Dumor Aerocard-strike User manual

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AEROCARD-STRIKE

USER MANUAL

AEROCARD STRIKE INSTRUCTIONS

Thank you for purchasing the AEROCARD-strike nisher.

This unit is a precision piece of machinery; therefore please read the manual carefully and the machine will give

you trouble free service.

The machine is complex with many functions, therefore we recommend reading the manual several times and do-

ing several dry run setups with re-used paper before trying a real job with new paper.

If you do not fully understand the instructions do not run the machine but call in a qualied technical service per-

son to give you full training

Note that due to our policy of continuous product improvement the information in this manual is subject to change

without prior notice.

SAFETY PRECAUTIONS

• The machine requires a ground line, make sure it is connected, the power inlet is protected by a fuse above the

socket.

• The machine uses several cutting blades, these are all covered by guards with interlocks, do not disable the

interlocks.

• The machine uses a low speed suction infeed belt, do not let loose clothing or hair get near the belt.

• The machine uses several outfeed cutting tools on a rotating shaft, these are guarded, do not disable the

guard.

• The electrical cabinet of the machine is covered, do not uncover the cabinet.

• Do not use the machine is direct sunlight as this may affect the sensors.

• Do not use the machine in a very hot / humid environment as the paper will become distorted and not run well,

best operation temp 25 deg c @ 60 % rh.

WHAT THE MACHINE IS DESIGNED TO DO

Basically its a device to produce many smaller sheets or cards from one large sheet of paper card.

The smaller sheets can then be further nished in line in the same pass by certain optional tools within certain limi-

tations as noted on the TEMPLATE A

OPTIONS

• Cross ways programmable creasing

• Cross ways programmable perng either continuous or stepped

• Lengthways scoring

• Lengthways perng

• Lengthways kiss cutting

• Lengthways slitting

• Lengthways programmable strike perng

• Business card stacking tray set option

• Card separator plates to separate small cards

• Stepping conveyor option

• For the specication of the use of the tools and options ; see the template below

90°

0Origin

Barcode optional

Min. 210mm - Max 650mm Sheet

Min. 210mm - Max 330mm

End trim 5 > 15mm

Gutter Slit 5 - 15mm

Bleed slit 0 or 3,2 > 38MM

Gutter Slit 0-2 pcs

Head 1

Head 2

Head 3

Head 4

Head 5

Head 6 ✂

✂✂

✂

Card Length 48mm to Full Sheet

Cross Perf

12, 24, 52 tpi

Full or stepped

1 - 32 lines

1mm

1 to 32 lines

Cross cut 0 - 32pcs Min 0 or 3 - 15mm

Min 50mm

Max Full Sheet

Front trim 0 or 3,2 > 15mm

8, 12, 24, 48 tpi

Strike Perf

1 - 4 Heads

Min Spacing

45mm

Min 5mm

Max Full Sheet

ON/OFF

to 12 times

CARD

WIDTH INFEED DIRECTION

TEMPLATE A

CARD LENGTH

GUTTER CUT

XY Mark optional

4pcs

20A

12A

21A

Packing Bracket X2

WHAT’S IN THE CRATE:

1Main unit attached to the skid by bolts and with 4 lifting handles

2Infeed tray extension => ts to the 3 screws on the lifting tray

3Infeed tray magnetic posts x3 pcs => they are positioned on the sides and the end of the paper pile to guide

the paper in during feeding.

4Infeed tray” hook on” and magnetic deectors x 4 pcs => are positioned on the suction box and in the slot of

the cross bar see the picture for reference.

5Outfeed tray => hooks onto the outfeed end panel and support arm into the slots below

6Optional outfeed stepping conveyor, plugs into the socket at the end of the machine

Outfeed tray magnetic side and end guides set=> are positioned to receive the out-fed sheets according to size.

8Creasing bar @1 mm pre-tted into the slot

9Waste bin pre- tted under the waste chute

11 Colour touch screen display ( requires tment by technical service) do not damage it on installation..

12 Power cord with earth line.

Small tool kit

Note that the machine is heavy and 4 strong persons will be needed to unload it from the skid

The unit is on casters with levelling feet.

Preparation of the machine before use

1. Check the voltage and frequency matches your power source before plugging in

The power source needs to be 10 amp and with a ground line.

2. Unbolt the lifting tray support plate ; failure to do so will break the lift motor and invalidate the warranty!

3. Have a technician to t the display ( see instructions for this later in the manual ) you may need to calibrate the

pixels in the screen (see later )

4. Fit the standard accessories as described above.

Functional parts of the machine from right to left (see pictures end of the manual)

2Infeed tray for about 20 cm pf paper

11 Touch screen

3Magnetic guides

4Paper deectors

13 Paper feed height adjustment sensor knob

14 Paper skew adjustment knob

15 Tray descent button (green)

12A Fuse in power socket

16 Air blast vents with vernier sequential opening

17 Air blast adjustment knob with scale

18 Separator ngers , adjustable up and down to let in only 1 sheet

18A Separator nger height adjustment knob with scale

19 Lifting plexi cover with interlock switch

20 x/y mark reader

20A Bar code reader option

21 Slitting heads 1 2 3

21A Slitting heads 4 5 6

12 Gutter bleed slit deector ON/OFF knob on heads 3 and 4

23 Cross cutting blade set

24 Pressure adjustment knob on front cover with 5 steps

25 Pressure adjustment compensation knob on the paper rollers 2 pcs

26 Slide in tool access hatch with interlock switch

27 End cover with interlock switch

28 Outfeed rubber traction rollers and or linear tools

29 Socket for strike perf tool option x 4

30 Mounting bar for linear tools with mm scale

31 Bayonet tting lower shaft with small locking clips and sliding bearing

5Outfeed tray; and/or optional stepping conveyor

7Outfeed tray magnetic guides

32 Card reception tray option with deectors option

33 Socket for stepping conveyor option

10 Waste tray under the slitters behind access door with interlock switch

HOW THE MACHINE OPERATES

Image Stretch / Shrink to 5%

650mm

330mm

X/Y register

Barcode reader

-5%

+5%

Original

INFEEDOUTFEED

TEMPLATE B

1 233645 869636

Up to

6x Slits

Up to

32x Cuts

Up to

16x Creases

or 16x Perfs

to 4

Strike Perfs

Cards

48mm

50mm

GENERAL PREPARATION OF THE JOB

Steps

0you select a pre-programmed job from the list on the screen

OR :

1you program in the paper size and weight to be in-fed

2you program in the slits to be made within the template spec

3you program in the cross cuts to be made within the template spec

4you program in the cross creases to be made within the template spec

5you program in the strike perfs to be made within the template spec

THEN:

6As needed you position any further linear tools required on the outfeed tool carrier bar as per the template spec

7You set the air blast according to paper weight; light paper ,almost closed , heavier paper open up the vents

gradually so the top sheet oats

8You set the separator ngers according to the paper thickness, thin paper almost closed , for thicker paper open

up gradually so only the top sheet feeds

9You set the magnetic infeed posts to lightly touch the sides and back of the paper to let is run freely but still be

guided closely, if they are too tight the paper will not feed. The posts are rolled into place to avoid scratching the

table

10 You set the outfeed tray guides to receive the paper without it getting caught by the side guides

Once this is done the paper is ready to be run the ﬁrst trial sheet

When you start the machine the following will happen in sequence:

- The paper pile will lift to the level of the upper sensor nger which stops it moving further up

As the pile is fed in and used up the tray will index upwards about each 15 fed sheets

- The air suction and blast will start up

- The feeding belt will index the top sheet forward about 6 cm

- The gripper rollers will grasp the sheet and move it to the mark reader and under the double sheet controller

- The double sheet controller will check that only 1 sheet is fed in , if not an error message will appear

- If the mark reader is on the slit heads will adjust to compensate for the mark drift

- The heads 1 to 6 will position according to the program requirement

- The machine will check if the gutter deectors are correctly set for the job , if not it will issue a error message and

they will need to be re-set

- The sheet will advance forwards into the slitters and be slit into several strips

- The strips will advance forwards into the cross cutter and be cut into several cards

- The cards will advance into the cross creasing or perng tool and be creased or perfed accordingly

- The cards will advance into the strike perf heads and will be intermittently perfed accordingly

- If other linear tools are used they will also re- work the cards

- The cards will be expelled into the outfeed tray or conveyor

ACCURACY OF THE MACHINE

The design accuracy of the machine is +- 0.2 mm cumulative

The machine is only as accurate as the paper that is put in the tray, it will not recuperate for correct poorly cut

paper.

VERY IMPORTANT

The paper has to be :

- Cut straight, or it will skew

- Cut parallel, or it may not feed and will wobble on infeed

- Cut square at least on the front edge, or the rst cut will be erratic

- Cut cleanly eg not hooked or rough edges, or the paper may not feed or pull in double sheets

- The paper is not wavy or distorted, or it will feed poorly

- The paper is not curled, or it will not feed correctly

See template C next page

Once all is double checked the machine can be turned ON

Understanding how the machine cuts to get a good result

To get the machine to work correctly you rst need to understand the cutting operation / measurements and set-

tings.

Deﬁnition of the cutting process

- The uncut sheet

The machine calculates and works from a unique reference point which is the back edge left side corner of the

paper

Known as the origin 0/0, all other things are referenced to this point.

- There are 2 cut axis

X direction means length-ways positioned cross cuts or cross creases or strike perfs

Y direction means cross positioned slits

- Mark reader

There is a mark reader that will re calculate the cut positions according to the movement or drift of the printed mark

as compared to the origin point in both axis.

If the mark is not positioned and printed correctly the cut positions will be incorrect.

- Laying out the cuts

If you want to layout a sheet and then cut it accurately you need to know certain reference points as compared to

the origin see the template.

In the X direction from left to right in order

- The total sheet length

- The lead edge rst cut

- The card length

- The gutter cut length between cards , if required

- The nr of repeat card cuts that need to be made

- The remaining trailing edge trim cut

All the amounts have to be within the template spec and add up exactly to the full length of the sheet

The length of the sheet = lead trim + (card length x n) + (gutter cuts x n) + tail edge trim.

In the Y direction from back to front in order

- The total sheet width

- The rear bleed trim

- The card width

- The gutter width

- The total nr of cards and gutters required (usually max 3 rows but can be up to 4 rows if no gutter slits required)

- The side trim bleed width

Note side trims are always deﬂected to the waste bin unless the heads are set at home position

Sheet width = front and back side trims + (card width x n) + (gutter strips x n)

Math

It sounds obvious but the numbers need to add up....

A precision steel rule with 0.5 mm increments is a must to set these jobs.

What can go wrong: >>>>>>>>

Error 1 CARD MOVING DOWN

320mm

450mm

Error 2 CARD MOVING UP

320mm

450mm

Error 3 CARD NOT CENTERED LEFT OR RIGHT

Error 4 CARD SKEWED LEFT OR RIGHT

STATIC ERRORS X OR Y

- The numbers dont add up

The machine will reject the input amounts if out of spec and indicate an error

- The print bleed end is too near the cut and any small difference will be noticeable

Make sure the bleed is at least 3 mm over the cut position to be sure.....

Dynamic errors X or Y

- The image is too short in the x direction compared to the cut settings and the image “progressively climbs up”

the cards in sequence of cut

- Same in the Y direction but the error is static

When you check remember the bottom card in the tray is the ﬁrst one out....

The image is too long or cross cut too short and the image “progressively climbs down” the card.

The sheet is skewed and the cards move to the left or right in sequence of cut

These are layout and printer errors and not machine cutting errors

The problem needs to be addressed at source.... eg the layout and or the printer

XY MARK (optional)

100 - 117mm

3 - 15mm

USE OF THE MARK

The position of the”☐” mark is indicated in the attached diagram

Note the mark has to be 100 % solid black or will not be read

Positioned as per the template

The machine will read the mark and re-locate the heads according to the movement.

This can take a little more time and reduce the throughput speed

So if you want full production speed then turn the function OFF

Note that in the screen to set the mark position the +/- button has 2 settings

Short press = incremental increase / decrease

Long press = button becomes backlit and then the value can be entered by the adjoining keyboard then press ENTER

USE OF THE BAR CODE

The bar code doesn’t set up the job from scratch

The bar code will cause a memorized job number to be recalled and the nr of sheets to be fed will be input

The way to program a bar code is indicated in the attached diagram

You need to have the program in your printing software to be able to print the bar code from the raw data

Source:

If you don’t already have a code 39 barcode generator in your pc here is a source:

a typical conversion program is on

http://www.barcodetrader.com/bct_scan_barcode.asp

Use the font called code39.ttf (there are many other codes but they are not supported )

You download the Font from the site and save it

Structure of the raw readable data

Star then 5 integers then star

eg: *12345*

The rst 3 digits are the job nr as per the machines loaded memory

Jobs 1-64 are factory installed in the factory program le

Jobs 165 - 228 are user programmable and saved in the user program le

Size of the printed barcode (see above)

Wide bar 1 mm x 3 pcs

Narrow bar 0.5 mm x 6 pcs ( black and/ or white )

Height 6,5 mm approx

String width 45 mm

X from edge 3 - 15 mm

Y from edge 140- 144 mm as from the last bar

Each digit is represented by

9 bars in total (5 black + 4 spacings)

NOTE

Job nr

Even if the job nr is 1it has to have 3 digits eg 001

Quantity

Same for the nr of sheets has to be 2 digits eg from 01 to 99

Processing speed

The data is processed by reading the rst sheet of the group which is fed in a little slower than usual

The rest of the sheets are then counted but not read individually in order to speed up the sheet feeding to full

speed

Once the last sheet of the batch is done the next batch rst sheet is read etc...

Speed setting button

There are 4 feed speed settings on the screen

Scroll to select

For the most accurate cutting use the lowest speed setting

Using the touch screen (Do not press too hard on the screen or you will kill the pixels, Warranty invalidated)

Calibration of the screen (Only to be used if the buttons on the screen are out of position)

To open the function

Press the OK button 5x repeatedly

The calibration screen will open

Use a blunt stylus to follow the pixel image

Once complete the screen will revert to the normal display

Turn ON

Welcome message appears

SCREEN 1 ___________________________________________________________________________________________

You will see the machine drawing on the screen

Note :this screen has all the data of the machine

- Software nr

- Serial nr

- Accessories tted

- nr of cuts ( for warranty )

- nr of sheets passed through

Press OK to go further into the main menu

SCREEN 2 ___________________________________________________________________________________________

No Description Remark

1 Manual Programming Input all the data one by one

2 Quick Programming Create Template Automatically

3 User Template Storage Recall the user template

4 Preset Template Storage Recall the factory template

5 Communicating with PC Reserved function

6 Settings

Enter into system settings of machine

7 Tray Down Let loading tray down to home position

8 Back Home Position Let all slitters back to home position

9 Start Enter the run screen according the last available job data

Top row icons, from left to right

Red calculator button = input data manually

Green calculator button = t - to - page program fast entry

Green oppy disc button = recall user programs

Green magnifying glass button = recall factory programs ( 64 )

PC USB link = future PC USB link

Lower Row

Red spanner/ wrench button = technical menu

Blue BIN button= tray down

Blue R button = send slit heads to home position

Green go button = run machine

3 4

SCREEN 3 ___________________________________________________________________________________________

Main screen with cut template

Icons - Left column

1 Go home

2 Go back one step

3 Process speed selection

4 Sheet count preset

5 Batch count preset

In the middle pictorial view of the current job selected

Icons - Right column

Press icon to call up

6 Feed continuously

7 Test feed 1 sheet only

8 Reset Slitter Heads to travel position

9 Make the tray descend

10 Register make ON/OFF

11 Barcode reader ON/OFF

SCREEN 4 ___________________________________________________________________________________________

Factory preset programs

Grouped by function infeed size mentioned rst, outfeed last

Press icon to call up

Note the factory programs can be called up, overwritten and memorized in the user memory

SCREEN 5 ___________________________________________________________________________________________

No Description Remark

1 File Name Template name

2 Paper Size Set Paper spec., Crease depth, Black mark position

3 Slit Data Set the data of the slitters

4 Cut Data Set the data of Cross Cutter

5 Crease Data Set the data of Creaser

6 Image Compensation

For dealing with the images shift or shrink/stretch caused by printing

7 Start Enter running screen

8 Next Page Go to the next page

9 Save as Save the temper template with a new name

10 Home Back to Main Screen

Screen information

Custom manual program entry page 1

In the header the current job le name

Icons across the Top

To home

Access table for infeed paper size input, crease depth, and mark position

Access table for slit settings

Access table for cross cut settings

Access table for crease line settings per card

Icons on the Right

Image shift x/y increments of 1 %

Image shrink/stretch x/y increments of 1 %

1 2

8 76

3 4 5

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