ITW Transtech AERO 60 User manual

Release 1.0 PAGE 1
AERO 60/90 2 COLOR
Release 1.02 as of 12/2013
REV 1 - #000 – 0000
Operation
Manual
Trusted Partner for Your Product Decorating Needs
Trans Tech 475 North Gary Avenue, Carol Stream, IL 60188
Tel [phone] Fax [phone]
Email [email protected]
www.itwtranstech.com www.itwids.com
A MEMBER OF

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This pad printer is a very versatile machine. The printer on the left
contains the master control and the printer on the right is the “drone”. The
pneumatic shuttle unit will move the product from the first print position to the
second print position and then return to the first print position with each cycle
of the system.
Due to the versatility of this printer, there are quite a number of screens
in the HMI (Human Machine Interface) which allow you to achieve the most
optimum setup for the job at hand. The operational descriptions of these
various screens presented in this manual, will guide you to solving the pad
printing challenges of your decorating application.
It is very important to remember that our highly experienced staff is
only a phone call away at 630-752-4000 to be of assistance. Please don’t
hesitate to call if the need arises.

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AERO 60/90 2 COLOR ............................................................ 1
1.1. ................................................................................................................................. Safety------ 5
1.1.1 .......................................................................................... Symbols and their Interpretations -----------5
1.1.2 .................................................................................................................................. Liability -----------5
1.1.3 ......................................................................................................... Warnings and Cautions -----------6
1.1.4 ......................................................................................................... Application Restrictions -----------6
1.2. ...................................................................................... Installation Instructions------ 7
1.2.1 ........................................................................................................... Selecting the location -----------7
1.2.2. ........................................................................................................... Connection to power -----------7
1.3. ....................................................... Description of SpaceFrame Tooling------ 8
1.3.1. ......................................................................... Installation of the Cliché and SpaceFrame -----------9
1.3.2 ............................................................................. Removal of the Cliché and SpaceFrame ---------10
1.3.3 ................................................................................................. Handling of the SpaceFrame ---------10
1.4. ..................................................................................... Main Operating Control---- 12
1.4.1 ........................................................................................................... POWER-UP - screens ---------12
1.4.2 ...................................................................................................................... MAIN - screen ---------13
1.4.3 ........................................................... MAIN SCREEN #2 (Accessed via the “Main Screen”) ---------14
1.4.4. .......................................................... SETUP – screen (Accessed via MAIN SCREEN #2) ---------15
1.4.5. ................................................................ CYCLE DELAY – screen (Accessed via SETUP) ---------16
1.4.6. .............................................................. BATCH COUNT – Screen (Accessed via SETUP) ---------17
1.4.7. ...................................................... SETUP CONTINUED – Screen (Accessed via SETUP) ---------19
1.4.8. ..................................... SETUP MASTER – screen (Accessed via SETUP CONTINUED). ---------20
1.4.9. ....................... MASTER FRONT PAD DELAY – screen (Accessed via SETUP MASTER. ---------21
1.4.10 MASTER FRONT DOWN DWELL – screen (Accessed via MASTER FRONTPAD DELAY. -------22
1.4.11 .......................... MASTER REAR PAD DELAY screen (Accessed via SETUP MASTER). ---------23
1.4.12 ..................................... SETUP DRONE 1 screen. (Accessed via SETUP CONTINUED) ---------24
1.4.13 ................................... DRONE 1 FRONT PAD DELAY (Accessed via SETUP DRONE 1) ---------25
1.4.14 ...... DRONE 1 FRONT DOWN DWELL ( Accessed via (DRONE 1 FRONT PAD DELAY) ---------26
1.4.15 ..................................... DRONE 1 REAR PAD DELAY (Accessed via SETUP DRONE 1) ---------27
1.4.16 ............................ SETUP CONTINUED (Accessed from previous SETUP CONTINUED) ---------28
1.4.17 ................. CYCLE COUNTER SETUP (Accessed from previous “SETUP CONTINUED”) ---------29
1.4.18 ...................................... SELECT DEVICE TO JOG (Accessed via MAN (manual) button) ---------30
1.4.19 ................. MASTER MANUAL MODE (Accessed from the “SELECT DEVICE TO JOG”). ---------31

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1.4.20 ................ DRONE 1 MANUAL MODE (Accessed from the “SELECT DEVICE TO JOG”). ---------32
1.4.21 .............. SELECT DEVICE TO JOG (Accessed from the first SELECT DEVICE TO JOG) ---------33
1.4.22 ....... SHUTTLE MANUAL MODE (Accessed from the second SELECT DEVICE TO JOG) ---------34
1.4.23“PASSWORD ENTRY SCREEN” (Accessed from the MAINT (maintenance) button). See 1.3.3--35
1.4.24 ............................................................................................................. NUMERIC KEYPAD ---------36
1.4.25 ................................................ MAINTENANCE (Accessed from the NUMERIC KEYPAD) ---------37
1.3.26 .................... MAINTENANCE CONTINUED (Accessed from the MAINTENANCE screen. ---------38
1.4.27MAINTENANCE CONTINUED (Accessed via the other MAINTENANCE CONTINUED screen)---39
1.5. ....................................................................... Recommended Maintenance---- 40
1.6. ............................................................................Recommended spare parts---- 41
1.7. .......................................................................................... Mechanical Drawings---- 42
1.8. ................................................................................................ Electrical Drawings---- 48
1.9. ............................................................................................ Pneumatic Drawings---- 54

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1.1. Safety
1.1.1 Symbols and their Interpretations
WARNING Neglecting a safety instruction identified with the WARNING symbol may
lead to personal injury.
CAUTION Neglecting a safety instruction identified with the CAUTION symbol may
lead to property damage.
POINTER It is strongly recommended to observe instructions identified with a
POINTER symbol.
1.1.2 Liability
•
In no event will ITW TRANS TECH be responsible or liable for indirect or
consequential damages resulting from the use of this equipment.
•The information contained in this manual is subject to change due to
improvements in design.
•Though this document has been checked for inaccuracies, ITW TRANS
TECH does not assume responsibility for any errors contained herein.
•This manual is provided as an aid when operating the Aero 60/90 pad
printing machine. Prior to operation, it is strongly advised that the user be
thoroughly familiar with this manual.
•ITW TRANS TECH is not responsible or liable for any disadvantage
occurred for not following the operating instructions.
All operators must be sufficiently trained.

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1.1.3 Warnings and Cautions
•
Switch off main switch prior to connecting/disconnecting power.
•Disconnect power prior to opening the electrical enclosure.
Switch the MAIN DISCONNECT off and disconnect the power cord prior to working
on the electrical system.
1.1.4 Application Restrictions
Any use other than described in this manual may cause damage to the
equipment, personal injury or property damage.

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1.2. Installation Instructions
1.2.1 Selecting the location
Choose a well-ventilated area away from direct sunlight to install your pad printing
machine. The ideal conditions for the inks used in pad printing are approximately
20°C (68°F) and 40 - 60 % humidity.
Make sure the machine is positioned away from walls and other obstructions and
placed on a flat surface with all four feet properly adjusted and secured. The
guards, operating panel and other machine openings must be accessible. Ensure
adequate area for setup tooling and for storage of parts before and after printing.
Temperature Humidity
1.2.2. Connection to power
Automation Connection
Foot Switch Connectoion
Auxiliary E-Stop
Connection
Power Connection
Air Connection
Pad ram speed adjustments
(4 on each printer)

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1.3. Description of SpaceFrame Tooling
Illustration 2-1. Cliché assembly device
Bill of Materials for SpaceFrame Assembly
No. Description 90 cup Part number 60 cup Part number
1 Setup Table 9901-30-001 9901-31-001
2 ExpressLiner 9260-20-004 (std)
9260-20-005 (tall) 9260-10-004
3 SpaceFrame 9260-26-100 9260-16-100
4 Magnetic Cup Clamp 9901-30-002 9901-31-002
5 Cliché Contact Trans Tech Contact Trans Tech
6 Carbide Doctor Ring 10902002 9260-20-003
7 Ceramic Doctor Ring 10903003 9260-10-003
1
2
2,3,6,(7)
4
5

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1.3.1. Installation of the Cliché and SpaceFrame
Illustration 2-2. SpaceFrame assembled on assembly table
When preparing the SpaceFrame to be placed into the machine for printing, proceed as described in
the following instruction:
1. Insert both ‘MAGNETIC CUP CLAMPS’ with the top down into the ‘SETUP TABLE’ (1) Tighten thumb screws
snuggly to retain clamps.
2. Place the ExpressLiner /Doctor Ring assembly with the opening up into the SpaceFrame (3)
3. Place SpaceFrame
assembly into ‘MAGNETIC CUP CLAMPS’ with both dowel pins engaged into the receiver
pockets of the cup.
4. Fill ExpressLiner (2) with ink to desired fill level.
5. Place the ‘CLICHÉ’ carefully with the image facing down. Slide cliché back until it is located firmly against the
back and side stops on the ‘SETUP TABLE’
6. Loosen the thumb screws and carefully lift the SpaceFrame/cliché assembly out of the SETUP TABLE
7. Turn the assembly over (the cliché is now on the bottom)
With the front guards open, slide the assembly into the Pad Printer.
8. Using a 4mm Allen wrench, tighten the cliché side locking device snugly. (do not over tighten)
Using a 4mm Allen wrench, rotate the cliché front clamp upward and tighten it. Again snugly.
9. Turn the clamping lever to clamp the SpaceFrame
Verify that the clamping fingers are properly engaged with the hold down ring
10. Remove the MAGNETIC CUP CLAMPS
11. Mount the pad onto the magnetic pad ram holding base
Thumb
Screw

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12. Close machine guard
The machine is ready to operate
1.3.2 Removal of the Cliché and SpaceFrame
When removing the SpaceFrame from the machine, proceed as described in the following instruction:
1. Stop the printer via the ‘STOP’ button in the ‘HOME’ position (Pad up).
2. Open the machine guard and remove pad
3. Place MAGNETIC CUP CLAMPS on the front and rear of the CUP
4. Loosen the cliché clamping screws and move the cliché clamp to clear the cliché
5. Turn the cup locking handle to lift the clamping fingers clear of the ‘HOLD DOWN
RING’ (3)
If the machine has been assembled for an extended period of time, accumulation
of ink may inhibit the removal of the cliché’. This may cause the SpaceFrame to
pull free from the cliché’ and to spill the ink. Verify that the cliché’ and
SpaceFrame slide out together!
6. Draw the cup/cliché assembly out of the machine and turn it over with the SpaceFrame
facing down
7. Set assembly into the ‘SETUP TABLE’ (1) and tighten the thumb screws
8. Carefully slide the cliché off the SpaceFrame.
If the printing machine will not be in operation for an extended time, it is
recommended that the cup and plate be removed from the machine. Ink in
contact with the printing plate for extended periods of time, can cause damage
to the printing plate. (This practice does vary based on the type of ink and or
thinner used.
1.3.3 Handling of the SpaceFrame
•
Always protect the doctor ring in the SpaceFrame from being damaged
•When not in use, place cup assembled with the cliché and clamped with the
‘CLAMPING TOOL’ (4) in the ‘SETUP TABLE (1)’ as shown in illustration 2.2
•If stored separately, place the SpaceFrame in the protective plastic container
•Rotate the cup frequently (steel cliché 2 hrs., polymer cliché 1 hr.) while in operation

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WARNING
The doctor ring has a very sharp edge that may cause personal injury if
improperly handled.
PLEASE HANDLE WITH CAUTION!

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1.4. Main Operating Control
1.4.1 POWER-UP - screens
These screens will appear when power is applied to the printer and will remain visible until the
servo motors have completed their “homing” action. Depending upon whether an E-Stop was
active at the time of power-up, one or both of these screens will appear.

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1.4.2 MAIN - screen
“PRINT MODE” (button dark) – Indicates that the machine is set to print when cycled.
“SINGLE CYCLE” (button light) – Indicates that the machine is set to complete one cycle when started.
(button dark) – Indicates that the machine is set to repeat the print cycle continuously
once started.
“DCTR MODE” (button dark) – Indicates that the machine is set to doctor (run the SpaceFrame back and
forth) continuously, thus doctoring the image, when started
“READY” – This area at the top of the screen indicates the current status/mode of the machine.
“CYCLE START” – This area at the bottom of the screen when touched, will start the machine cycle.
(NOTE: When continuous cycling is selected this button will display “STOP” which
When pressed, will cause the machine to complete the current print/doctor cycle
and then stop.
“L” – This square box to the left of the bottom message display indicates if the left part has been detected
via a vacuum switch if the VAC function has been enabled in the Maintenance Screen.
“R” – This square box to the right of the bottom message display indicates if the right part has been
detected via a vacuum switch if the VAC function has been enabled in the Maintenance Screen.
“RIGHT ARROW” – When touched, will present another screen (Screen #2) with additional options.

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1.4.3 MAIN SCREEN #2 (Accessed via the “Main Screen”)
“LEFT ARROW” – When touched, will be taken back to the “MAIN” screen.
“SETUP” – When touched, will present another screen.
“MAN” (Manual mode) – When touched, will present another screen.
“MAINT” (Maintenance) – When touched, will present another screen.

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1.4.4. SETUP – screen (Accessed via MAIN SCREEN #2)
“CYCLE DELAY” – When touched, will present another screen.
“BATCH COUNT” – When touched, will present another screen.
“VAC PULSE” – When touched, will present another screen.
“LEFT ARROW” – When touched, will return to “SCREEN #2”
“RIGHT ARROW” – When touched, will present another screen.
“MAIN” – When touched, will be taken to the “Main” screen.

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1.4.5. CYCLE DELAY – screen (Accessed via SETUP)
The setting in this screen is functional when running in the “Auto Cycle” mode. It adds a delay to
when the next cycle starts.
Touching the data field causes a numeric keypad to appear whereby a time value in fractions of a
second can be entered.
“LEFT ARROW” – When touched, returns you to the “SETUP” screen.
“MAIN” – When touched, will be taken to the “MAIN” screen.

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1.4.6. BATCH COUNT – Screen (Accessed via SETUP)
“OFF”(light)/”ON”(dark) – Selects the batch counter to be active. Once the number
Machine cycles has been reached, the counter must be
reset or turned off to allow the machine to be cycled.
“RESET” – When touched, will reset the count of elapsed cycles to be reset to “0” (zero).
“CURNT” (CURRENT) – When the batch counter is active, this displays the count of completed
cycles.
“SETPNT (SET POINT) – To set the number of batch count cycles, touching the data field will
cause a numeric keypad to appear whereby a value can be entered.
See 1.3.24 (the maximum cycle count which can be entered is 9999)
“LEFT ARROW” – When touched, returns you to the “SETUP” screen.
“MAIN” – When touched, will be taken to the “MAIN” screen.

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1.4.6.1 VACUUM PULSE - Screen (Accessed via SETUP)
The setting in this screen is functional when the cycle ends. It turns on output Y1 for the duration
of the inputted time.
Touching the data field causes a numeric keypad to appear whereby a time value in fractions of a
second can be entered.
“LEFT ARROW” – When touched, returns you to the “SETUP” screen.
“MAIN” – When touched, will be taken to the “MAIN” screen.

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1.4.7.SETUP CONTINUED – Screen (Accessed via SETUP)
“MSTR” (MASTER) – When touched, will present another screen.
“DRONE 1” – When touched, will present another screen.
“LEFT ARROW” – When touched, returns you to the “SETUP” screen.
“RIGHT ARROW” – When touched, will present another screen.
“MAIN” – When touched, will be taken to the “MAIN” screen.

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1.4.8. SETUP MASTER – screen (Accessed via SETUP
CONTINUED).
“FRONT DELAY” – When touched, will present another screen.
“REAR DELAY” – When touched, will present another screen.
“1 HITS (2,3,4)” – When touched, will change the number of hits (prints (4 max))
“LEFT ARROW” – When touched, returns you to the “SETUP CONTINUED” screen.
“MAIN” – When touched, will be taken to the “MAIN” screen.