “OPEN LAST JOB” to load the cutting le.
-Set the copy mode ON, and set 2 as number of copies.
-Click “START”.
-Check the horizontal position and the gap between the cuts.
-If necessary adjust the offset X and the distance between each cut in “STEP BOX”.
-Once the cut is set properly, select copy mode: ON if you desire a preset quantity of
copies or OFF if you desire unlimited copies until the media roll is nished.
-Working with DLF-220L or DLF-350L models, please open Advanced button, click on
Settings and uncheck Media/Lamination Sensor option, then save and close the pop up.
-Click “START”.
10

After the CUT TEST where users set
the cutting quality required, press
“START” to cut few labels to get
enough media to allow the matrix
remover module loading.
Pull the media through the aluminium
rollers rst (the guide can be adjusted
in order to prevent the web from rolling)
then through the clutch system.
Close the loading system and the
media will be automatically loaded into
the clutch path.
The user can adjust the clutch force thanks to the position of the clutch system.
Maximum Cluth (rewinded roll more tight)
Minimum Cluth (rewinded roll less tight)
HOW LOAD THE MATRIX REMOVER & SLITTER
Pull the sides of the black knobs and lift up the clutch system, other black knobs will keep
it open.
Minimum clutch
Maximum clutch
11

- Load empty cardboard core(s) and tighten the core holder, then place the motorized core
holder in position.
- Peel back the matrix.
- Pull the matrix and attach it to the matrix remover core holder.
- Load empty cardboard core(s) and tighten the core holder, then place the motorized core
holder in position.
(Cardboard core(s) width should equal (or narrower) the width of the nished roll).
- Pull the media through the aluminium rollers and attach the labels to the core using a
waste label.
WARNING: Before starting a job, always remove completely
the waste media from the matrix remover core.
Tape the matrix uniformly on the cardboard core.
System operating issues might happen if the above
suggestions will not be respected.
HOW TO LOAD THE MATRIX REMOVER CORE HOLDER
HOW TO LOAD THE REWINDER CORE HOLDER AND SET THE
SLITTER MODULE
12

Slitter module has 3 positions:
- Upper position (A), the blades are lifted to allow the media loading;
- Middle position (B), align the blades with the edges and the center of the labels, tighten
the thumb screw once the blade is in position;
- Lower position (C), the blade cut the media.
OPEN CLOSE
B
C
A
The black knobs lock the slitter
module in the requested position.
Screw the thumb knobs to move the
blades to the right or to the left.
A
B C
- Turn ON the Matrix Remover
module to rewind and start to split
the media, than turn OFF.
13

- Cut the labels at the same point where the rst “good” labels are visible;
- Make sure the tension on all rolls is even and attach each label to the core using a waste
label;
- Feed edges trim waste into the waste basket under the hole.
Press RESUME to start your nishing process.
Keep out the iron slide bar unscrewing
the thumb screw.
1
Slide in or out the blade holder.
Relocate the slide iron bar in its
position and rescrew the thumb screw.
2
Metal guides can be adjusted in order to prevent the web from rolling.
HOW TO ADD OR REMOVE A BLADE HOLDER
METAL GUIDE ALIGNMENT
14

1
17 16
2
15
6 7
814
10
11
9
12
3
13
4
5
DLF cutting manager (DLF CM)
USER INTERFACE
11
20
18
19
15

1. Cutting le preview
2. Open and load cutting le
3. Open and load the previous cutting le used
4. Status bar
5. Start/stop the cutting process. (In black-mark mode, the cutting process moves to the
next black-mark after the cut test)
6. Pause/resume the cutting process
7. Run one cut at time to check the values set, feature available in black-mark mode only.
8. Arrow buttons to move the media forward or backward
9. Increase or decrease the cut force
10. Increase or decrease the cutting speed
11. Offset adjustment
12. Current camera view
13. Screenshot of the previous black-mark detected
14. Preset quantity of labels to be cut (on) or cut to end/manual stop (off)
15. Number of labels cut
16. Set the gap between black-marks (top to top)
17. Set black-mark size
18. Enable blank media mode (no black-mark printed)
19. Set the gap between each artwork to be cut in blank media mode
20. Advanced options
MovE down thE
Cutting filE
MovE to thE right
thE Cutting filE
MovE up thE
Cutting filE
MovE to thE lEft
thE Cutting filE
-y+x
+y-x
cutting
direction
16

Settings (21)
ADVANCED OPTIONS
21
22
23
24
25
26
Report (22)
Delta X and Y show the predened offset adjustment.
After each cut, Delta X and Y keep saved the sum of the
predened offset and the values set by the user.
Media/Lamination Sensors feature allows to activate or
deactivate the monitoring for presence of material.
Whenever you change those settings, press save to set the
new values.
You can nd the complete report history le of all the jobs run since cutting manger has
been installed through this link “YourDocumentsFolder/DLF Cutting manager/CutHistory.
txt”.
Clicking “SAVE AS” your can save wherever you prefer the current work session report
Report displays the cuts run since
Cutting Manger software has been
open.
Each session report is automatically
added and saved to the history report
when cutting manager is closed.
21. Settings
22. Report
23. Set unit (mm or inch)
24. Set the interface language
25. Restore default plotter settings
26. Shows the software version
17

If the plotter is not connected correctly to the computer, the following errors will be
displayed at the application launch:
Make sure the plotter is switched on and properly connected.
In case it is turned off, please turn the plotter on and than press
the button 2 on control panel and wait until the display will show
“READY” as status. Then press retry on the popup window.
Load properly the media and rise the lever on the plotter, than
press the button 2 on control panel and wait until the display will
show “READY” as status. Then press retry on the popup window.
wrong poSition CorrECt poSition
For a correct functionality and prevent any issue, it is mandatory to have the camera
reading properly the black-mark.
Press ARROW buttons to move the media until the black-mark goes in the center position
of the blue rectangle’s area. If necessary, it is possible to slide the camera to left or to right
in order to get the black-mark centered as much as possible.
Cutting les: Adobe Illustrator or and Corel Draw (PDF).
The artwork le within the cutting shape must be equipped with a register square
black-mark having a size of 4x4mm (0.16”x0.16”) or 2x2mm (0.08”x0.08”).
In the “cutting le” the cutting shape and black-mark (not for the blank labels) only
must be saved. Graphic is not required to be saved.
If the le is using few drawing layers, it is not enough to disable the view of them, the
grapich layers must be deleted or the prole shape must be copied in a new le and
saved.
18
ERROR MESSAGES
BLACK-MARK DETECTION
CUTTING FILE SPECIFICATIONS

The cutting shape and the black-mark can be placed anywhere inside the layout le, the
cutting shape does not require any special color and thickness.
The black-mark must be always the object placed in the lower left corner of the layout le.
The DLF Cutting Manager (DLF CM) work with the VECTOR PDF FILE. You can
create this le with Adobe Illustrator or Corel Draw.
minimum distance from
left side of label graphics
4 mm (0.16”)
black-mark
can overlap
label on
bottom
Black-mark size: 4mm x 4mm (0.16” x 0.16”) or 2mm x 2mm (0.08” x 0.08”)
4mm is the minimum distance betwen black-mark
and label graphics on bottom side.
Black-mark MUST be the leftmost object.
for round or complex labels
black-mark can partially
overlap the left side of label.
19
BLACK-MARK POSITION INTO THE CUTTING FILE AND PRINTED ARTWORK