Intimus POWERCUT 5280 EPS User manual

5280 EPSP
Single Knife Paper Cutter
Operation Manual
intimus International GmbH, Bergheimer Straße 6-12, 88677 Markdorf / Germany
Tel.: ++49 (0)7544 / 60-0 --- E-mail: [email protected] --- www.intimus.com
96256 1 04/21

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CONTENTS
1. GENERAL INFORMATION ........................................................................................ 7
1.1 Identification ................................................................................................................. 7
1.2 Purpose of use ............................................................................................................. 8
1.3 Documentation ............................................................................................................. 8
1.4 Introduction ................................................................................................................. 8
2. SAFETY OF USE.............................................................................................................. 9
2.1 Symbols: meaning and application ..............................................................................10
2.2 Employee qualifications...............................................................................................11
2.3 Requirements for the operator's workplace. ................................................................12
2.3.1 Personal protection equipment..............................................................................12
2.3.2 Permissible environmental and operational conditions ..........................................12
2.4 Expected risks when operating the cutter ....................................................................12
2.5 Description and evaluation of residual risk ..................................................................13
2.6 Safety systems used in the cutter................................................................................14
2.7 Ways to prevent threats...............................................................................................15
2.8 Safe working rules.......................................................................................................16
2.9 Safety control ..............................................................................................................17
3.TRANSPORT AND STORAGE .........................................................................................18
3.1 Packaging .....................................................................................................................18
3.1.1 Package characteristic ..........................................................................................18
3.1.2 Package removal ..................................................................................................18
3.2 Transport.....................................................................................................................18
3.3 Delivery status.............................................................................................................19
3.4 Setting the cutter .........................................................................................................23
3.5 Work area....................................................................................................................24
4. TECHNICAL CHARACTERISTICS OF THE GUILLOTINE..............................................25
4.1 Destiny ........................................................................................................................25
4.2 Basic parameters ........................................................................................................25
4.2.1 Technical data.......................................................................................................25
4.2.2 Technical data - electrical system .........................................................................26
4.2.3 External dimensions..............................................................................................26
5. OPERATION ....................................................................................................................28
5.1 Operating safety ..........................................................................................................28
5.1.1 Safety instructions.................................................................................................28
5.1.2 Warning about special hazards .............................................................................28
5.2 Control system ............................................................................................................29
5.3 Electrical apparatus.....................................................................................................32
6. POWER SUPPLY ............................................................................................................33
7. USING THE CUTTER ......................................................................................................34
7.1 Work area for operational staff ....................................................................................34
7.2 Danger zones in the cutter ..........................................................................................34

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7.3 Starting the cutter........................................................................................................34
7.3.1 Commissioning .....................................................................................................34
7.3.2 Diagnostics of the safety curtain after switching on the power supply....................35
7.3.3 Emergency stop of the cutter.................................................................................36
7.3.4 Starting the cutter after emergency stop................................................................36
7.4 Determining the position of the approaching beam......................................................36
7.4.1 Changing the position of the beam with the handwheel.........................................36
7.5 Pressing the material...................................................................................................37
7.5.1 Pressing the material without cutting (determination of the cutting line).................37
7.5.2 Clamping and holding of sliced material. ...............................................................38
7.5.3 Change of clamping force .....................................................................................39
7.5.4 Rules for selecting the contact pressure................................................................39
7.6 Cutting line indicator (optical) ......................................................................................39
7.7 Cutting (pressing and cutting)......................................................................................39
8. OPERATIONAL ACTIVITIES...........................................................................................41
8.1 Replacing the knife in the cutter ..................................................................................41
8.1.1 Removing the knife ...............................................................................................42
8.1.2 Inserting a knife.....................................................................................................48
8.2 Reversing or replacing the cutter bar...........................................................................53
8.3 False clamp.................................................................................................................55
55
8.4 Adjusting the parallelism of backguage .......................................................................58
9. MAINTENANCE...............................................................................................................59
9.1 Daily maintenance.......................................................................................................59
9.2 Treatments that should be performed cyclically...........................................................59
9.3 Lubrication...................................................................................................................60
9.3.1 Oil change in gearboxes........................................................................................64
9.4 Inspections ..................................................................................................................66
9.4.1 General recommendations ....................................................................................66
9.4.2 Knife regeneration.................................................................................................66
10.FAILURES ......................................................................................................................67
10.1 Determining the causes of the fault ...........................................................................67
10.2 Basic procedures for removing various types of defects ............................................67

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Program modules
1. MACHINE START............................................................................................................69
2. MANUAL MODE ..............................................................................................................70
2.1 Absolute mode - Automatic move to input dimension ..................................................70
2.2 Incremental mode - Repeating same dimension on next steps....................................71
2.3 Manual Backgauge Movement ....................................................................................71
2.4 Paper Eject..................................................................................................................71
2.5 Numerical Keyboard....................................................................................................72
3. AUTO MODE- PROGRAMMING......................................................................................72
3.1 Program selection .......................................................................................................72
3.2 Launching program from memory................................................................................73
3.3 Program edit and saving..............................................................................................74
3.4 Cut & Save ..................................................................................................................75
4. CARD CUTTING ..............................................................................................................76
5. OPTIONS .........................................................................................................................77
5.1 Options – special functions..........................................................................................78
5.2 Options – Language ...................................................................................................78
5.3 Options – Knife change ..............................................................................................79
5.4 Options - Calibration – Base dimension corr................................................................81
5.5 Options - Clamp adjustment on touch screen .............................................................82
5.6 Options – Sensor - Diagnostics ...................................................................................82
5.7 Options-Reset programs – program cancelling.........................................................83
5.8 Options - Service – to enter service mode..................................................................83
5.8.1 Options – SERVICE – dimensions. ......................................................................84
5.8.2 Options – Service – Encoder................................................................................84
5.8.3 Options – Service – Factory settings ....................................................................85
5.8.4 Options – Service – Calibration ............................................................................85
5.8.5 Options- Service – Test........................................................................................86

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IDENTIFICATION
Machine type: Single knife paper cutter
Item: INT-GU-05280EPSP

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EC-Conformity Declaration

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1. GENERAL INFORMATION
•This operator manual introduces the machine for the user and shows what for the
machine was designed for to enable safe and comfortable work on the machine
•Inside the manual there are listed special safety requirements necessary to use the
product
•The manual should be stored near the machine and secured from lost or damage
•The operator should read the manual before using the machine with special focus on
chapter "Safety rules"
•The manual should be accessible by operator at any time and read carefully by all the
machine operators. It refers to:
I. Operation and first installation
II. Troubleshooting of workflow
III. Maintenance (service, repairs) and transportation
•In addition to the manual operator should keep general safety norms and local,
national health and safety requirements. The employer is also obliged to train the
staff properly to operate the machine in harmony to the manual.
1.1 Identification
Single knife paper cutter is marked with nameplate sticker located on the right side of the
guillotine 1 (figure. 1)
Figure 1
After the machine purchase in is suggested to check the serial numbers of machine
nameplate with purchase documents.

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1.2 Purpose of use
This Single knife cutter is designed for cutting to requested dimension reams of paper,
cardboard and other materials like pvc, plastics, fiber, foils, lamination and rubber etc. It is
mainly used by printing houses, print finishing specialists, copy shops and offices. In case of
some materials (like ex. plastics) it is recommended to use smaller ream than maximum
designed (to be consulted with manufacturer). The machine must be used according to the
rules given in operator manual and conditions as assemble, disassemble, reassemble,
installation, controlling and maintenance should be respected.
Danger of damage in case of wrong usage!
•operator is fully responsible for any damages caused by incorrect using of the
machine!
•the machine is designed only for purposes given in this manual by the
manufacturer!
1.3 Documentation
•This operator manual is deliver with the machine
•The operator manual is not the service manual.
•It is a must to use only the original spare parts delivered by manufacturer or
authorized agent.
•The drawings in the manual are example and may slightly differ from the real machine
received.
•The maintenance substances mentioned in the manual like oils, greases etc. are
exemplary, available at manufacturer region when the manual was created. It is
allowed to use other materials with similar properties available at local market.
•The manual should be always stored near the machine
•The staff of user should be familiar with the manual before starting to operate the
machine.
1.4 Introduction
In this manual there are included information about safety features of the guillotine. The
manual should be stored near the machine and secured from lost or damage. It is necessary
to operate the machine according to manual but also to local, general rules of safety. The

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employee is also obliged to train respectively the the operators of the machine according to
the manual. Each operator should confirm receiving of the manual and sign the obligation to
respect it. The requirement is necessary to start working on the machine.
2. SAFETY OF USE
The elements of mechanics, electronics of the guillotine are made according to latest
solutions and general rules of technology to secure the operator in case of failure. The
adequate level of safety elements ensure operator safety. It is necessary to check with
manufacturer if user wants to use special, extra equipment which was not installed and
delivered by manufacturer. Otherwise the factory warranty is no longer valid and
manufacturer takes no responsibility for modifications done in the machine and damages
cause by such.
This requirement is also applicable to the spare parts used during the repairs!
The repairs should be made only by servicemen who were trained by the manufacturer. In
case of the repairs done by unauthorized service the warranty given by manufacturer is not
valid and manufacturer is no longer responsible for any damages.
•Warranty is terminated if the machine is modified by user without any
permission of manufacturer.
•Modification by user removes all responsibility from the manufacturer for any
damages.
Despite all precautions the operating of the machine by not trained staff or wrongly trained
can cause the risk of damage.
Each person present during the installation, maintenance and usage of the machine must be
familiar with the manual, especially the chapter Safety of use.
Despite the obligation to do it prior using the machine such means should be also repeated!
Possible effects of incorrect usage:
•risk of life
•risk of body damage
•risk of machine damage
•risk of deterioration of technical condition of machine

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2.1 Symbols: meaning and application
Table 1. Symbols meaning
Read operator manual
Respect operator manual
INFORMATION
WARNING!
Risk of machine damage
Risk of deterioration of technical condition of machine
CAUTION! DANGER!
Danger to life
Danger of body damage
Dangerous electrical voltage!
Children must not operate the device!
Do not put hands underneath the knife!
Do not leave knives unattended
Do not remove or transport knives without covers!
Risk of injury!
Do not cut hard materials or materials, which may be splattered

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2.2 Employee qualifications
•The guillotine can only be operated by qualified employees who have been properly
trained by the cutter manufacturer. With regard to safety rules, in the contents of this
instruction, by a qualified employee should be understood as a person authorized to
set machines, circuits and electrical circuits in accordance with the standards of
security technology.
•The guillotine should only be operated by employees trained and authorized for this
purpose by the employer. Such employees must be of legal age.
•An operator who does not use the language of the available version of the user
manual in speaking or writing, should be fully instructed in verbal instructions and
complete comprehensive and practical training to familiarize with the content of the
document.
This requirement is especially important for chapter "Safety of use".
The manufacturer recommends that the operator be given the translation of "Safety of
use" in his mother language with confirmation of receipt of such a document.
Info
Before operating the cutter the operator must read the operating
instructions.
•Every employee delegated to work during assembly, disassembly, reassembly,
commissioning, servicing and maintenance (technical inspection, servicing, repairs) of
the cutter must read the entire operating manual, in particular the chapter "Safety of
use".
•The manufacturer recommends that the buyer of the machine, transferring it for use,
obtained a written confirmation of the contents of the instructions.
•Every employee authorized to perform assembly, start-up, operation and
maintenance and repair of the cutter must read the entire operating manual, in particular
the chapter "Safety rules".

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2.3 Requirements for the operator's workplace.
The user is obliged to create working conditions at the cutter workplace that preclude
the operator from slipping, slipping or falling due to poor ground conditions, the way
of routing the wires or the lack of convenient access!
2.3.1 Personal protection equipment
If necessary or if it results from the regulations in force, use the following personal protective
equipment:
•Wear safety shoes
•Wear safety goggles - eg when cutting fragile material
•Use hearing protection - eg when cutting hard material
2.3.2 Permissible environmental and operational conditions
•Operation of the machine is permitted in closed rooms
•Humidity: 35% - 95% (non-condensed)
•Ambient air temperature: + 5 ° C - + 30 ° C
2.4 Expected risks when operating the cutter
Using the single cutter as intended, you can predict some of the risks to your life and
health. To avoid existing hazards, the rules of using and operating the cutter must be
explained in detail. Special attention should be paid to the cutter units and situations
posing a threat to the operator and third parties:
DANGER!
The operator can operate the machine in good technical condition.
At the beginning of each work shift and after each knife replacement, check the operation of
the safety devices. Interference in security or bypassing them (eg safety light curtains, two-
handed controls) creates a danger to life or injury!
At the moment, the cutter can only support one operator!
The operator himself must also make sure that the machine is not operated by unauthorized
persons!

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Table 2. List of threats occurring while operating the cutter
Lp.
Factor and / or dangerous place
Type of threat
I
Mechanical hazards
1
Motor, belt drive mechanism of the pressure
beam drive
Rapture, crush
2
Motor, belt drive for the backguage drive
mechanism
Rapture, crush
3
Motor, belt drive for the knife drive mechanism
Rapture, crush
4
Pressing movement of the pressure beam
Crush
5
Approach move of the backguage
Crush
6
Cutting zone
Cut off, cut
7
Manipulation with a knife during the change
Cut off, cut
8
The edges and corners of the cutter elements
Cut
9
Surfaces
Chipping, clash
II
Electrical hazards
1
Direct touch
Electric shock
2.5 Description and evaluation of residual risk
Intimus International GmbH takes responsibility for the construction of the cutter in order to
eliminate the danger, although some risk elements during the cutting machine operation are
possible. Residual risk resulting from incorrect behavior of the cutter operator.
•Failure to follow the safety rules described in the operating instructions
•Using the cutter for other purposes than those described in the user's manual
•Staying unauthorized persons, especially children, when cutting on the
machine
•Unauthorized making any alterations
•Cleaning and lubrication of the cutter during operation
•Work with dismantled or defective covers
•Manipulation within the drive units and moving parts of the cutter during
operation
•Checking the cutter's technical condition and performing servicing or repairs
with the cutting machine
•Checking transmission gears during operation

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When presenting the residual risk, the cutter is treated as a device that was
designed and manufactured according to the state of the art in the year of its
manufacture.
Residual risk assessment
When following such recommendations as:
•Comply with the safety rules described in the operating instructions
•Careful reading of the operating instructions
•It is forbidden to put your hands in dangerous and forbidden places
•It is forbidden to make any alterations on your own
•Prohibition of the cutter in the presence of unauthorized persons, especially children
•No modification of the software of programmable control systems
•Maintenance and repair of the cutter only by suitably trained persons
•Operating the cutter by persons who have been previously trained and read the
operating instructions
•Cutter protection against access of children residual threats can be eliminated.
2.6 Safety systems used in the cutter
•Two-handed protective device - the cut is released by the two-handed cut start
system
•Non-contact protection device - an optoelectronic device that creates a safety
curtain
•Cam device - a device that controls the knife stop in the upper position.

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2.7 Ways to prevent threats
9
Figure 3. Arrangement of covers and protective elements
Table 3. Safety measures used to eliminate hazards (according to Figure 3)
1.
Factors and / or dangerous
places Security measures
Identification
I
MECHANICAL
1.
The lever assembly
mechanism of the pressure
beam drive
fixed cover
Emergency stop
1, 3, 4
10
2.
Motor, belt drive mechanism
of the pressure beam drive
fixed cover
Emergency stop
3, 4
10
3.
The belt drive for the drive
mechanism of the backguage
beam
fixed cover
front table
emergency switch
3, 4
2
10

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4.
The screw mechanism of the
backguage drive
cutter body
fixed cover
2
6
5.
Motor, lever mechanism of
the knife drive mechanism
fixed cover
front table
Emergency stop
3, 4, 1
2
10
6.
Approach move of the
clamping beam
fixed cover
electro sensitive
protective device
two-handed device −Emergency stop
1
7
5
10
7.
Approach move of
backguage
fixed cover
Emergency stop
6
10
8.
Cutting zone
two-handed device
electro sensitive protective device
cam device that monitors the knife
stop at the upper turning point
Emergency switch
5
7
9
10
9.
Manipulation with a knife
during its replacement
transport handles
special protective packaging
10.
Sharp edges and corners of
the cutter elements
refraction, dullness, rounding
11.
Uneven or rough surfaces
precise workpiece machining
paint coatings
II
ELECTRICAL
1.
Direct contact of active
elements
closed housing
partially reduced voltage supply to the
control system up to 24V AC/DC.
3,4
2 Indirect touch
protection against indirect contact
according to PN-EN 60204-1
continuity of the protective conductor
2.8 Safe working rules
1. training of the operator:
• aware of the potential hazards that may occur when operating the cutter
• clearly defining activities which, under the conditions of a given plant, are or are not the
responsibility of the cutter operator and are reserved for designated authorized persons, in
particular as regards the removal of defects and repairs - including electrical installations.
2. prohibition to use the cutter if:
• the machine is used contrary to its intended use and/or the cutting parameters specified in
the operating instructions would be exceeded
• the cutter is visibly inefficient
• any covers of moving parts have been removed from the cutter

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3. order:
• Checking the correctness of the protection devices:
- two-handed control (each time before starting work)
- contactless protective device (each time before starting work)
• order to carry out maintenance and repairs with disconnected electrical power
The above-mentioned requirements should be the subject of training and the content
of the station instructions!
2.9 Safety control
Periodic security check should be carried out in accordance with the law. These provisions
concern:
•accident prevention
•guarantee of efficient work and precision of operation
•eliminating production stoppages.
Info
At the latest after 5 years of use, at least control of the following functions should
be carried out and the results should be documented.
•operation of the control function
•check the correct position of the knife
•control of the power supply of the cutter linear indicator
•operation of the safety curtain
•operation of the two-hand control function
•protection against continuous knife movement.
The above mentioned service should be ordered by the cutter manufacturer's
technical service.

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3.TRANSPORT AND STORAGE
3.1 Packaging
3.1.1 Package characteristic
The transport packaging used is a disposable packaging. The transport platform is made of
wood and the outer packaging is made of cardboard. Inside the box the cutter and
accessories are packed in anti-corrosion covers made of plastic and oiled paper.
3.1.2 Package removal
Used packaging should be removed in accordance with legal regulations applicable in the
country of the user.
3.2 Transport
The box with the machine should be transported in accordance with the markings on it (fig.4).
When using a forklift (Fig. 5a), make sure that the fork length is suitable so that you can
grasp the entire depth of the box.
Figure 4. Cutter in a transport crate.

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Figure 5a. Transporting the cutter in the crate using a forklift.
Figure 5b. Transporting cutters with a pallet truck
3.3 Delivery status
The cutter can be supplied by the manufacturer:
•completely assembled and ready for use (Fig. 6a).
•with disassembled side tables, assembly of tables according to Figure 6b.
•with unfolded base and disassembled side tables, (non-standard equipment), assembly
according to figures 6b and 6c

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Figure 6a. Cutter without side tables
Figure 6b. Tightening of the side tables
1. Left side table + M8x25 screw (4 pieces) + washer 8 (4 pieces)
2. Right side table + M8x25 screw (4 pcs.) + 8 washer (4 pcs.)
3. Left photocell + M8x25 screw (4 pcs) + washer 8 (4 pcs) + M8 nut (4 pcs)
4. Right photocell + M8x25 screw (4 pcs.) + 8 washer (4 pcs.) + M8 nut (4 pcs.)