Markem Imaje DigiConvert MC004-2014 P1082 User manual

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Markem Imaje CSAT GmbH
DigiConvert
Mach. no. MC004-2014
P1082
Operating Instructions
© Feldbaum + Vogt GmbH
Dieselstr. 12
32791 Lage
Germany
Version modifications:
Version
Date
Name
Comments
1.0
Wiens

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Contents
1. MACHINE........................................................................................................................................ 4
2. FIELD OF APPLICATION............................................................................................................... 4
3. MACHINE SPECIFICATION........................................................................................................... 4
4. WARNINGS AND SAFETY INSTRUCTIONS ................................................................................ 5
4.1. GENERAL INFORMATION ................................................................................... 5
4.2. CONTACT FOR SALES,MAINTENANCE AND HELP ............................................... 5
4.3. SKILLED PERSONNEL....................................................................................... 6
4.4. UTILISATION.................................................................................................... 6
4.5. WARNING OF RESIDUAL RISKS .......................................................................... 6
4.6. MAINTENANCE INSTRUCTIONS........................................................................... 7
5. INSTALLATION AND STARTUP ................................................................................................... 7
5.1. INSTALLATION ................................................................................................. 7
5.2. STARTUP ........................................................................................................ 7
6. INTRODUCTION............................................................................................................................. 8
6.1. FUNDAMENTALS OF DRIVE ENGINEERING........................................................... 8
6.2. OPERATOR TERMINAL...................................................................................... 9
6.2.1. MAIN OPERATOR TERMINAL ........................................................................ 9
6.3. WARNING LIGHT SYSTEM FOR THE ENTIRE MACHINE........................................ 10
7. SAFETY FUNCTIONS .................................................................................................................. 11
7.1. SAFETY HOODS............................................................................................. 11
7.2. EMERGENCY STOP FUNCTION......................................................................... 12
7.2.1. TRIGGERING EMERGENCY STOP............................................................... 12
7.2.2. ACKNOWLEDGING EMERGENCY STOP ....................................................... 12
8. OPERATING THE MACHINE....................................................................................................... 13
8.1. SWITCHING ON THE SYSTEM ........................................................................... 13
8.2. OPERATIONAL CONCEPT................................................................................ 13
8.2.1. GENERAL OPERATION.............................................................................. 13
8.2.2. ICONS AND COLOURS............................................................................... 14
8.2.3. LATERAL EDGE CONTROL ........................................................................ 14
8.3. MACHINE CONTROL BUTTONS,MACHINE STATUS............................................ 15
8.4. SWITCHING OFF THE SYSTEM.......................................................................... 17
9. MENU STRUCTURE..................................................................................................................... 18
9.1. WELCOME SCREEN........................................................................................ 18
9.2. MACHINE OVERVIEW...................................................................................... 19
9.3. CHANGE OF OPERATOR.................................................................................. 28
9.4. DRIVE VALUES TREND DIAGRAM ...................................................................... 29
9.5. MACHINE SETTINGS AND JOB MEMORY........................................................... 30
9.6. QUICK OPERATION ........................................................................................ 37
9.7. REGISTER REGULATOR TREND DIAGRAM ........................................................ 39
9.8. ALARMS –HISTORICAL VIEW.......................................................................... 41

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9.8.1. ALARMS FROM INDIVIDUAL AXES............................................................... 42
9.9. SYSTEM DIAGNOSIS....................................................................................... 43
9.10. GENERAL MACHINE INFORMATION ............................................................... 44
9.11. HELP......................................................................................................... 45
10. ERROR MESSAGES AND WARNINGS .................................................................................. 46
11. OPERATING THE ASSEMBLIES............................................................................................. 47
11.1. REELER..................................................................................................... 47
11.1.1. REELER MAIN MENU STANDARD REELER............................................... 47
11.1.2. REELER SUBMENU REELER................................................................... 50
11.1.3. CONFIGURATION MENU ........................................................................ 54
11.2. LONGITUDINAL CUTTER,TRANSLATIVE PULL AND MATRIX REMOVAL ............. 56
11.2.1. MAIN MENU ......................................................................................... 56
11.2.2. MENU SMO LONGITUDINAL CUTTER....................................................... 58
11.3. PUNCHING STATION .................................................................................... 61
11.3.1. GENERAL INFORMATION ABOUT THE PUNCHING STATION ........................ 61
11.3.2. MAIN MENU ......................................................................................... 62
11.3.3. PUNCH SUBMENU................................................................................. 65
11.4. TRANSLATIVE COMPENSATION..................................................................... 68
11.4.1. MAIN MENU ......................................................................................... 68
11.5. WEB STORAGE .......................................................................................... 70
11.5.1. MAIN MENU ......................................................................................... 70
11.6. LABEL DELIVERY........................................................................................ 72
11.6.1. MAIN MENU......................................................................................... 72
11.7. COUNTING FUNCTIONS MAIN MENU ............................................................. 74
12. MAINTENANCE INSTRUCTIONS............................................................................................ 77
13. FIGURES................................................................................................................................... 79

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1. Machine
Fig.: 1 Machine overview
2. Field of Application
The main focus of the manufactured products is on punching, cutting and winding up material webs.
3. Machine Specification
Type
DigiConvert
Machine speed
1 m/min ... max. 50 m/min
Machine speed (translative)
1 m/min ... max. 40 m/min
Safe machine speed
1 m/min ... max. 5 m/min
Web tension
max. 250 N m (± 5% with acceleration)
Web width
22 ... 230mm
Cylinder length
mm
Gearing
1/8 in c.p.
Reeler core diameter of tensioning shaft
3 in / 76.20 mm
Reeler, max. diameter
400 mm
Matrix reeler, max. diameter
600 mm
Compressed-air supply building side
6 bars
Sound-pressure level
< 75 dB(A)

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4. Warnings and Safety Instructions
4.1. General information
These operating instructions describe all functions and procedures that are necessary for a safe and
proper operation of the machine.
To ensure a precise and faultless utilisation of the machine, please make yourself familiar with the
operating instructions before you start operation.
Only instructed skilled personnel are allowed to operate and maintain the machine.
Ensure that all persons who work on the machine have access to these operating instructions, and
that the specifications and instructions are observed and followed.
Please ensure that these operating instructions are always complete, without any missing pages, and
are in a good and readable state.
Operate the machine only if you are sure that it is in a safe and faultless state.
Comment:
Under certain conditions, incorrect parameter settings can have a negative effect on the tool station
and the entire machine. This is particularly important for the configuration parameters, which should
only be set and modified by skilled personnel who have been authorised for this work by Feldbaum +
Vogt GmbH, or by properly trained persons.
These critical parameters are password-protected. The corresponding chapters in these operating
instructions inform whether or not a parameter can be modified by the operator.
4.2. Contact for Sales, Maintenance and Help
Feldbaum + Vogt GmbH
Dieselstr. 12
32791 Lage
Phone: [phone]
Fax: [phone]

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4.3. Skilled Personnel
The person who is responsible for the overall system is obliged to delegate and entrust the operation
to skilled personnel.
In accordance with this documentation, these are persons who:
•Are familiar with the general safety and accident-prevention regulations.
•Are authorised to operate the system and are, in accordance with their training and
experience, familiar with the operating instructions and the applicable directives and
regulations.
4.4. Utilisation
Operate the system only in accordance with the descriptions in the documentation. Any exceptions
must explicitly be approved by Feldbaum + Vogt GmbH.
The system described in the documentation was developed, manufactured, tested and documented in
accordance with the valid safety directives. Under normal conditions, there should therefore not be
any danger to health or risk of material damage.
Proper transport, correct installation, and cautious operation and maintenance are prerequisites for
normal and safe operation of the system.
The system is intended to be used and operated in a closed building.
Certain configuration parameters can not be accessed by the machine operator and may not be
modified. Such parameters are password-protected. They may only be modified by skilled personnel
who have been authorised by Feldbaum + Vogt GmbH.
4.5. Warning of residual risks
As soon as you open the doors of the control cabinet or remove devices that protect against
accidental contact, you have access to certain system components that can carry dangerous voltage.
Only skilled personnel are allowed to access the system.
Danger of crushing and cutting!
The system controls moving machine components (such as punching tools and cylinders). Ensure that
no limb can get into the danger zone of such a machine component. This could cause severe injuries.
Please observe and follow always the valid safety and accident-prevention regulations that are
applicable when you operate the machine.

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4.6. Maintenance Instructions
Working on the system
Only personnel who have been authorised by Feldbaum + Vogt GmbH, or personnel who have been
adequately trained and instructed are allowed to repair or modify the system.
Improper maintenance or unauthorised opening of the control cabinet and its components can cause
severe injuries and/or significant material damage.
Only appropriately trained personnel are allowed to carry out the general maintenance work in
accordance with this documentation.
Under normal working conditions, the system components do not require any measures or
modifications. Changing the settings of the knobs underneath the control unit and the servo amplifier
front panel is not permitted. Any manipulation of these components has a direct and negative effect on
the system and possibly on higher-order machine components. As a result, there can be unpredictable
and dangerous situations.
5. Installation and Startup
This chapter contains instructions for initialisation and startup of the machine. The subchapters refer to
the corresponding applicable electrical circuit diagrams and mechanical drawings.
5.1. Installation
The electrical and mechanical modules must be installed in accordance with the valid regulations. All
work must be carried out by skilled personnel.
(See Chapter 4.3 Skilled Personnel).
5.2. Startup
Only service engineers who have been approved by Feldbaum + Vogt GmbH are authorised to
parameterise and start up the machine in agreement with special customer agreements in the current
setting.

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6. Introduction
6.1. Fundamentals of Drive Engineering
The following figure shows the basic components of an
electrical drive system:
Fig.: 2 Components of the Electrical Drive System
The machine (mechanical process) is driven by an electric motor. If necessary, the mechanical
coupling uses a mechanical gearbox to adjust speed and torque. The electrical drive converts
electrical energy into mechanical
energy (torque, force). To control the motor movements, a power converter converts the electrical
energy as required. A position encoder informs of the current position of the drive and the position of
the machine. The power converter receives its commands from a controller CPU. In this CPU, the
application program is executed that implements the required
sequence of movements.

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6.2. Operator Terminal
The entire system is controlled via the main control panel, that consists of a touch screen monitor and
several buttons.
Fig.: 3 Main Operator Terminal
6.2.1. Main operator terminal
The base functions, such as STOP, PREP, START, JOG, are activated by the buttons with these
inscriptions on the screen.
The key switch with the states "0" and "1" is used to enable configuration mode (SERVICE mode). In
configuration mode, you can make power-unit-specific settings and settings for the entire machine.
Only trained personnel are allowed to make these settings.
With the exception of the above-mentioned base functions, the entire machine is controlled via the
touchscreen monitor. All system components are represented graphically with corresponding icons.
An alarm menu transfers real-time information about the fault status of each individual drive.
Production data (speeds, web tensions) is interrogated and displayed continuously.
Once the system has been switched on, the operator can calibrate the touch screen monitor to ensure
that the console software can allocate all button activities correctly. Recalibrating the monitor is not
usually necessary. The calibration data is continuously saved in the console memory.
Use the following procedure if recalibration is necessary (if buttons can be pressed,
but no longer aligned):
•Start the system
•Inside the remaining time that is shown by the moving bar, press at any point on the monitor to
get to the calibration page.
•This displays little targets at various points. Press these points at the highest precision
possible.
•Calibration is completed when the original screen reappears.
•Calibration was not successful if the first target reappears.
•In this case, repeat calibration.

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6.3. Warning Light System for the Entire Machine
Signal column at the operator terminal
Status red
The red status means:
➢Blinking: EMERGENCY STOP mode active, acknowledgement with the emergency stop reset
button necessary
oThe blue lamp of the emergency stop reset button shines continuously
➢Permanently red: The machine is in STOP mode
Status yellow
The yellow status means:
➢Blinking: PREP status has not yet been reached
➢Permanently yellow: The machine is in PREP mode
Status green
The green status means:
➢Blinking: Although the machine is in START mode, it has not yet reached the desired speed.
➢Permanently green: The machine is in START mode, the desired speed is reached.