Zünd S3 Series User manual

Operating Manual
S3 Digital Cutter

2
Keep it in a safe place for future use!
Original operating manual
Software/Firmware version: FW1.71
Creation date: 05-2019

Contents
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Contents
1 Introduction.......................................................................................................................................7
1.1 Using the operating manual.............................................................................................................8
1.2 Points to note when reading this operating manual.........................................................................9
1.3 Publishing details..............................................................................................................................9
2 Product description........................................................................................................................11
2.1 Important information about the product........................................................................................11
2.2 Orientation.......................................................................................................................................12
2.3 Product identification...................................................................................................................... 13
2.4 Intended use...................................................................................................................................13
2.5 Cutter overview...............................................................................................................................14
2.6 Modules, tools.................................................................................................................................16
2.7 Material handling............................................................................................................................ 21
2.8 Options............................................................................................................................................23
2.9 Accessories box..............................................................................................................................24
2.10 Technical description....................................................................................................................25
2.11 Technical data.............................................................................................................................. 27
3 Safety...............................................................................................................................................39
3.1 General........................................................................................................................................... 39
3.2 Proper use......................................................................................................................................39
3.3 Examples of reasonably predictable unintended use.....................................................................39
3.4 Hazard warnings, important instructions........................................................................................ 41
3.5 Areas of responsibility.................................................................................................................... 43
3.6 Personnel requirements..................................................................................................................43
3.7 Personal protective equipment.......................................................................................................44
3.8 Rules and occupational safety....................................................................................................... 45
3.9 Conduct in the event of malfunctions.............................................................................................45
3.10 Danger areas................................................................................................................................46
3.11 Warnings on the product..............................................................................................................49
3.12 Protective devices.........................................................................................................................51
3.13 Mechanical hazards......................................................................................................................55
3.14 Risk of burns................................................................................................................................ 56
3.15 Electrical hazard...........................................................................................................................56
3.16 Risks arising from the emission of toxic dust...............................................................................57
3.17 Risks arising from the processing of toxic materials/materials hazardous to health.....................57
3.18 Environmental hazards.................................................................................................................58
3.19 Handling and storage of chemicals..............................................................................................58
3.20 Risk of fire and explosion.............................................................................................................61
3.21 Danger from laser beam.............................................................................................................. 62
3.22 Safety instructions for the operating personnel............................................................................62
3.23 Safety precautions for service personnel.....................................................................................63
3.24 Disposal........................................................................................................................................ 63
4 Controls and operation..................................................................................................................65
4.1 Safe working practices................................................................................................................... 65
4.2 Controls...........................................................................................................................................66
4.3 Menu navigation............................................................................................................................. 72
4.4 Menus and functions...................................................................................................................... 73

Contents
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4.5 General settings..............................................................................................................................75
4.6 User level........................................................................................................................................76
4.7 Malfunctions....................................................................................................................................78
4.8 Daily checks prior to start-up......................................................................................................... 81
4.9 Behavior in dangerous situations...................................................................................................81
4.10 Start-up......................................................................................................................................... 83
4.11 operating mode.............................................................................................................................85
4.12 Moving the beam/module manually..............................................................................................87
4.13 Handling modules/tools.................................................................................................................88
4.14 Material fixing..............................................................................................................................102
4.15 Material transport (optional)........................................................................................................110
4.16 Automatic tool initialization - AKI (optional)................................................................................114
4.17 Job processes.............................................................................................................................119
4.18 Film handling.............................................................................................................................. 124
4.19 Laser pointer, reference point (optional).................................................................................... 126
4.20 ICC camera, automatic registration (optional)............................................................................129
4.21 Module carriage slot protective plate......................................................................................... 132
4.22 Signal lights (optional)................................................................................................................133
5 Tips for cutting.............................................................................................................................135
5.1 Select tool.....................................................................................................................................135
5.2 Selecting a blade..........................................................................................................................135
5.3 Preparing cutting data.................................................................................................................. 142
5.4 Settings, speed, quality................................................................................................................ 142
5.5 Recognising processing errors.....................................................................................................144
5.6 Oscillating cutting..........................................................................................................................154
5.7 Tips for increasing the rate of production.................................................................................... 156
5.8 Identifying and rectifying quality problems................................................................................... 156
6 Maintenance..................................................................................................................................159
6.1 Safe maintenance of the machine................................................................................................160
6.2 Tools, operating and auxiliary materials.......................................................................................160
6.3 Maintenance list for trained operating personnel.........................................................................164
6.4 Maintenance list for authorized service technicians.....................................................................166
6.5 Cutter maintenance mode............................................................................................................168
6.6 Service flaps and covers..............................................................................................................169
6.7 Visually inspecting the machine for damage................................................................................174
6.8 EMERGENCY STOP control devices function test......................................................................174
6.9 Cleaning the machine...................................................................................................................175
6.10 Cleaning the inside of the beam................................................................................................175
6.11 Cleaning the X axis guide rails.................................................................................................. 177
6.12 X axis, oiling the guide carriage.................................................................................................178
6.13 Clean/oil Y axis guide rails.........................................................................................................181
6.14 Cleaning the feeding clamps/feed guide rail..............................................................................181
6.15 Draining the maintenance unit condensate water......................................................................183
6.16 Resetting 12.5/14.0 kW vacuum pump motor protection relay...................................................184
6.17 Reset 2.2/2.55 kW, 4.0/4.6 kW, 5.5/6.3 kW vacuum pump, motor protection relay....................185
6.18 Replacing the conveyor belt.......................................................................................................186
6.19 ICC camera, cleaning the lens (optional)...................................................................................204
6.20 Instructions for disposal..............................................................................................................205
6.21 Starting up after periods of standstill..........................................................................................206
7 Tools..............................................................................................................................................207

Contents
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8 Modules.........................................................................................................................................209
9 Material handling..........................................................................................................................211
10 Additional specifications...........................................................................................................213

Contents
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Introduction
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1 Introduction
Dear customer,
With your decision to purchase our product you are participating in the worldwide success of Zünd
cutter systems.
The modular design of our systems provides the following benefits, among others things:
• A system solution that meets your individual requirements in terms of speed and quality.
• The availability of the most up-to-date technology thanks to continuous development.
Our approach
Constant and intensive cooperation with experienced users is essential for developing innovative
and practical solutions. We are therefore grateful for any comments or suggestions on how we can
improve.
Contact
Zünd Systemtechnik AG
Industriestrasse 8
CH - 9450 Altstätten
Tel: [phone]
[email protected]
www.zund.com

Introduction
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1.1 Using the operating manual
The supplied operating manual is intended to enable you to operate the machine safely, perform
routine maintenance and use the machine optimally in every way.
To do this, you need to be able to find what you need in the documentation.
Scope of the operating manual
Volume 1 - Operating instructions
This volume contains information on engineering, commissioning, operation
and maintenance of the machine.
Volume 2 - Service manual
This volume contains information on the design of the machine and on
servicing by authorized service technicians. The service manual is not included
in the scope of delivery of the machine.
Spare parts catalog
The spare parts catalog is not included in the scope of delivery of the machine.
Structure of the operating instructions
The operating instructions consist of separate sections, which are numbered consecutively and
arranged according to the ring binder tabs.
The table of contents provides information on the structure of the individual sections.
Indication of optional accessories
There are many optional accessories available for the machine. Descriptions of optional additional
equipment are labeled in the operating manual with the wording (optional) .
Safekeeping of the documentation
Always keep Volume 1 of the "User manual" close at hand in the vicinity of the workstation.
Current status of the documentation
In order to ensure that the operating manual always remains complete and up to date, the following
must be observed:
• Do not remove individual documents.
• Request copies of missing or illegible pages from the manufacturer, or download them from the
Zünd homepage and print them out.
• If any new documentation is provided as a result of conversions, add it immediately.
• Replace changed documents and destroy the old version.
• If the documentation exists in more than one language, ensure that all languages are kept up to
date.

Introduction
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1.2 Points to note when reading this operating manual
Text references
Chapter headings are numbered consecutively in the chapters, with the first figure corresponding
to the chapter number. Where reference is made to sections outside the current chapter, note the
first figure and turn to the corresponding chapter, which contains the cited section. See chapter 2.4
Cutter; overview, for example, leads to chapter 2 Product description, which contains section 4 Cutter
overview.
Block diagrams and simplified representation
Note that all representations are provided for general information and do not necessarily correspond to
the latest version of the machine.
Dimensional information
Dimensional information is listed in the SI/US units, depending on the installation site.
1.3 Publishing details
Designation
Operating instructions for S3 series cutters.
Layout, illustration, and print
Zünd Systemtechnik AG - Technical Communications Department
©Copyright
Zünd Systemtechnik AG

Introduction
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Product description
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2 Product description
This chapter contains information on the following:
• Representation conventions in the operating manual
• Usage possibilities of the machine
• Structure of the main components
• Important technical data
• General technical description of the machine
2.1 Important information about the product
Tip:
"Tip" refers to useful information which enhances the usability and prolongs the service life of the
machine or makes the work process significantly easier.
Tip:
With tips combined with the sheet we give you usage tips and useful information which can
improve the energy efficiency of the machine or optimize its environmental effects.
Important:
Usage tips and important machine operating information are labeled with Important.

Product description
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2.2 Orientation
Directions such as "right, left" or "front, back" relate to the operator's view of the machine during
operation.
1 front
2 rear
3 right
4 left
X X-axis
Y Y axis

Product description
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2.3 Product identification
2.3.1 Rating plate
1 Position of the signs 10 Year of manufacture
2 Rating plate 11 Serial number
3 Additional UL sign 12 UL mark of conformity
4 Additional connection values 13 Nominal voltage
5 Additional FCC sign 14 Rated current
6 CE mark of conformity 15 Frequency
7 UL functional safety 16 Nominal voltage
8 Product name 17 Current consumption
9 Type designation 18 Frequency
2.4 Intended use
The cutter system can be used for the following purposes:
• As an output station for CAD/CAM data.
• For processing and labeling of materials.
The intended use and the usage restrictions are also dependent on the available tool and material
transport system, which are described in the "Tools", "Modules" and "Material handling" chapters.

Product description
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2.5 Cutter overview

Product description
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1 Air supply to maintenance units
2 Beam
3 Tool/module power supply
4 Extractor
5 Workstation
6 Control panel with optional workstation
7 Vacuum pump
8 Working area

Product description
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2.6 Modules, tools
Zünd cutters are highly specialized and can be easily converted to process other materials through the
use of modules and tools.
Two modules can be attached to slots 1 and 2 on the module carriage as standard. Either an
electrically or pneumatically driven marking module can be installed in slot 3 (MAM-SP, MAM-SE).
Tip:
You can find detailed information in section Handling modules/tools on page 88 as well as in
the individual operating manuals of your modules and tools.
1 Module (e.g., KCM-S, UM-S)
2 Tool (e.g. CT, UCT, EOT, POT)
3 Tool insert: router, blade, pen

Product description
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2.6.1 Universal applications
Universal modules - UM-S
Universally applicable carrier module for a wide range of tools.
Tools for use in the UM
Electric Oscillating Tool - EOT
Cutting tool with high oscillation frequency for soft and medium hard
materials.
Electric Oscillating Tool - EOT-250
Robust tool with high-performance electric drive for processing thick
cardboard and leather materials.
Pneumatic Oscillating Tool - POT
Powerful cutting tool with large oscillation stroke for hard and tough
materials of up to 50 mm thickness.
Driven Rotary Tool - DRT
Tool for technically demanding textiles and textile materials. The powered
rotary knife enables a very high processing speed.
Universal Cutting Tool - UCT
Universally usable cutting tool for materials of up to 5 mm thickness.

Product description
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Scoring Cutting Tool - SCT
Combination tool for scoring and cutting cardboard and coating blankets of
up to 5 mm material thickness.
V-Cut Tool - VCT
Tool with five different cutting angles. Creation of complex 3D
constructions from high expansion foam or sandwich boards.
Passepartout Tool - PPT
Exact 45° oblique cuts in constantly high quality.
Perforating Tool - PTT1
Ideal tool for creating precise perforations in corrugated cardboard, solid
board, polypropylene, and foil.
Kiss Cutting Tool - KCT
Kiss-Cutting tool with adjustable pressing pressure for the processing of
numerous vinyl materials.
Universal Routing Tool - URT
Cost-effective routing and engraving tool.
Creasing Tools - CTT1/2
Creasing of various types of materials. The pressing pressure is
separately adjustable laterally and longitudinally along the shaft.
Universal Drawing Tool - UDT
Drawing tool for the use of standard commercial leads in various line
thicknesses.
Raster Braille Tool - RBT
Efficient procedure for the creation of tactile Braille markings (for the
blind).

Product description
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2.6.2 Routing, engraving:
Router modules - RM-S
Universally usable routing system, fitted with a powerful high
frequency spindle.
• Routing depth up to 25 mm
• Effective dust extraction, actively air-cooled
• Surface compensation for precise depth setting
• Optional Minimal Quantity Lubrication- MQL for
processing soft aluminum alloys
• 1 kW high-frequency spindle for very high processing
speeds
Tools for use in the RM-S
HF motor spindle 4040 DC-SZ
Motor spindle with 1000 W and manual roll pin.
2.6.3 Punching, perforating
Punch and Pricking Module - PPM-S: Combined high-performance
tool for perforating and punching leather, rubber and textile materials
with up to 8 holes per second. A punching spike is integrated.

Product description
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Punch and Pricking Module - PPM-S: High-performance tool for
perforating leather, rubber and textile materials with up to 8 holes per
second. A marking tool is integrated.
2.6.4 Kiss-cutting
Kiss-cut module - KCM-S
KCM-S: This module cuts films with the highest precision and processing
speed without damaging the carrier material.