AFINIA LABEL DLP-2100 User manual

DLP-2100
Digital Label Press
User Manual
Version 1.0
DLP-2100 Digital Label Press

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Print, Laminate, Back-slit, Cut, Remove Matrix
The Afinia Label DLP-2100 is a digital label press that is powered by Memjet. The DLP-2100 prints in
vibrant, 1600 DPI, photograph-quality color at 6 inches per second and requires no plates. The 15”
diameter cylinder accepts flexible dies up to 12 inches in length allowing for fast, accurate die cutting of
any shape, including perforations.
The DLP-2100 can also convert stock to blank labels, ready for printing. With a flexible die, it’s possible
to convert blank labels at a rate of up to a foot a second.
The DLP-2100 Digital Label Press brings the incredible “up to 12 ips” speed, quality and economical low
cost-per-print of Memjet Technology together with the precision and performance of magnetic cylinders
and dies. Finally, labels can be printed, laminated and cut in-line.

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Contents
Features ........................................................................................................................................................ 5
Specifications ................................................................................................................................................ 6
Installation .................................................................................................................................................... 7
Unpacking ................................................................................................................................................. 7
Adjusting Pinch Rollers.............................................................................................................................. 8
Components.................................................................................................................................................. 9
Identifying major components.................................................................................................................. 9
Safely Features........................................................................................................................................10
Connecting power................................................................................................................................... 11
Overview .....................................................................................................................................................12
The Control Panel....................................................................................................................................12
Startup Screen..................................................................................................................................... 12
Restart Screen.....................................................................................................................................12
Program Run Screen ........................................................................................................................... 12
Settings Screen.................................................................................................................................... 14
Manual Screen ....................................................................................................................................14
Parameters Screen..............................................................................................................................14
Diagnostics Screen ..............................................................................................................................14
Loading media......................................................................................................................................... 15
Adjusting the Guide Collars.....................................................................................................................16
Using the splicing table ...........................................................................................................................17
Adjusting mark sensor position .............................................................................................................. 18
Recalibrating the Mark Sensor................................................................................................................ 18
Cutting blank labels................................................................................................................................. 19
Removing Waste .....................................................................................................................................20
Loading laminate..................................................................................................................................... 21
Laminate Adjustments ............................................................................................................................22
Attaching die plates ................................................................................................................................23
Removing plates...................................................................................................................................... 24
Back Slitting.............................................................................................................................................25
Slitting .....................................................................................................................................................26
Designing labels ...................................................................................................................................... 27
Troubleshooting..........................................................................................................................................28

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Media problems......................................................................................................................................28
Registration problems............................................................................................................................. 29
Cutting problems ....................................................................................................................................29
Electrical problems.................................................................................................................................. 30
Maintenance ...............................................................................................................................................31
Maintenance Schedules..........................................................................................................................31
Buying Die Plates......................................................................................................................................... 32
What and how to order ..........................................................................................................................32
Magnetic Cylinder Information...............................................................................................................33

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Features
If you need to print, laminate, and convert continuous material, the Afinia DLP-2100 offers the complete
solution.
It may be used as a stand-alone unit or in-line with the Afinia L901 printer. Simply print your continuous
labels with a black registration mark and easily laminate and die cut with this remarkable machine. The
DLP-2100 uses a combination of an electronic mark sensor together with precision electronics and
touchscreen to ensure an amazing +/- 0.3mm registration accuracy.
Die cutting is handled by a full rotary 15 inch circumference cylinder. It uses economical flexible steel
cutting plates, for very high precision and long die life.
The use of high quality electronics for logic control ensures the DLP-2100 will produce high quality,
accurate labels. When combined with back-slitters, post-slitters, dual output mandrels for easy finished
roll separation, and an easy to navigate touchscreen control panel, the DLP-2100 is the complete
solution to your laminating and die-cutting requirements.
Visit our website at www.afinialabel.com for detailed information and downloads.
Automatic
Use with the Afinia L901 Label Printer or use as a stand-
alone finishing unit
Reliable
Solid Industrial Design
Fast
Variable speed up to 12” per second
Easy to use
Simple setup and touchscreen operation
Perfect Control
Adjustable tension clutches provide full control
Accurate
Precision sensor
Digital and mechanical cut adjustments available
Wide Appeal
Suits industrial and bureau label converters
Range of Uses
Provides high durability for your printed labels in a
variety of finishes for a variety of uses.

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Specifications
Print Speed Up to 12 in/sec.
Print Quality 1600 DPI full-color output
Cutting Speed
Max 7.87″/sec (200 mm/sec) re-registering or 140 ft/min full rotary for
blank labels
Speed Control Variable
Max. Web Width 9.65″ (245 mm): in-line prinitng will reduce this width
Max. Diecutting dimensions 9″ (230 mm) width; 12" (304.8 mm) length
Core Sizes 3″ (76 mm)
Unwinder Integrated, 19″ (480 mm) max. outside diameter
Loop Photoelectric distance sensor
Back Slitters 2 rotary knives
Laminate
Economical, self-wound and supported laminate (on a liner). Liner
removal included for use with high quality, liner-supported laminate
Max. Laminate OD 11″ (280 mm)
Registration Sensor Laser
Registration +/-0.01″ (+/- 0.3mm )
Registration Sensor Adjustment 9″ (230 mm) x 12″ (304.8 mm)
Sensor Mark 0.2″ x 0.27″ (5 mm x 7 mm )
Cylinder 15" (381 mm)
Cutting Dies Flexible steel – any size from 0.2″ (5 mm) to 12″ (304.8 mm) repeat
Lateral Cylinder Adjustment 0.5″ (12 mm)
Max. Waste Matrix Rewind 11.8″ (300 mm)
Razor Slitter Assembly 6 knives
Razor Slitter Lateral Adjustment 0.47″ (12 mm)
Max. Finished Label Rewind 11″ (280 mm)
Dimensions 65″ (1650 mm) x 41.33″ (1050 mm) x 33″ (840 mm)
Frame 0.4″ (10 mm) solid aluminum
Power 220 Volt 10 Amps required
Weight 420 lbs (190 kg)
Motors 2, 400 W / 90 W
Control Touchscreen control panel, PCB. Inverter, Encoder

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Installation
Unpacking
1. Remove the top panel of the crate and then the 4 side
panels
2. Inspect the DLP-2100 for damage prior to removing it
from the base of the crate
3. Undo and remove the four M10 bolts holding the four
corners of the DLP-2100 to the base of the crate
a. You may need to lift the crate using a forklift to
hold the nuts underneath the base that secure
the bolts
4. Lift the DLP-2100 from the base plate using a forklift
a. It is recommended that the front of the DLP-
2100 be facing the forklift
5. Attach the feet to the four corners
a. Install the feet so they are above the bottom of
the wheel ; this will allow you to roll the DLP-
2100 to the operating location
b. The two center supports will have feet already
attached
6. Move the DLP-2100 away from the crate base and
carefully lower to the floor
7. Roll the DLP-2100 to the operating location
a. Be sure the rollers are not locked before
attempting to roll the unit
8. Lower the feet so the DLP-2100 is level and supported
by the feet
9. Connect 220V power to the DLP-2100
Caution: This machine is extremely heavy. Do not attempt to move the crate or
machine without suitable lifting equipment. Failure to follow these instructions may
result in serious injury.
Caution: Use a forklift to remove the DLP-2100 from its
crate. Do not attempt to lift the unit manually!
View from underneath the crate
3
3a
5b

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Adjusting Pinch Rollers
The DLP-2100 is fitted with silicone rubber nip rollers. Do not use a knife on these rollers and clean with
a mild solvent if required.
The DLP-2100 is supplied with pre-set maximum roller settings. If the machine is supplied
with no roller pressure, simply rotate each arm clockwise until it stops.
Do not use excessive force.
NIP ROLLER PRESSURE
Rotate the Nip Roller
levers counter-clockwise
to release pressure.

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Components
Identifying major components
Caution: Do not proceed until you have a good understanding of the major components
of your machine and their locations. Do not attempt to start or run the DLP-2100 before
reading the instructions detailed on the following pages.

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Safely Features
Following is an outline of the main safety features included with the DLP-2100. Please ensure that you
are familiar with all of the safety features before proceeding.
•EMERGENCY STOP: Note the location of the
emergency stop switch. The switch is designed
to immediately stop the press and apply the
motor brakes. Follow the on-screen instructions
to resume operation after an emergency stop.
•ELECTRICAL CABINET: The cabinet is secured by
4 – 4mm bolts which should be kept tight at all
times and removed by authorized technicians
only.
•DRIVE BELTS: These are inside the back cover. If the back cover is open, ensure that hands, hair,
or clothing cannot be caught in the drive belts.
•NIP ROLLERS: The orange rollers are driven by
powerful motors. Never under any
circumstances place fingers, hair, or clothing
near the nip rollers while the machine is
running.
•WARNING LABELS: These labels indicate important safety considerations for your machine.
Never remove, damage or obscure warning labels.
Caution: The safety features included with your machine are for your protection. Never
remove warning labels or disable cut out switches. Be aware of your emergency stop
location and use common safety precautions and care at all times.