Manual 220444g Dcl2 550 Eng

USER MANUAL
Original Document
Original Document
Produced by
GRAFOTRONIC Sp. z o. o
Annopol 4A building E, 03-236 Warsaw, Poland
Telephone: +48 22 45 67 400, E-Mail: office@grafotronic.se
Person responsible for documentation: Service Engineer Hubert Kobyłka
Declaration of conformity
In accordance with directives 2006/42/EC, 2014/30/EU
Applicable harmonized standards:

EN 1010-3: 2004
EN 1034-1: 2003
EN 1034-3: 2012
EN 60204-1:2006 + A1:2009
EN 61000-3-11: 2000
EN 61000-3-12: 2011
DIN EN ISO 12100
DIN EN ISO 13849
EN 61310-1
We declare that:
Machine name: GRAFOTRONIC DCL2

Type: 550
Serial number: 220444G
AC: 3x400V+N+PE / 13kW
Weight: 3950kg
Year of production: 2022
complies with the applicable regulations:

Directives: 2006/42/EC , 2014/30/EU
The above declaration relating to the directives will be invalidated if the machine is converted or changed
without our consent.
01st-July-2022, Warsaw Vice President / CTO

Tomasz Skrobik
Original Document
Grafotronic Sp. Z.o.o. Phone: +46 (0) 418 567 00 Service Manager: Hubert Stasiński
Annopol 4a, building E
03-236 Warsaw, Poland E-mail: service@grafotronic.se E-mail: hust@grafotronic.se
www. grafotronic.se
manual 220444G DCL2 550 ENG 5
Table of content
1 General Information ................................................................................... 14
1.1. Introduction...................................................................................... 14
1.1.1. Correct use and storage of the user manual....................................... 14
1.1.2. Copyrights ............................................................................... 14
1.2. User manual format ............................................................................ 15
1.3. Manufacturer responsibility ................................................................... 15
2 Safety .................................................................................................... 16
2.1 Introduction...................................................................................... 16
2.2 Intended use of the machine ................................................................. 16
2.3 Intended use of the machine ................................................................. 16
2.4 Safety symbols .................................................................................. 17
2.5 Main dangers..................................................................................... 18
2.6 Dangers during machine operation .......................................................... 19
2.7 Dangers during repair and maintenance work ............................................. 20
2.8 Requirements for the operator and technical staff. ...................................... 21
2.9 Risk assessment manual ....................................................................... 22
3 Acceptance, positioning and lifting ................................................................. 23
3.1 Transport and acceptance of the machine ................................................. 23
3.2 Placing the machine in a designated, appropriate place ................................ 24
3.3 Machine positioning ............................................................................ 25
3.4 Levelling.......................................................................................... 26
3.5 Setting up modular machines. ................................................................ 27
3.6 Connection of the pneumatic system ....................................................... 30
3.7 Electrical Connection .......................................................................... 31
3.7.1 Connecting the machine to the Internet ........................................... 33
3.7.2 Maintenance of the electrical connection system ................................ 33
4 Technical data of the machine ...................................................................... 34
Grafotronic Sp. Z o. o. Phone: +48 22 45 67 400 Service Manager: Hubert Stasiński

Annopol 4a, building E,
www.grafotronic.se
5 Unwinding spindle ..................................................................................... 36
5.1 General information ............................................................................ 36
5.2 Operation ........................................................................................ 37
5.2.1 Tension force characteristics ........................................................ 39
5.2.2 Unwind direction ....................................................................... 40
5.3 Reel lifter ........................................................................................ 41
5.3.1 General .................................................................................. 41
5.3.2 Lifter remote ........................................................................... 42
5.4 Roll lifter ......................................................................................... 43
5.4.1 General .................................................................................. 43
5.4.2 Lifter remote ........................................................................... 44
5.4.3 Handling ................................................................................. 45
5.5 Decurler (optional) ............................................................................. 50
5.6 Flag and material splice sensor (optional).................................................. 51
5.6.1 Learning procedure .................................................................... 51
5.7 Maintenance of the unwinder station ....................................................... 52
5.8 Troubleshooting ................................................................................. 53
5.9 Risk assessment ................................................................................. 54
6 Web guiding and worktops ........................................................................... 55
6.2 Control of the machine ........................................................................ 56
7 Printing station ......................................................................................... 62
7.1 General Information ............................................................................ 62
7.2 Setting up the work station ................................................................... 66
7.3 Print adjustment ................................................................................ 70
7.4 Operation ........................................................................................ 72

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7.4.1 Setting work of register ............................................................... 75
7.4.2 Teaching the register pin sensor .................................................... 77
7.5 Lamination and Cold foil ...................................................................... 78
7.5.1 Lamination operation.................................................................. 82
7.6 GEW lamp ........................................................................................ 83
7.7 Setting the pressure of the system .......................................................... 84
7.8 Maintenance of the print module ............................................................ 85
7.10 Risk assessment .............................................................................. 87
8 BOBST printing station ................................................................................ 88
8.2 Setting up the work station ................................................................... 92
8.3 Print adjustment ................................................................................ 95
8.4 Operation ........................................................................................ 97
8.4.1 Setting work of register ............................................................. 100
8.4.2 Teaching the register pin sensor .................................................. 102
8.5 GEW lamp ...................................................................................... 103
8.6 Setting the pressure of the system ........................................................ 104
8.7 Maintenance of the print module .......................................................... 105
8.8 Troubleshooting ............................................................................... 106
8.9 Risk assessment ............................................................................... 107
9 Printing station ....................................................................................... 108
9.1 General Information .......................................................................... 108
9.2 Setting up the work station ................................................................. 112
9.3 Print adjustment .............................................................................. 116
9.4 Operation ...................................................................................... 118
9.4.1 Setting work of register pin ........................................................ 121

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9.5 Semi-rotary print ............................................................................. 124
9.5.1 Operation in the semi-rotary mode ............................................... 125
9.5.2 Cold foil semi-rotary mode ......................................................... 127
9.6 GEW lamp ...................................................................................... 129
9.7 Setting the pressure of the system ........................................................ 130
9.8 Lamination and Cold foil (optional) ....................................................... 131
9.8.1 Lamination operation................................................................ 135
9.9 Maintenance of the print module .......................................................... 136
9.10 Troubleshooting ........................................................................... 137
9.11 Risk assessment ............................................................................ 138
10 KELVA web cleaning system ........................................................................ 139
11 Delam / Relam ....................................................................................... 140
12 Grafotronic hot air dryer ........................................................................... 142
13 Missing label device ................................................................................. 143
13.1 Basic information .......................................................................... 143
13.2 Operation ................................................................................... 144
14 Turnbar ................................................................................................ 148
14.1 General information ...................................................................... 148
14.2 Operation ................................................................................... 148
15 Full rotary die cut station .......................................................................... 150
15.1 General Information ...................................................................... 150
15.2 Replacing magnetic cylinder ............................................................ 153
15.3 Menu die cutting station ................................................................. 156
15.4 Winding of matrix material .............................................................. 158
15.4.1 Operation .............................................................................. 159
16 Front-Loading die cutting station ................................................................. 161

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16.1 General ..................................................................................... 161
16.2 Preparing the station ..................................................................... 163
16.3 Replacing magnetic cylinder ............................................................ 164
16.4 Maintenance of the die cutting station ................................................ 165
16.5 Menu die cutting station ................................................................. 167
16.6.1 Operation .............................................................................. 169
16.7 Backscore knives .......................................................................... 171
16.7.1 Setting the job........................................................................ 172
16.9 Risk assessment ............................................................................ 174
17 Semi-rotary cut station ............................................................................. 175
17.2 Operation ................................................................................... 178
17.2.1 Manual die cutting plate loading .................................................. 182
17.2.2 Manual die cutting plate unloading ............................................... 185
17.2.3 Automatic unloading of the die .................................................... 186
17.2.4 Automatic die loading procedure.................................................. 191
17.2.5 Die cutting setting ................................................................... 196
17.2.6 Planning of the functioning of the register pin ................................. 197
17.2.8 Setting cutting in register pin ...................................................... 201
17.2.9 Control of the pressure of the system ............................................ 202
17.3.1 Operation .............................................................................. 204
17.4 Die cut station maintenance ............................................................ 207

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17.6 Risk assessment ............................................................................ 210
18 Sheeter with conveyor .............................................................................. 211
18.2 Operation ................................................................................... 214
18.2.1 Planning of the functioning of the register pin ................................. 218
18.2.3 Setting cutting flying saw mode ................................................... 222
18.2.4 Setting cutting in register .......................................................... 223
18.2.5 Knife replacement ................................................................... 224
18.3 Conveyor .................................................................................... 225
18.3.1 Dismantling the sheet table ........................................................ 226
18.4 Dance system (optional) ................................................................. 227
18.5 Station maintenance ...................................................................... 228
18.7 Risk assessment ............................................................................ 231
19 Digital cross perforation ............................................................................ 232
19.1.1 Operation .............................................................................. 233
19.1.2 Loading of the perforating die. .................................................... 235
19.1.3 Unloading the perforation die ..................................................... 235
20 Auto-set under/back scorer knives ............................................................... 236
21 Cutting section ....................................................................................... 238
21.2 Operation ................................................................................... 240
21.3 Razor blade insert (optional) ............................................................ 245
21.4 Razor knives on the idler................................................................. 248

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21.4.1 Construction of the station ......................................................... 248
21.4.2 Equipping razor knife stations ..................................................... 250
21.4.3 Razor knives operation on the web ............................................... 251
21.5 Vacuum system for edge trim removal (optional) ................................... 255
21.6 Maintenance of the knife station 6E ................................................... 256
22 Slitting station 6E .................................................................................... 258
22.2 Handling .................................................................................... 261
22.2.1 System pressure control ............................................................ 265
22.2.2 6E adaptation for razors ............................................................ 266
22.2.3 Razor blades in 6E station (optional) ............................................. 268
22.3 Maintenance of the knives station...................................................... 270
23 Cutting section ....................................................................................... 270
23.2 Operation ................................................................................... 272
23.3 Razor knives on the idler................................................................. 274
23.3.1 Construction of the station ......................................................... 274
23.3.2 Equipping razor knife stations ..................................................... 276
23.3.3 Razor knives operation on the web ............................................... 277
23.4 Maintenance of the crush knives ....................................................... 281
24 Sci-Fi Knives .......................................................................................... 283
24.2 Handling .................................................................................... 285

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24.2.1 System pressure control ............................................................ 288
24.3 Replacing knives ........................................................................... 289
24.4 Vacuum system for edge trim removal (optional) ................................... 293
24.5 Maintenance of the SciFi knife station ................................................ 294
24.6 How to maintenance SciFi station ...................................................... 295
25 Buffer module ........................................................................................ 299
26 Roller nip .............................................................................................. 301
26.2 Operation ................................................................................... 302
26.2.1 Dismantling the rubber roller ...................................................... 303
26.3 Maintenance of the roller nip station .................................................. 305
27 Winding spindle ...................................................................................... 306
27.2 Operation ................................................................................... 307
27.2.1 Tension force characteristics ...................................................... 308
27.2.2 The spindle replacement process ................................................. 309
27.3 Autocut...................................................................................... 313
27.3.1 General information ................................................................. 313
27.3.2 Operation .............................................................................. 314
27.3.3 Auto cut knife replacement ........................................................ 318
27.4 Automatic front shaft support .......................................................... 321

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27.5 Autoholder.................................................................................. 322
27.5.1 General information ................................................................. 322
27.5.2 Operation .............................................................................. 323
27.6 Web advancer .............................................................................. 325
27.6.1 General ................................................................................ 325
27.6.2 Operation .............................................................................. 326
27.7 Lay on roller................................................................................ 327
27.8 Web clamp.................................................................................. 328
27.9 Support brush (optional) ................................................................. 329
27.10 Label counters ............................................................................. 330
27.10.1 Optical counter ................................................................... 330
27.10.2 Optical counter learning procedure ........................................... 330
27.10.3 Ultrasonic counter ................................................................ 331
27.10.4 Ultrasonic counter learning procedure ....................................... 331
27.12 Risk assessment ............................................................................ 333
28 Operator's panel...................................................................................... 334
28.2 Main menu operation ..................................................................... 336
28.2.1 Counters ............................................................................... 337
28.2.2 Alarms.................................................................................. 338
28.2.3 Formulas ............................................................................... 339
28.2.4 Air pressure control .................................................................. 340
29 Troubleshooting ...................................................................................... 341

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1 General Information
1.1. Introduction
The documentation of the operation of the machine has been prepared to facilitate the use
and operation of the machine by the user. Anyone involved in the installation, commissioning,
operation, maintenance and repair must read and understand the contents of the manual before
operating the machine All warnings contained therein must be followed in order to ensure the
safety of all users.
1.1.1. Correct use and storage of the user manual
The documentation of the operation of the machine has been prepared to facilitate the
use and operation of the machine by the user. Anyone involved in the installation,
commissioning, operation, maintenance and repair must read and understand the contents of
the manual before operating the machine All warnings contained therein must be followed in
order to ensure the safety of all users.
These instructions must be kept for future reference during installation, use and
maintenance. The attached document must be kept in a place accessible to all persons who
are to perform work on the machine. Common access of the user manual by the users allows
to exclude uncertainty related to the operation of the machine and thus reduce the
likelihood of an accident or damage to the equipment.
Instructions for installing, maintenance and operation of the machine are provided for
each type of machine in paper form. To obtain an electronic copy, please contact the
manufacturer. The instructions must be handed over to any subsequent owner of the machine.
In case of excessive wear or loss of the user manual in paper form, contact the
manufacturer to obtain a copy.
The machine owner is responsible for making sure that the contents of the manual are
read and understood.
The manufacturer of the machine reserves the right to refuse any liability for damage to
health and damage to the equipment caused by failure to comply with the instructions, attached
documents, safety symbols on the machine as well as by failure to comply with maintenance
instruction or resulting from improper maintenance of the machine.
1.1.2. Copyrights
The installation, operation and maintenance manual for the machine is protected by
copyright and is the property of the manufacturer:
Grafotronic Sp. z o. o.
03-236 Warsaw, Poland
www.grafotronic.se

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No part of the manual, either on paper or in digital version, may be modified or
reproduced without the prior written consent of the manufacturer.
1.2. User manual format

The manual has been divided into sequentially numbered chapters. When referring to
another chapter, the first number is always the number of the main chapter that should be
consulted in order to broaden the knowledge of the given topic.
All units indicated in the manual are standard SI units, only in some places converted to
U.S. customary system.
The user manual is based on the maximum configuration of the machine, where the
mechanics and the program may slightly differ from the actual state of the machine. The layout
of the buttons in the operator panel may differ. The marking of buttons is consistent with the
actual state.
1.3. Manufacturer responsibility

Responsibility for damage to the equipment and damage to health is borne by the
manufacturer only if there are proven design or safety errors in the machine. The manufacturer
reserves the right to refuse responsibility in case of: incorrect use of the machine, incorrect
maintenance, dismantling or bypassing of protections, modifications not accepted by the
manufacturer, use of non-original spare parts.

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2 Safety
2.1 Introduction
The safety of both the operator and people around the machine is paramount. It is
essential to comply with the safety rules and to understand the possible dangers of the residual
risk. The "Safety" chapter is the most important chapter of the manual.
2.2 Intended use of the machine

The Grafotronic machine is used for the production of labels, the specific purpose
depends on the configuration of the machine and is detailed at the beginning of each chapter.
Intended use can be determined only after all safety requirements specified in the manual are
met, all safety devices installed on the machine are present, maintenance and inspection of the
machine for defects have been carried out by qualified personnel in accordance with the rules
contained in the manual.
See the machine's technical data section for the maximum web width. The minimum web
width is defined as half the maximum web width.
The manufacturer is not responsible for faults caused by work performed on the machine
not in accordance with its intended use.
2.3 Intended use of the machine

Using the machine inconsistently with its intended use may result in: danger of injury to
the operator and people in the vicinity of the machine, damage to the machine, inefficient
effects of the machine's operation.
Using the machine inconsistent with its intended use is defined as: installation of spare
parts not approved by the manufacturer, modification of the machine that affects the operation
of the machine not approved in writing by the manufacturer, acceptance of the machine by
persons who have not been designated by the manufacturer, have not read the manual and have
not received the necessary training.

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2.4 Safety symbols

The safety symbols shown below identify hazardous situations that must be considered
when working with the machine. The three-stage gradation was introduced in order to identify
the hazard level.
DANGER
Indicates immediate danger

Failure to comply will result in death or disability.
WARNING
Indicates potential danger

Failure to comply may result in death or disability.
ATTENTION
Indicates a probable dangerous situation

Failure to comply may cause damage to the equipment, moderate or
minor injuries.
INFO
Refers to general instructions or tips that do not affect safety.

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2.5 Main dangers
DANGER
High voltage!
High voltage. Do not touch, risk of death.
• Always turn off the power during repair and maintenance work
• During repair and maintenance work, secure the switch to protect
against possible activation by unauthorised persons.
• Electrical work may only be performed by qualified personnel!
DANGER
High voltage!
After the machine is turned off, the lethal voltage is
still present. Wait 5 minutes before working on the
electrical cabinet!
DANGER
Repair and maintenance work.
Performing repair and maintenance work while the
machine is working can be fatal!
ATTENTION
Risk of injury and equipment damage.
Tools left behind may enter the machine and
seriously damage the equipment.
• Do not leave wrenches and other tools on the machine while the
machine is working.
• Do not place heavy objects on the machine.

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2.6 Dangers during machine operation
DANGER
Immediate threat to life.
Missing or defective covers and protective devices can
be lethal!
• Always check the technical condition of guards and protective
devices before starting the machine.
• Always check the completion of safety devices before starting the
machine.
• Always work with the covers in place and take precautions
ATTENTION
Risk of burns.
• Machine parts can reach high temperatures
• Always wear gloves to protect against burns when working with
hot surfaces
ATTENTION
Printing material.
Contact with the printing material may cause cuts
• Be careful when inspecting moving material
• Stop the machine during adjustment work
ATTENTION
Noise emissions.
Long-term exposure to the machine may cause
hearing loss
• The noise level is in the range of 70 - 85 dB. According to grade
A.
• Hearing protectors are recommended for long-term operations on
the machine

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ATTENTION
Risk of mutilation.
Risk of being drawn in between rotating rollers
• Risk of body parts being drawn in between rotating rollers.
• Be careful when inspecting moving material
• Do not touch the rotating rollers.
ATTENTION
There are cooling and ventilation systems installed in
the door of the machine. Lack of ventilation can have
a significant effect on the technical condition of
electrical equipment.
• Always work on the machine with the door locked.
• When turning on the machine, make sure that all fans are
working.
2.7 Dangers during repair and maintenance work
DANGER
Repair and maintenance work.
Performing repair and maintenance work while the
machine is working can be fatal!
WARNING
Activation of drives.
Carrying out maintenance while the machine is
working can be harmful to your health.
• Lock the switch to protect from possible starting of the machine
• Next to the switch, place the information "repair work, do not
turn on"
• When restarting, make sure that there are no people near the
machine.

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WARNING
Switching on the pneumatic system.
Carrying out maintenance work on a functioning
pneumatic system can be harmful to health
• Always perform maintenance work when there is no pressure in
the pneumatic system
• Disconnect the air supply before starting work
• Next to the main valve, place the information "Repair work on
the pneumatic system"
• When disconnecting and connecting, make sure that the sudden
increase or decrease in pressure in the system does not cause any
health damage to people nearby.
ATTENTION
Risk of mutilation.
Adjusting the machine while the machine is working
can cause serious injury.
• Stop the machine.
• Disable all auto modes when installing the web and adjusting
machine parts.
INFO
When the machine and the drives are still switched on, it is possible to
start the machine in an unintended manner due to a defect in the control
system. Disconnecting the machine from the power supply disconnects
the drives.
2.8 Requirements for the operator and technical staff.

Before working on a Grafotronic machine, the operator must read the user manual and
receive training by a Grafotronic representative or a designated person in writing. The transfer
of knowledge to subsequent operators should be carried out by an appropriately trained and
qualified person.
Before starting repair work on the Grafotronic machine, the technical staff must read the
user manual, have the necessary technical knowledge and experience in repairing similar
machines.

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2.9 Risk assessment manual

Hazardous situations have been divided into modules and sections as a result of the
modular construction of the device. Reference to risk assessment can be found in individual
chapters. As presented below:
1. Catch point - Potential risk of a body part being drawn in between the parts of the
machine
2. Impact - Potential risk of injury due to the operator's body part being hit by a moving
part of the machine
3. Contact - Potential risk of contact with sharp, hot, cold or living elements.
4. Entanglement - Potential risk of hair, rings, gloves being pulled in.
5. Ejection - Potential risk of harm due to the ejection of material.
6. Fall / Skid / Tripping - Potential risk of an accident in the vicinity of the machine.
7. Ergonomics - Potential risk of an accident resulting from the operator being overcharged
with duties, using the wrong tools, performing repetitive tasks in uncomfortable
positions.
Danger Level:
1. Low - possible minor injuries.
2. Medium - possible serious injuries.
3. High - possible threat to life or disability.
Risk probability:
1. Low - unlikely
2. Medium - probable
3. High - highly probable
The analysis is linked to the instructions provided with the device. The probability and the level
of the hazard are related to the safety devices installed on the machine, the training provided
by a qualified person and the warning information contained in the attached instructions.

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3 Acceptance, positioning and lifting

3.1 Transport and acceptance of the machine
The machine is delivered on a pallet. In the case of a machine consisting of more than
one module, the modules are marked and numbered. Each module is packed in a foil that
protects against temperature and moisture. Before unpacking, make sure that the machine has
reached the ambient temperature.
INFO
Unpacking
Before cutting the foil, make sure that no part of the machine is
damaged. It is best to make an incision where there is air on the other
side of the foil. Remove the foil by hand.
After unpacking, check that the machine has not been damaged in any way. Damage
should be reported to the manufacturer immediately.
INFO
Accessory List
Accessories are often included inside the machine. After unpacking,
inspect each module, take out the accessories and carefully check if
additional accessories are present and have not been damaged. Any
damage or missing accessories should be reported to the manufacturer
immediately.
ATTENTION
The minimum weight of the machine is specified in the
shipping documents.
• Only qualified personnel may lift the machine on a pallet.
• Lifting is only possible with a forklift with the required lifting
capacity

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INFO
Tool list
• Knife
• Flat-head screwdriver.
• Multimeter
• Allen wrench No. 8
• Torx Allen wrench No. 40
• Ratchet spanner 24mm, 13mm
• Spirit level with scale value 0.05 mm / m (optionally 0.1 mm /
m)
• Pallet jack minimum capacity 1800 kg, minimum length 2000 mm
• Forklift
3.2 Placing the machine in a designated, appropriate place

Lifting of the machine from the pallet is only possible after removal of the belts and
wooden beams securing the machine during transport. Make sure the machine stands straight.
Figure. 33.1 Machine placed on a pallet
The machine rests on wooden beams. Cut the straps and lift the machine by its legs using
an Allen wrench and a flat ratchet spanner until the beams can be removed and there is enough
space for the forks of the forklift. A Torx Allen No. 40 is needed to remove the beams.

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ATTENTION
Risk of mutilation.
The belts are tight. Tension will disappear when the
belt is cut.
• Keep a safe distance when cutting the belt.
ATTENTION
The machine can only be lifted from the door side by
the transport bars. Poor evaluation of lifting operation
may damage the equipment or injure people around.
• Lift the machine only by the transport bars.
• Lift the machine only from the door side.
• Be especially careful when lifting the machine
Make sure the legs are properly attached to the machine.
INFO
Machine height
We recommend setting the machine height to 95 mm from the ground to
the cantilever beam. Setting all the legs to the same height before
leveling the machine will speed up the leveling process.
3.3 Machine positioning

The machine should be placed in the designated area using a pallet jack or a forklift. We
suggest you place the machine no closer than 2 meters to any wall or fixed equipment. Additional
space around the machine may become necessary for repair work. Leave a safe area of 2 meters
to ensure safety for the operator. The dimensions of the machine are included in the supplement
to the technical documentation named "floor plan".
The machine must be placed on a stable, load-bearing surface which meets the technical
requirements and can withstand the weight of the machine as specified in the technical data
section.
The room in which the machine is to be installed must meet the requirements for
temperature, power supply, air humidity as set out in the technical data section of the machine.

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3.4 Levelling
The machine must be leveled horizontally and vertically with an accuracy of 0.05 mm /
m (optionally 0.1 mm / m). Before levelling, the worktop must be wiped of dust and dirt. Due
to the distribution of the mass, the levelling should be carried out with regard to several
reference points. After completing the leveling, check that the machine is stable on the ground.
Figure 3.2 Leveling the machine
After leveling the module, lock the height of the legs with the nuts.
Figure 3.3 Leg-locking nut

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3.5 Setting up modular machines.

A machine consisting of several modules must be positioned in parallel. The machine's
legs are built to dampen vibrations. In order to make it easier to move the modules, we
recommend placing a slippery surface under the legs.
Make sure all spacers are removed after each module is positioned!
Figure 3.4 Silicone support
Parallel alignment of the modules is crucial for maintaining the correct tension of the
web and good quality of the produced materials. For this purpose, Grafotronic products are
equipped with laser spirit levels that can be set on each module roll.
Figure 3.5 Parallel positioning

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The use of advanced equipment does not guarantee the correct position of modules.
Screws of the same length and a cord are sufficient for correct alignment. When screwing the
screw into the first correctly positioned module, make a knot at the edge. Screw in the screw
on the other module and tie the cord. If the distance from the cord to the worktop at each point
of (along) the cord is the same, the machine is correctly positioned. Below is an example of an
incorrectly positioned machine. If the distance from the worktop to the cord is not the same
along the cord, the machine is not positioned correctly.
Figure 3.6 Screw on the first module
Figure 3.7 Screw on the next module

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Figure 3.8 Incorrectly positioned module
After setting the modules in parallel, connect them with the connector included in the
equipment of the machine. Correct tightening of the fasteners is crucial during longer work, an
incorrectly positioned machine may "sink" after many years of work.
Figure 3.9 Connector in the machine

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3.6 Connection of the pneumatic system

The machine must be connected to the pneumatic system of the building. Requirements
for the pneumatic network can be found in the chapter containing technical data of the machine.
The air in the pneumatic system must be dry and oil-free.
WARNING
Switching on the pneumatic system.
Carrying out maintenance work on a functioning
pneumatic system can be harmful to health
• Always perform maintenance work when there is no pressure in
the pneumatic system
• Disconnect the air supply before starting work
• Next to the main valve, place the information "Repair work on
the pneumatic system"
• When disconnecting and connecting, make sure that the sudden
increase or decrease in pressure in the system does not cause any
health damage to people nearby.
There are pneumatic connections between the worktops: please make sure all cables
are connected properly.
Figure 3.10 Pneumatic connection inside the machine
The main air supply connection is on the side of the machine.

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Figure 3.11 Main air valve
1. Pressure adjustment.
2. Main valve
3. Pneumatic quick release coupling type KS4-1/4-A-R
4. Manometer indications
3.7 Electrical Connection
DANGER
High voltage!

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DANGER
High voltage!
After the machine is turned off, the lethal voltage is
still present. Wait 5 minutes before working on the
electrical cabinet!
For electrical requirements, see the machine's technical data chapter.
DANGER
High voltage!
Defects in connecting the main power supply are
unacceptable. They can cause death
• All wires must be firmly attached to connectors in electric box
• No foreign objects in electric box
• The cables used to connect the power supply must comply with
the requirements of the international electrical code and the
data contained in the chapter containing technical data of the
machine.
• Do not connect the power supply when machine’s switch is in “I”
position
Figure 3.12 Electrical connections of the machine

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1. Main switch
2. Ethernet port to connect the machine to the Internet
3. Main power electric box
3.7.1 Connecting the machine to the Internet

Each Grafotronic machine has a router. Information on how to connect the machine can
be found below.
Unlock the ports for L2TP and PPTP VPN connection
Route the cable to the Ethernet port on the side of the machine (RJ-45 with IP address
DHCP).
Connecting a VPN requires correct setting up of the network firewall.
IP protocol Type = UDP, UDP Port Number = 500 <Used by IKEv1 (IPSec control path)
IP protocol Type = UDP, UDP Port Number = 4500 <Used by IKEv1 (IPSec control path)
IP protocol Type= UDP, UDP Port Number =1701 < Used by L2TP control/data path
IP protocol Type = 50 < Used by data path (ESP)
VPN server Port

PPTP TCP 1723, Other 47
Open VPN UDP 1194
IPSec UDP 500, UDP 4500
INFO
Connecting the machine to the Internet
The machine's continuous access to the Internet allows for a faster
diagnostic response in the event of a failure and monitoring of the
machine for faults. The manufacturer recommends that the machine is
at all times connected to the Internet.
3.7.2 Maintenance of the electrical connection system

In order to ensure a long service life of the electrical system, the system must be checked.
After repair, maintenance or replacement of any elements, check the pipes for mechanical
damage. To protect the electrical installation against moisture, oils, bad weather and climatic
conditions. All repairs may only be performed by authorized specialists. Electrical devices and
the condition of screw connections are checked and maintained every 2-3 months, depending on
the conditions of use and always in case of damage.

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4 Technical data of the machine
Maximum web width: 550 mm
Maximum diameter of the unwinder: 1000 mm
Unwinder spindle diameter: 76 mm
Maximum reel diameter: 600 mm
Maximum winding speed: 250 m / min
Maximum die cutting speed: 110 m / min
Maximum printing speed: 70 m/min
Minimum cutting width: 15 mm
Label counter (label units / meters): Optical
Web guiding system: FMS
Electrical requirements: 3x400V+N+PE / 63A
Energy consumption: kW
Air pressure requirements: ca. 2 m3 / h,

0.6 MPa
Weight: 0kg (all

modules)

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OPERATING CONDITIONS
- max temp +40°C (104°F)
- min temp +5°C (41°F)
-air humidity 15-90%

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5 Unwinding spindle
5.1 General information
The unwinder is used to generate tension on the reel. Depending on the equipment, the
unwinder brake is an electromagnetic brake or servo drive acting as a brake. The maximum
diameter and width of the new roll can be found in the machine technical data section. Expansion
of the spindle is possible from the main panel of the machine.
Figure 5.1 Unwinder spindle
ATTENTION
Ergonomics
The unwound rolls are heavy. Changing the rolls
frequently without the proper tools can overload the
operator.
• Always use a hoist intended for loading and unloading the roll.
• When loading and unloading a roll, position the spindle so that
the bearing line helps the roll to roll on the spindle. (with
bearings facing up)
• Wear safety shoes!

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5.2 Operation
To go to the settings of the unwinder, press the button "settings of the unwinder" in the main
panel.
6
9
2
8
3
7
5
Figure 5.2 Unwinder control panel
1. Tension - Set value of the generated tension force. Range 0-150 N

2. Characteristics - Characteristics of the interdependence between the tension and the
diameter of the unwound roll.
3. Unwind direction - For unwinder equipped with a servo as a brake. Brake action reversal.
4. Diameter - Value of the set diameter of the roll placed on the spindle.
5. Set Diameter - Resets the diameter to the value specified in the "diameter" window
6. Current roll diameter - The current roll diameter calculated by the program during
unwinding.
7. Slow down diameter - The value of the roll diameter set at which the machine slows down
to idle speed (5m / min).
8. Stop diameter- The value of the set diameter of the roll at which the machine stops.
Back to the main menu

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The spindle expansion button is located on the unwinder on the main panel and is marked
with the symbol below. The green light indicates the spindle has been expanded.
INFO
Tension
The tension force of the web. The force to be applied depends on the
type of material and its width. The evaluation of the correct tension
depends on the experience of the operator.
1 7
4
2
Figure 5.3 Side panel
1. Side panel
2. Jog button - When pressed and held, the machine moves at a speed of 5 m / min
3. IDLE button - When pressed, the machine moves at a speed of 5 m / min
4. START button - When pressed, the machine moves at the speed set in the main menu.
5. STOP button - When pressed, the machine slows down and stops.
6. Speed control - Speed control on
7. Emergency button - Emergency stop of the machine.
8. Shaft expansion button - When pressed, the shaft will expand and lock the reels.

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5.2.1 Tension force characteristics
INFO
Build-up of the tension force
The interdependence between the tension and the diameter. The
program adjusts the diameter of the unwound / wound roll to the tension
force. The build up system helps to keep the unwind / rewind force
constant. Unwinding and winding with low parameters may cause that
the roll is play inside the machine.
tension characteristics
35 700
100%
30 600
75%
25 500
Tension [N]
50%
Diameter
20 400
[mm]
25%
15 torque flat 300
10 200
5 100
0 0
Diameter
Torque flat
Strenght 25%
Figure 5.4 Characteristics of the relation between the tension and the diameter

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5.2.2 Unwind direction
The direction of the brake on the unwinder depends on the direction of unwinding the roll.
For machines equipped with an electromagnetic brake, the generated tension always acts in the
opposite direction to the unwinding direction. For machines equipped with a servo drive, change
the direction of brake operation when changing the unwinding direction.
Figure 5.5 Inner unwind direction
Figure 5.6 Outside unwinding direction

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5.3 Reel lifter

5.3.1 General
Reel lifter is used to lift rolls. To control roll lifting use a remote.
Figure 5.7 Reel roll lifter
ATTENTION
Possible equipment damage and personal injury.
• Be especially careful when lifting the roller. Visually inspect the
lifting process.
• Do not put your hands between the moving parts of the lift.
• Raise the spindle only after the roller is completely removed.

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5.3.2 Lifter remote
Roll lifter is used to lift rolls with maximum diameter 800 mm. To control roll lifting use a
remote or push the buttons on main panel. Only slower option for lifting and lowering the roll
is available from main panel.
Figure 5.8 Reel roll lifter remote
1. Roll lift up - Two step button. Push it lightly lift the roll slowly. Push it to the end to lift
the roll faster.
2. Roll lift down – Two step button. Push it lightly to lower the roll slowly. Push it to the
end to lower the roll faster.
3. Safety button - – Push it for safety stop. To reset safety twist the button and reset
safety on main panel.

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5.4 Roll lifter

5.4.1 General
Roll lifter is used to lift rolls with maximum diameter 1000 mm. To control roll lifting
use a remote.
Figure 5.9 Roll lifter

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5.4.2 Lifter remote
Figure 5.10 Roll lifter remote
1. Roll lift in- Two step button. Push it lightly insert the roll slowly. Push it to the end to
insert the roll faster.
2. Roll lift out – Two step button. Push it lightly to go out with the roll slowly. Push it to the
end to go out with the roll faster.
3. Roll lift up - Two step button. Push it lightly lift the roll slowly. Push it to the end to lift
the roll faster. Faster lifting is usable only when lifter’s actuator is fully extended.
4. Roll lift down – Two step button. Push it lightly to lower the roll slowly. Push it to the end
to lower the roll faster. Faster lifting is usable only when lifter’s actuator is fully extended.
5. Safety button - – Push it for safety stop. To reset safety twist the button and reset safety
on main panel.

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5.4.3 Handling
To put the roll on the unwinder shaft using roll lifter open the support doors (picture
below)

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Push roll out button [2] to fully go out with roll lifter and roll the material on lifter (picture
below)
Don’t stand or put anything in the way of roll lifter to avoid accidents!
Figure 5.12 Roll loading

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To lift roll press button [3] on the remote. Before going in with lifter, make sure that roll is
concentric to the spindle. (picture below)
Figure 5.13 Roll positioning

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Gently press roll lift in [1] to slide the roll on spindle going with lifter towards the machine.
(picture below)
ATTENTION
Possible injury or equipment damage
Extracting lifter can cause the injury or damage parts
• Don’t stand in the way of roll lifter to avoid accidents
• Make sure that unwinder plate is not In a way of lifting spindle
Figure 5.14 Loading roll

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Press roll lift down button [4] until plate is fully on the ground. (picture below)
DON’T press roll lift up [3] button, when roll is loaded to not to damage the spin

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5.5 Decurler (optional)

Decurler is optional part of Grafotronic machine which is responsible for material
straightening/decurling. Wraps which are outside the roll are less curled than wraps near
core because they are wrapped on bigger diameter. So, if we have new full roll with
diameter 600mm for example, we do not have to use big angle to straightening. When
we have end of roll with small diameter, we have to use bigger angle to straight the
material more.
Figure 5.16 Decurler on machine
To enter to Decurler menu, open Unwinder module operating panel and find shown
below “Decurler” button and press it.
Then the following window will appear:
3 2 1 4 5 6 7 8
1. Manual angle adjustment
2. Manual angle adjustment
3. Auto – automatic angle adjustment depending on current roll
diameter
4. Current angle – current angle value
5. Max. angle – maximum angle value for maximum roll diameter
6. Min. angle – minimum angle value for minimum roll diameter
7. Max. diameter – diameter of new mounted roll
8. Min. diameter – minimum diameter of used roll

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5.6 Flag and material splice sensor (optional)

The sensor works by contrast. Sensor is mounted on holder which can be moved along the
idler roll. Sensor has to be pointed on the way of the flag.
Figure 5.17 Flag sensor
Model: Balluff BKT 000H
5.6.1 Learning procedure

To teach the sensor for a given type of material, hold down the button for 5 seconds when
there is a flag (marker) in its zone. Then move the material so that there is a label in the sensor
zone and press the button for about 3 seconds. After correct learning, the sensor should flash
when there is a flag in its zone.
INFO
Flag and splice sensor
The sensor works by contrast. To teach the sensor for wider range of
colors. Teach the sensor on the flag where the contrast between flag and
roll is the lowest.

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5.7 Maintenance of the unwinder station

Process daily weekly monthly annually
Cleaning the station from dust and

x
label residue
Checking the condition of gears,
belts, and the general condition of x
the station

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5.8 Troubleshooting
Below is a list of alarms that may occur on the unwinder. For a list of servo alarms, see
Troubleshooting chapter in the user manual of the machine.
Problem / Alarm name Solution
Spindle expansion not activated

• Turn on the spindle expansion
Spindle expansion pressure too low
• Check that the pneumatic conduit in the machine is
not bent.
Unwinder pressure
• Check if there is a leak in the system.
Failure of the relay controlling the unwinder solenoid valve
• Check relay switching.
Solenoid valve failure
• Check the switching status of the solenoid valve.
Incorrect unwinding direction
Incorrect unwinding direction
• Change the unwinding direction
Release diameter reached
Little roll • Enter the correct release diameter
• Change the roll
Release diameter reached
End of roll • Enter the correct release diameter
• Change the roll
Belt too loose
• Tension the belt by moving the motor
Belt transmission broken
• Replace the belt with a new one.
Electromagnetic brake wear.
• Check the voltage on the brake contacts in the range
The electromagnetic brake of 0-24V at high tensions and large diameter, voltage
stretches the web too weakly around 24V.
• Check the voltage at the signal input of the TCG
module in the range of 0-10V at high tensions and
large diameter, voltage around 10 V. The module is
located on the worktop in the unwinder module.
• If the above values are correct. Replace the
electromagnetic brake.
Belt too loose
• Tension the belt by moving the motor
Belt transmission broken
The brake is not working
• Replace the belt with a new one.
properly
Wheel hub bearings worn
• Characteristic grinding sound and resistance to
spindle rotation. Contact service

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5.9 Risk assessment
Numb Hazardous Safety solutions

Section Risk level Risk probability
er situation used
User manual
warning, guard,
guard rod,
1a. Roller nip Catch point High Low
restricted access,
guard open
sensor
Roller nip Warning in the

1b. Impact Low Low
cover manual, sticker
Warning in
2. Web edge Contact Low Low manual, operator
knowledge
Web infeed Blade guard,

3. Contact Low Low
roller Sticker
Warning in the
4. Guide roller Catch point Medium Low
manual,
Roll loading Warning in the

5. Ergonomics Low High
/ unloading manual,

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6 Web guiding and worktops

Worktops are used to splice a new web with the material already placed on the machine
or to cut waste. On the left and right side there are airbags that the operator should close in
order to evenly cut or splice the web.
The web guiding system may be equipped with a worktop for connecting the web
depending on the machine configuration.
The web guiding system is used to automatically keep the web in the same width of the
guiding rollers and the rewinder spindle. Operation in an automatic system is possible if the
ultrasonic sensor is correctly positioned at the edge of the material or, in the case the line
guidance sensor is installed, the sensor is facing the print guiding line.
For more information on guiding the web, see the web manufacturers' instructions
included with your machine. The system may differ depending on the manufacturer.

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6.2 Control of the machine
1 5 2
2
Figure 6.1 Web guiding system and a worktop
Switch "1" and "2" - turn on the web pressure on the worktop.
3. Adjusting screw - Adjusts the worktop for precise cutting
4. Sensor position lock - Locking the sensor movement at the end of the web
5. Automatic mode - In this operating mode, the web guiding works to the sensor position. THE
BUTTON MUST BE RED.
6. Tape dispenser - for precise web splicing

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Figure 6.2 Web splicing worktop 1
Figure 6.3 Web splicing worktop 2
Expansion worktops - The worktops can be closed via the main panel. Press the "worktop"
button with the number corresponding to the worktop position.

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ATTENTION
Possible equipment damage
When cleaning the rubber cushions of the rollers,
there is a risk of cutting the cushions.
• Be careful when removing label waste.
• Do not use sharp tools to remove label waste.
Figure 6.4 BST web guiding
1. Automatic mode - In this operating mode, the web guidance works to the sensor
position
2. Manual position adjustment - The web guiding system can be adjusted manually using
the buttons.
3. Central mode - In this mode, the web guidance is perpendicular to the web.
4. Control Arrows - They are used to manually adjust the web position
5. Sensor side - Change the location of the sensor depending on the sensor side. From the
machine / operator side.

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6.3 Line guide sensor (optional)

6.3.1 General information
Line guide sensor is an optional device for FMS which helps guide the material.
Optical sensor reads the printed line from the web and guides in relation to it.
3
5
Figure 6.5 Line guide sensor
1. Sensor modes
2. Line Edge Selection
3. Contrast Focus
4. Holographic Pattern
5. Calibration
6. Profile Management
The sensor should be 15mm(+/-2mm) from the web. Reference line should be 8mm from the
web edge or from adjacent printing, because it may cause interference. Also high contrast is
needed to correct work of sensor. The best is black line on white background.

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6.3.2 Operation
1. Horizontal positioning:
a) Press three times button “Contrast”
b) Move sensor along the rail until the projected red dots cover the line (or edge)
c) If finished press once more time “Contrast” button or wait 30sec.
2. Adjustment of Focus:
a) Press twice the “Contrast” button
b) Move the sensor closer or farther away from the material following the LEDs
c) If finished press “Contrast” button or wait 30sec.
3. Contrast Measuring:
a) Press once “Contrast” button
b) Check the contrast
c) If finished press “Contrast” button once or wait 30 sec.
4. Sensor Calibration:
a) Choose sensor operating mode
b) Press “Calibration” button for longer than half a second. If the calibration was
successful the sensor will display the actual line or edge position in relation to the
sensor detection range. At unsuccessful calibration the sensor will display an error by
LEDs alternating flash.
More information about sensor and operating in attached FMS manual.

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6.4 Troubleshooting
Troubleshooting should be performed by the maintenance department.
Worktop is not turned on the control panel

• Turn on the worktop with the button on the panel
Cushion expansion pressure too low
• Check whether the pneumatic conduit in the
machine is not bent.
The worktop does not hold the
• Check that there is no leakage in the system.
material
• Check that the pressure in the machine is correct
Failure of the relay that controls the airbag solenoid valve
Sensor adjusted incorrectly
The web guidance does not
• Correct the position of the sensor
work in auto mode
• Perform a reset by turning on / off auto mode
Sensor location incorrect
• Change sensor position or selection on the panel
After switching on the auto
Sensor set out of range
mode the web moves to the
• Set the sensor in the range as specified by the
extreme side position
manufacturer (depending on the type of web
guiding. See the manufacturer's instructions)
Sensor adjusted incorrectly
• Correct sensor positions
Poor quality of the reel Incorrect projection adjustment of the starter reel
• Check the roll projection and compare it with the
web guiding range

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7 Printing station
7.3 General Information
The printing station, depending on the equipment, is used to apply varnish, glue, water-
based and UV inks as well as to reprint. The selection of appropriate parameters depends on the
work to be performed, the operator's knowledge in the field of flexographic printing and his
experience.
Figure 7.1 Printing station

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7. Anilox - cylinder that transfers the ink to the printing cylinder

8. Printing cylinder - The printing cylinder transfers the ink to the material. Number of
teeth 88T-200T
9. Inkwell - The ink tray with an ink ductor which transfers the ink to the anilox.

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Figure 7.3 Register pin sensor
10. Thrust cylinder - Paper supporting cylinder

11. Register pin sensor - Marker sensor
12. Closing actuators - Actuators locking the cylinder in the station.
WARNING
Rotating elements.
The roller nip is driven. Pulling the body in may cause
disability.
• Do not wear loose clothes when the machine is working!
• Do not put your fingers near the working roller nip station!
• As soon as you notice a dangerous situation, press the
emergency button
• Always work with closed covers
ATTENTION
The rubber surface of the roller requires maintenance.
• Do not use sharp tools to clean the rubber roller from label
residue.
• Use only pure alcohol, washing benzene, or a spray for cleaning.

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6
a
a
ATTENTION
The surface of the cylinders requires safe cleaning.
• Do not use sharp tools to clean the cylinders from label or paint
residue.
• Use only pure alcohol or cleaning agents designed for this
purpose.

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7.4 Setting up the work station

The safe job setup procedure is as follows:
1. Pour the ink over the inkwell, insert the ink doctor into the inkwell and push it until you
feel a click.
INFO
Inkwell
The maximum level of paint poured into the inkwell should not exceed
half the height of the ink doctor. Pouring too much paint can cause paint
to splash out of the ink tray.
Figure 7.5 Extendable ink tray
ATTENTION
Installation of the anilox ink tray can be dangerous
• Before adjusting the ink tray, make sure that it is fully locked in
the station (you heard a click).
• Do not put your hands in the path of the moving ink tray.

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2. If there are no doctor blades. Loosen the 4 screws (picture below) to allow the blade to
be retracted.
Figure 7.6 Blade lock in the handle
The doctor blade angle is adjusted by loosening the two screws on either side of the
doctor blade. Loosening the blade holder locking screw reduces the blade pressure force.
Figure 7.7 Doctor blade holder

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ATTENTION
Risk of injuries.
The doctor blade is sharpened during operation by the
anilox.
• Be careful when replacing the doctor blades.
• When adding a doctor blade, do not grab the blade, use the
designated handle.
3. Put the anilox in the station.
Figure 7.8 Anilox handle
INFO
Anilox (anilox roller)
Be careful when inserting the anilox, the surface carrying the paint is
fragile and can be easily damaged. The cylinder should fit tightly in the
holders. In order to facilitate the installation of the anilox, you can
adjust the side of the station. Adjusting the station in central position
allows better access.

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4. Close the anilox in the station and press the "Block anilox" button in the printing station
menu.
INFO
For safety reasons, the anilox holder must always be locked in the station
regardless of the presence of the anilox.
5. Move the inkwell to the anilox by pressing the "ink tray" button in the printing station
menu
ATTENTION
Risk of mutilation.
Inserting the ink tray can be dangerous
6. Put the cylinder in the station. The cylinder should slide slightly over the adjustable arms.
Figure 7.9 The arrangement of cylinders in the station
7. Turn on the printing station by locking the cylinder in the station

8. Optionally switch on the anilox standstill torque that removes excess paint from the
anilox when the machine is at standstill.

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9. Turn on the lamp in the menu and on the GEW panel on the front of the machine. More
in the chapter "GEW lamps"
10. Press print in station menu and adjust station press.
7.5 Print adjustment
1 3
a
5
a
2
4
a
Figure 7.10 Station adjustment
Before adjusting the station, it is recommended to set the knobs to about 5mm and adjust the
printing parameters only when the machine is in motion and the printing process and lamps are
on.
1. Turn the knob clockwise to increase the amount of ink applied from the anilox to the printing
cylinder on the left side. Turning to the left reduces the amount of ink applied from the anilox
to the printing cylinder on the left side.
cylinder on the right side. Turning to the left reduces the amount of ink applied from the anilox
to the printing cylinder on the right side.
3. Turn the knob clockwise to increase the amount of ink transferred from the printing cylinder
onto the web on the left side. Turning to the left reduces the amount of ink transferred from
the printing cylinder to the web on the right.
onto the web on the right side. Turning to the left reduces the amount of ink transferred from
5. Turn the knob clockwise to move the printing stations to the right (operator), by turning the
knobs to the left, the stations will be moved to the left (towards the operator).

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ATTENTION
Using too much force to adjust the station can damage
the side adjustments.
• The resistance felt during adjustment is the signal that the
maximum control range has been reached.
• Adjusting the station while the machine is at a standstill can
damage the web and the polymer
ATTENTION
Pressing the cylinder too hard against the material can
destroy the printing plate and puts stress on the drive
of the station.
• Adjust the print quality only with active cylinder press when the
machine is functioning.

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7.6 Operation
Figure 7.11 Rotary print station menu
1. Register - The button must be activated to work in the register pin reprint mode.
2. Cylinder size – The cylinder size indicated as the number of teeth.
3. Window – The range in which the sensor looks for a marker for every format. The smallest
window value should be half the distance between the closest markers. There should be
no other markers on the marker line. Marked red on photo below.

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Figure 7.12 Print format
4. Number of markers - Number of markers per cylinder revolution

5. Station off / on - Turns on the print station.
6. Anilox lock - Anilox lock button in the station.
INFO
regardless of the presence of the anilox. Equipment may be damaged if
the machine is started with the anilox open.
7. Anilox run - Activation of the anilox standstill torque.
INFO
Standstill torque
The standstill torque enables the removal of excess paint from the
anilox, preventing the paint from drying out and clogging the paint-
carrying trays.

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8. Print - Adjusting the cylinder to the material while the machine is functioning. The
cylinder can only be lowered with the lamp on.
ATTENTION
of the station.
9. Ink tray - Raise / lower the ink tray
ATTENTION
10. Lamp - Turns the lamp on. The lamp can be turned off only when printing is turned off.
INFO
Lamp
Switching off the lamp enables e.g. foil to be passed without the risk of
burning the material. The lamp can be turned off only when printing is
turned off.
11. Compensation - Print layout adjustment. The values given will be around the set value.

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7.6.1 Setting work of register
The semi-rotation setting requires the material to be rewound through the station's
guiding trolley according to the machine's print run shown on the machine or included at the end
of the operating instructions.
The procedure for setting work of the semi-rotary is as follows:
1. Position the station to the center using the side adjustment.

2. Select anilox with the appropriate capacity for the job.
INFO
Anilox roller
Aniloxes with high fineness and low cell volume (capacity) are
recommended for detailed work. For printing large elements or uniform
backgrounds, a lower fineness and high cell capacity are recommended
3. Select a cylinder with the number of teeth corresponding to the length of the print.
4. Turn on the print station, lamp and print.
5. Set the print by adjusting the press with the knobs
6. Choose the right window. The value must be half the distance between the closest
markers.
INFO
Anilox roller
The manufacturer recommends that there are no other prints in the line
of markers. If there are many prints on one line, the distance between
the marker and another print should not be less than 30 mm. The
machine will achieve the best working parameters by placing the marker
start halfway from the first cutting line. The marker should be a 6x3mm
black rectangle.
Figure 7.13 Register

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7. Teach the register pin sensor on the marker and start the register pin before marker on
which the sensor was taught
ATTENTION
Lowering and pressing the cylinder when the cylinders
are not interlocked properly can damage the teeth and
cylinder.
• Press down on the cylinder making sure that the cylinder is not
standing on the teeth!
8. Adjust the fineness using side adjustment and compensation
ATTENTION
Using too much force when adjusting the station can
affect the adjustment.
• Adjusting the station while the machine is stopped with the die
pressed down can cause the web to break.
9. The speed can be adjusted up to the set value.

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7.6.2 Teaching the register pin sensor
Grafotronic machines can be equipped with a marker sensor to enable register pin
cooperation. The sensor beam should be a narrow strip that can be obtained by positioning the
sensor at an angle of 15 degrees, 10 mm from the web.
Figure 7.14 Sick KTM registration sensor
1. Teaching button
2. Signal LED
3. Power On LED
4. Light beam
KT5W sensor learning procedure:
1. Press the teach button (1) on the marker

2. Move the machine off the marker and press the teaching button on the face material.
KT5W sensor on the run learning procedure:
1. Hold the teach button (1) on the marker. Light beam will change color to white.
2. Run the machine for at least 3 markers while holding the button (1).
The sensor has been taught, the LED (2) flashes on the marker
For more information, see the sensor manufacturer's instructions included with the machine.

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7.7 Lamination and Cold foil

The lamination module is used to apply the top layer of material to the unwound material
in full-rotary mode. The tension of the wound and unwound material is in the main menu.
Depending on the equipment of the machine, it is possible to unwind the laminate without
primer, laminate with primer and apply gold plating. All possible web guiding options are marked
below.
Gilding / cold foil
The web movement in the figure shows the default position of the guide rollers. The web
tension is enabled by an adjustable handle (3). Pressing the foil against the material allows you
to turn on the lamination nip (4) in the menu and adjust the pressure so that no creases appear
on the foil. The glue should be distributed evenly, otherwise it will be visible on the foil. The
foil discharge handle (5) should be set so that the discharged foil runs over the bearing shaft,
slightly touching the material. The selection of appropriate strings requires the operator's
experience and depends on the type of gilding and the width of the web
INFO
Guiding foil
It is recommended to pass the foil under the lamp when the lamp is
turned off. This will avoid burning the foil and cleaning the insert.
ATTENTION
residue.

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Figure 7.15 Super lamination / Cold foil
1. Unwinding spindle
2. Winding spindle
3. Guide handle / Delamination shaft
4. Lamination nip with double-sided pressure regulation - Nip allows for smoothing the
material in order to properly adhere the laminate. Double-sided pressure adjustment
allows for precise adjustment of the adhesion depending on the used laminate.
5. Foil discharge holder - A holder that allows the tension of the gilding to be transferred to
the winding spindle.

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Lamination with primer
tension is enabled by an adjustable handle (3) on which the primer is delaminated. It is wound
on the winding spindle (2). Pressing the laminate against the material allows you to turn on the
laminating nip (4) in the menu and adjust the pressure so that there are no laminate creases and
air bubbles.
Figure 7.16 Lamination with primer
2. Winding spindle

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Laminating without primer
tension is enabled by an adjustable handle (3). Pressing the laminate against the material allows
you to turn on the laminating nip (4) in the menu and adjust the pressure so that there are no
laminate creases and air bubbles.
Figure 7.17 Laminating without primer
2. Winding spindle

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7.7.1 Lamination operation
3
5
4
Figure 7.18 Lamination menu
1. Tension – Set value of the tension generating force. Range 0-150N

2. Build-up –Characteristics of the interdependence between the tension and the diameter
of the unwound roll
3. Unwind / Wind Direction - Change the direction of spindle operation.
4. Changing the spindle operation - Changing the spindle operating mode from unwinding
to winding spindle. A gray icon indicates the spindle is currently working as a winding
spindle.
5. Current roll diameter - Set roll diameter calculated by the program during unwinding /
winding. Turning off spindle expansion or pressing a number will reset the value to the
current roll diameter.
6. Shaft On / Shaft expansion - Button for turning on the shaft and expanding the shaft to
immobilize reels. The green highlighted button means that the spindle is on.

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7.8 GEW lamp
5 2
6
3
7 8
Figure 7.19 Lamp panel
1. Lamp start
2. Lamp reset – Resetting alarms
3. Lamp Shutdown - It takes 5 minutes for the lamp to cool, regardless of when the lamp
is started
4. Lamp Power Bar - A green bar indicates that the lamp is ready. Orange bar means the
lamps is warming. The blue bar means the lamp is being cooled down while the red bar
means that the lamp is not ready for operation.
5. Lamp alarm – Shows alarm on the lamp
6. Lamp number and activation - By pressing the number you activate the lamp (yellow
backlight) or deactivate the lamp (no backlight)
7. Event log – Lists of alarms with time they occurred
8. Tools – Settings for lamps power and fan
For more information on the print curing system, see the GEW manual that came with your
machine.

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7.9 Setting the pressure of the system
How to change the pressure in section “Operator’s panel”.
Recommended section pressures refer to the maximum machine configuration:
Pressure Section Minimum Maximum

gauge pressure pressure
marking [bar] [bar]
Printing
Printing station 2 4
station
Nip Laminating nip
0.1 4
lamination clamp

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7.10 Maintenance of the print module


x
label residue
the station
Cleaning the station from paint, glue
x
and varnish

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7.11 Troubleshooting
Shaft not expanded

• Make sure the shaft is expanded
No pressure
Slipping of the reel on the • Check the pressure in the machine
spindle Incorrect diameter of the reel
• If the above points are correct, measure the
diameter of the reel / increase the pressure on the
shaft gauge
Waste material at the station
• Clean the station of any residue of labels and glue.
Station shaft axle not closed
• Check that the rubber roller correctly adheres to the
web along its entire width
Too low pressure in the roller nip closure system
Play on the material • Check that the pneumatic conduit in the machine is
not bent.
Cyclic sound
The spindle is turning in the wrong direction
Wrong direction
• Change direction (inner / outer winding)
Inactive spindle
The spindle does not turn
• Activate the spindle
Clogged anilox cells
• Wash the anilox properly using the appropriate
products
Printing not enabled
• Enable the lowering of the printing cylinder
Anilox does not transfer Printing cylinder raised too high
varnish • Adjust the cylinder extension so that it touches the
anilox evenly
Anilox capacity too low
• For works requiring the application of a thick layer
of paint or varnish, anilox with a larger capacity is
necessary

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7.12 Risk assessment
Hazardous Risk Risk

Number Section Safety solutions used
situation level probability
Lifting the
1a. Impact Medium Low Operator training, sticker,
ink tray
Operator training, ductor

1b. Ductor blade Contact Low Low
blade holder,
Warning in manual, cover,

Anilox
1c. Catch point High Low restricted access, electrical
cylinder
protection

Printing
1d. Catch point High Low restricted access, electrical
cylinder
protection
1e. Station cover Impact Low Low Variation range
Station
Warning in the manual,
2. trolley Impact Low Low
sticker
sliding cover
Station Warning in user manual,

3. Impact Low Low
trolley sticker, restricted access

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8 BOBST printing station

experience.

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1. Anilox - cylinder that transfers the ink to the printing cylinder

teeth 88T-200T

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WARNING
Rotating elements.
disability.
emergency button
ATTENTION
residue.

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ATTENTION
residue.
purpose.

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1. Pour the ink over the inkwell, insert the ink doctor into the inkwell
INFO
Inkwell
half the height of the ink doctor. Pouring too much paint can cause paint
ATTENTION
the station
2. If there are no doctor blades. Loosen the 3 screws (picture below) to allow the blade to
be retracted.

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ATTENTION
Risk of injuries.
The doctor blade is sharpened during operation by the
anilox.
• Be careful when replacing the doctor blades.
• When adding a doctor blade, do not grab the blade, use the
designated handle.
INFO

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4. Close the anilox in the station and press the "lock anilox" button in the printing station
menu.
INFO


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1 3
a
5
a
2
4
a
on.

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ATTENTION
ATTENTION
of the station.

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8.6 Operation
13. Cylinder size – The cylinder size indicated as the number of teeth.
no other markers on the marker line. Marked red.

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Figure 8.8 Print format

INFO
INFO
Standstill torque
carrying trays.

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19. Print - Adjusting the cylinder to the material while the machine is functioning. The
ATTENTION
of the station.
ATTENTION
INFO
Lamp
turned off.

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8.6.1 Setting work of register

INFO
Anilox roller
markers.
INFO
Anilox roller
black rectangle.
Figure 8.9 Register marker

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ATTENTION
cylinder.
ATTENTION

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Figure 8.10 Sick KTM registeration sensor
5. Teaching button
6. Signal LED
7. Power On LED
8. Light beam

4. Move the machine off the marker and press the teaching button on the face material.

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8.7 GEW lamp
5 2
6
3
7 8
1. Lamp start
3. Lamp Shutdown - It takes 5 minutes for the lamp to cool, regardless of when the lamp is
started
4. Lamp Power Bar - A green bar indicates that the lamp is ready. Orange bar means the lamps
is warming. The blue bar means the lamp is being cooled down while the red bar means that
the lamp is not ready for operation.
machine.

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The pressure is controlled by pressure gauges on the side of the machine. The method of
adjustment is described on the housing of the pressure gauge.
Figure 8.12 Pressure gauge
1. Gauge dial
2. Marking of the sections in English with the allowable maximum pressure.

marking [bar] [bar]
Printing
station
Nip Laminating nip
0.1 4
lamination clamp

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x
label residue
the station
x
and varnish

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Shaft not expanded

No pressure
shaft gauge
not bent.
Cyclic sound
Wrong direction
Inactive spindle
products
Anilox does not transfer Printing cylinder raised too high
varnish • Adjust the cylinder extension so that it touches the
anilox evenly
• For works requiring the application of a thick layer
of paint or varnish, anilox with a larger capacity is
necessary

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Hazardous Risk Risk

Lifting the
ink tray

blade holder,

Anilox
cylinder
protection

Printing
cylinder
protection
Station
sticker
sliding cover

3. Impact Low Low

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9 Printing station
experience.

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1. Anilox cylinder that transfers the ink to the printing cylinder

teeth 88T-200T

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6. Closing cylinders - Cylinders locking the cylinder in the station.
WARNING
Rotating elements.
disability.
emergency button
ATTENTION
residue.

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ATTENTION
residue.
purpose.

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1. Pour the ink over the inkwell, insert the ink ductor into the inkwell and push it until you
feel a click.
INFO
Inkwell
half the height of the ink ductor. Pouring too much paint can cause paint
Figure 9.5 Extendable ink tray
ATTENTION

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2. If there are no ductor blades. Loosen the 4 screws (picture below) to allow the blade to
be retracted.
The ductor blade angle is adjusted by loosening the two screws on either side of the
ductor blade. Loosening the blade holder locking screw reduces the blade pressure force.
Figure 9.7 Ductor blade holder

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ATTENTION
Risk of injuries.
The ductor blade is sharpened during operation by the
anilox.
• Be careful when replacing the ductor blades.
• When adding a ductor blade, do not grab the blade, use the
designated handle.
Figure 9.8 Anilox handle
INFO

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4. Close the anilox in the station and press the "Block anilox" button in the printing station
menu.
INFO
5. Move the inkwell to the anilox by pressing the "ink tray" button in the printing station
menu
ATTENTION
Risk of mutilation.
Inserting the ink tray can be dangerous

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1 3
a
5
a
2
4
a
on.
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ATTENTION
ATTENTION
of the station.

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9.6 Operation
2. Cylinder dimensions – The cylinder size indicated as the number of teeth.
window value should be half the distance between the closest markers. Format is marked
with green arrows, window is marked with red arrows.
Figure 9.12 Print format:

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INFO
INFO
Standstill torque
carrying trays.
8. Printing - Adjusting the cylinder to the material while the machine is functioning. The
ATTENTION
of the station.
ATTENTION

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INFO
Lamp
turned off.

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9.6.1 Setting work of register pin

INFO
Anilox roller
markers.
INFO
Anilox roller
black rectangle.
Figure 9.13 Marker

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ATTENTION
cylinder.
ATTENTION

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Figure 9.14 Sick KTM marker sensor
1. Teaching button
2. Signal LED
3. Power On LED
4. Light beam

2. Move the machine off the marker and press the teaching button on the primer

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9.7 Semi-rotary print

The station, equipped with the possibility of working in semi-rotary mode, allows for
printing on material moving longitudinally in two directions. The material is moved by the nip
located under the thrust cylinder and the nip located behind the semi-rotary trolley.
Figure 9.15 Semi rotary printing station
1. Semi-rotary nip - under the thrust cylinder

2. Semi-rotary nip - behind the semi rotary trolley
3. Semi rotary trolley
INFO
Semi-rotary nips
When working in the semi-rotation mode, both nips must always be
closed! Both nips must be open to work in rotary mode.

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9.7.1 Operation in the semi-rotary mode
Figure 9.16 Semi-rotary printing station menu
Init - Initialization button for semi-rotary mode. When activated, the appropriate cylinder
position is calculated. Starting the work of the station with the register pin requires pressing the
register pin button first. After pressing the button, the cylinder will be set to the beginning of
printing and the material will move the distance entered in the start of printing window.
INFO
Semi-rotary nips
closed!
Nip 1 - Button closing the nip under the thrust cylinder.
Nip 2 - Button closing the nip behind the semi rotary trolley.
Rotation mode - The button for starting the rotation mode of the station disables the operation
in the semi-rotation mode. Opening the nips allows you to work in a rotary mode with a rotary
cylinder.
INFO
Semi-rotary nips
closed!

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Print Length - The length of the plate in millimeters equal to the size of the reprinting
Semiprint len. compensation – value for printing format length adjustment.
Print cliche start offset - The distance from the plate start to the baseline of the printing
cylinder.
Gap compensation - The amount by which the gap between labels can be increased or
decreased. The value has to be corrected according to the distortion of the polymer plate.
Marker sensor distance - A parameter that determines the physical distance from the marker
sensor to the beginning of printing.
Skip marks after init – count of ignored marks after initialization
Stop offset enable – value which determined stop position of printing cylinder while machine
stopping. Option available in full and semi print mode.
INFO
Start of printing
Change this parameter if the tag is not at the start/beginning of the
label, for example, if the tag is in the middle of the label, the distance
between the tag and the first print line will change with the length of
the label.
ATTENTION
Possible equipment damage - semi-rotation mode
of the station.
• The alignment of the cylinder needs to be adjusted only when the
polymer surface is touching the web! Failure to do so may cause
the cylinder to break.

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9.7.2 Cold foil semi-rotary mode
Machine is equipped with additional equipment to apply cold foil in semi rotary mode.
The foil has to be guided as on the web path.
Figure 9.17 Web path semi cold foil
Figure 9.18 Web path foil return

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ATTENTION
Possible injury
Rolls and nip are in movement.
• Don’t put any part of the body near moveable parts during work.
• Press emergency button as soon as dangerous situation occurs.
To enable the cold foil in semi rotary mode click on flying cold foil nip icon. Selected
pressure text box enables the nip pressure regulation.
INFO
Guiding foil

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9.8 GEW lamp
5 2
6
3
7 8
1. Lamp start
3. Lamp Shutdown - It takes 5 minutes for the lamp to cool, regardless of when the lamp is
started
4. Lamp Power Bar - A green bar indicates that the lamp is ready. Orange bar means the lamps
is warming. The blue bar means the lamp is being cooled down while the red bar means that
the lamp is not ready for operation.
machine.

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gauge pressure pressure [bar]
marking [bar]
Printing
station
Nip Laminating nip

0.1 4
lamination clamp

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9.10 Lamination and Cold foil (optional)

The lamination module is used to apply the top layer of material to the unwound material
in full-rotary mode. The tension of the wound and unwound material is in the main menu.
Depending on the equipment of the machine, it is possible to unwind the laminate without
primer, laminate with primer and apply gold plating. All possible web guiding options are marked
below.
Gilding / cold foil
tension is enabled by an adjustable handle (3). Pressing the foil against the material allows you
to turn on the lamination nip (4) in the menu and adjust the pressure so that no creases appear
on the foil. The glue should be distributed evenly, otherwise it will be visible on the foil. The
foil discharge handle (5) should be set so that the discharged foil runs over the bearing shaft,
slightly touching the material. The selection of appropriate strings requires the operator's
experience and depends on the type of gilding and the width of the web
INFO
Guiding foil
ATTENTION
residue.

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Figure 9.20 Super lamination / Cold foil
2. Winding spindle
5. Foil discharge holder - A holder that allows the tension of the gilding to be transferred to
the winding spindle.

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Lamination with primer
tension is enabled by an adjustable handle (3) on which the primer is delaminated. It is wound
on the winding spindle (2). Pressing the laminate against the material allows you to turn on the
laminating nip (4) in the menu and adjust the pressure so that there are no laminate creases and
air bubbles.
Figure 9.21 Lamination with primer
2. Winding spindle

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Laminating without primer
tension is enabled by an adjustable handle (3). Pressing the laminate against the material allows
you to turn on the laminating nip (4) in the menu and adjust the pressure so that there are no
laminate creases and air bubbles.
Figure 9.22 Laminating without primer
2. Winding spindle

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9.10.1 Lamination operation
3
5
4
Figure 9.23 Lamination menu

2. Build-up –Characteristics of the interdependence between the tension and the diameter
of the unwound roll
3. Unwind / Wind Direction - Change the direction of spindle operation.
4. Changing the spindle operation - Changing the spindle operating mode from unwinding
to winding spindle. A gray icon indicates the spindle is currently working as a winding
spindle.
5. Current roll diameter - Set roll diameter calculated by the program during unwinding /
6. Shaft On / Shaft expansion - Button for turning on the shaft and expanding the shaft to
immobilize reels. The green highlighted button means that the spindle is on.

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x
label residue

the station

x
and varnish

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Shaft not expanded

No pressure
shaft gauge
not bent.
Cyclic sound
Wrong direction
Inactive spindle
Activate the spindle
products
Anilox does not transfer
Printing cylinder raised too high
varnish
• Adjust the cylinder extension so that it touches the
anilox evenly
For works requiring the application of a thick layer of paint
or varnish, anilox with a larger capacity is necessary

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Hazardous Risk Risk

Lifting the
ink tray

blade holder,

Anilox
cylinder
protection

Printing
cylinder
protection
Station
sticker
sliding cover

3. Impact Low Low

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10 KELVA web cleaning system

Cleaning system by KELVA is responsible for cleaning the web from dust and other
undesirable contamination. All of them are sticking to polymer roll/rolls (depending on version)
inside KELVA device which lift them from web and transfer to easily replaceable adhesive sheets.
Figure 10.1 KELVA web cleaning system
Specification and more information about operating in device producer’s manual.

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11 Delam / Relam
If glue between base and covering material is too strong, Delam/Relam option is helpful.
Delam/Relam process starts with taking of covering material from base material (delamination)
and put covering material again on base material (lamination). This process make glue weakness.
2
1
3 3
Figure 11.1 Delam/Relam option on machine
4 4
Figure 11.2 Delam/Relam option on machine

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1. Delamination roll – place of delamination
2. Screws for delamination angle adjustment
3. Screws for precision lamination angle adjustment
4. Knob with indicator for lamination NIPs pressure adjustment
5. NIP lamination– place of lamination
INFO
To get the best quality of Delam/Relam process the most important is

correct lamination angle and lateral materials fitting.

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12 Grafotronic hot air dryer

Printing with high speed or using different types of paints requires sufficient dryer. This
machine is equipped with Grafotronic hot air dryer. This option allow machine to print with
higher speed cause machine with this option can dry more material meters per minute.
To enable drying fan system find in Printing station menu “Drying fan off” button shown
below. If it is grey highlighted it means that the fans will be activated with printing. If button is
green highlighted that means fans will not working when machine will be started with printing.
Figure 12.1 “Drying fan off” button
Figure 12.2 Grafotronic hot air dryer
ATTENTION
Risk of burns.
Dryer parts may be hot.
• Machine parts can reach high temperatures
• Always wear gloves to protect against burns when working with
hot surfaces

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13 Missing label device

13.3 Basic information
Missing label system allows us to check the material for faulty labels. It is possible thanks
to a sensor which is comparing the actual image to the reference one. Press the eye symbol in
the menu to enter the camera settings.
Figure 13.1 Missing label system MLD

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13.4 Operation
The image displayed on the screen is the most up-to-date recorded by system. The faulty
label displayed on the screen is the first faulty label that passed the sensor. Until the image is
removed from the error queue, it will be displayed on the screen.
1 2 3 4 5
Figure 13.2 Main menu of the missing label system
1. Main menu – Go back to the main menu.

2. Areas – Modify the areas.
3. MLD activation – Button for activating the missing label system.
4. Clearing faults – Clearing faults button.
5. Tolerance button – Press it to set the tolerance of the image.
6. Faults queue area – Displays labels and errors.
7. Faults row area – Space of displayed error numbers in a row of labels. Pressing the
displayed number will clear the error count.

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Setting algorithm:
1. Make sure there is enough material on the machine to take the 30 repetitions reference
image sample.
2. Press the button (2) to modify areas.
14
13
12
8 9 10 11
Figure 13.3 Areas menu
8. Undo – Go back to the menu

9. Delete the area line
10. Add the area line
11. Teaching mode – The camera goes into teaching mode.
12. Horizontal area line – The horizontal lines define the repeat range. The white point on
the line allows you to move the area lines. The range may include more than one label,
use the arrows to move the image.
13. Vertical area line - Defines a row of labels. The white point on the line allows you to
move the area lines. To add or delete lines, use the buttons (9) or (10).
14. Marker – The area that should be set in a unique spot of the label, e.g. on the unique
lettering or in the corner of the label.
3. Set the horizontal lines (12) defining the repeat area by moving the white marker.
4. Set the vertical lines (13) that define the area of the labels’ row. When adding vertical lines
(10), the distances between the lines will be kept. In case of inaccurate line alignment, it
will be necessary to correct the alignment. The lines should be as close as possible to the
center of the gap.
5. Set the marker (14) in the unique spot of repetition.
6. Make sure that the areas are defined correctly.
7. Press the teach mode button (11) in order to acquire a reference image of 30 repetitions
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Figure 13.4 Teach mode of the MLD
INFO
The speed of acquiring reference image.
It is recommended to teach the camera on the JOG speed (5 m/min) to
make sure that the reference image does not contain gaps or faults.

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1 2 3 4
Figure 13.5 MLD menu
The activation / deactivation of the MLD system is indicated by the button (3). The
missing label is displayed as a red rectangle in the error queue area (6). The machine is equipped
with an inspection table with a buffer, which allows you to stop the machine in order to eliminate
faulty labels or to completely remove the defective section of web. The row of labels at the top
of the error queue (top right corner) corresponds to the table's location. After fixing the faults
and starting work, the web will stop where the next error occurs. To ignore all faulty labels,
press the clearing faults button.

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14 Turnbar
The turnbar is the optional part of the machine that allows the web to be turned upside down.
The 45-degree spindles (1 and 2) do not rotate. There are air holes in the place where the web
slides on the mandrel. Compressed air is fed through them between the web and the mandrel,
which reduces friction.
Figure 14.1 Turnbar
14.4 Operation
To turn on the turnbar it is necessary to touch Turnbar button. If it is on, the button will
have green highlighted.
Figure 14.2 Turnbar on/off button

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Side adjustment of the Turnbar is carried out by using a knob. It allows to move the Turnbar
along with the web in the desired direction.
Figure 14.3 Turnbar side adjustment knob

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15 Full rotary die cut station

The full-rotation cutting station is used to die-cut labels in a full-rotational mode of
operation. The cut, placed under appropriate pressure, imprints the shape on the material
moving longitudinally.
Figure 15.1 Full-rotary station
Figure 15.2 Full-rotary station. View without front cover

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6
9
9
Figure 15.3 Left side of the full-rotary station
Figure 15.4 Right side of the full-rotary station
1. Pressure control
2. Side adjustment
3. Magnetic cylinder
4. Anvil roller
5. Left and right side covers
6. Cut marker sensor. (optional)

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WARNING
Rotating elements.
The nip rollers and the cylinder system are driven.
Pulling the body in may cause disability.
• Do not put your fingers near the working station!
emergency button
ATTENTION
Before starting work, check the station for foreign
objects.
• Do not use sharp tools to remove the dies.
• Check if there is any foreign object inside the station that could
damage the die and cylinders!

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15.4 Replacing magnetic cylinder

Turn the clocks counter clockwise until you feel play on the pins.
Figure 15.5 Pressure clocks
Loose pins of the clock allow the fasteners to be moved to the center of the station, from
where it is possible to remove the fasteners. Keep the clocks in a safe place.
Figure 15.6 Fasteners moved

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Figure 15.7 Pressure slides
To remove the pressure slide, unlock the nuts securing the slide to the bearing cubes.
Figure 15.8 Sled blocking nut.
Remove the sled, leaving the pins attached to the bearings cubes.
Figure 15.9 Sled removing

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Install the cylinder removal handle securing the cube pins with the nuts.
Figure 15.10 Cylinder removal handle
ATTENTION
Possible hardware damage.
Cylinders are heavy.
• Make sure that the pin is threaded securely into the cubes and
that the nut is properly attached to the handle.
• Raise the cylinder gradually without tilting either side, taking
care not to damage the cylinder and do other parts of the
machine around the station.
• Wear safety shoes!
• The cylinders are fragile, keep order around the station so as not
to damage the cylinder.
Figure 15.11 Cylinder rising

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15.5 Menu die cutting station

Standard full rotary die cutting doesn’t have any menu due to changing the cylinders
mechanically. More than one station can work in synchro mode, which relies on matching
magnetic cylinder speed with the next station using compensation. There will be a die cutting
menu only with register option.
Figure 15.12 Full rotary die cut menu
1. Cylinder size - The size of the magnetic cylinder that is currently in the machine. Print
repeat have to correspond with magnetic cylinder to die cut in the register.
2. Number of mark - Value of how many markers there is on the print
3. Compensation - The compensation window displays the values detected by the sensor. The
detected values should stabilize after three revolutions around one value. By moving the
cut line forward and backward, the compensation values will change. After setting the
accuracy appropriate for the operator, the compensation will stabilize around one value.
4. Registration - Activates the marker sensor and enables cutting of register. The button
highlighted in green means the register pin sensor is activated.
5. Window – The range in which the sensor looks for a marker for every repeat. The smallest
window value should be half the distance between the closest markers. There should be no
other markers on the marker line.

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Figure 15.13 Repeat format and window.

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15.6 Winding of matrix material

The matrix winding system consists of an expandable winding spindle and a rubber press
roller that helps to separate the laminate from the primer. The roller can be lifted by lifting the
handle (4). The press force of the roller can be adjusted on both sides with the knobs (3). The
auxiliary roller (5) reduces the web delamination angle, improving the quality of matrix removal,
depending on the material and shape of the label. The matrix can be upgraded to the snowball
version, in which the web presses against the rubber roller, improving the winding quality. In
the event of the matrix being broken, an alarm will be triggered and the machine will stop.
Figure 15.14 Basic matrix wounding
1. Expansion spindle
2. Rubber roller
3. Adjustment of the roller's press force
4. Adjustment of the rubber roller
5. Auxiliary roller
6. Roller rotation adjustment screws
INFO
Winding of matrix material
Due to the wide range of materials available on the market. Winding
matrix requires the selection of appropriate tensions and the use of
material. Irregular shapes with narrow gaps between the labels can
significantly reduce the winding speed and reduce the tensions of the
matrix waste section.

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Figure 15.15 Snowball matrix section
15.6.1 Operation
6
4
3 5
Figure 15.16 Matrix menu
1. Tension – Set value of the tension generating force. Range 0-150 N

2. Build-up –Characteristics of the interdependence between the tension and the
diameter of the unwound roll
3. Turn on the matrix - Turns on the work with the matrix and expands the spindle to
immobilize the reels. The green highlighted button means the matrix is on.
4. Matrix press - Spindle press to the rubber roller in the snowball winding system.
unwinding.
6. Selected pressure - The pressure of the matrix against the rubber roller. Range (0.1-1
bar)

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ATTENTION
Risk of injury
The moving pin of the matrix can injure the body.
• Watch out for your head and hands so that they do not get in the
way of the elements working with the matrix!

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16 Front-Loading die cutting station

16.3 General
Front loading die cut station enables quick change of magnetic cylinders. Station is
equipped with standalone trolley for unloading and loading cylinders.
Figure 16.1 Die cutting station
1. Pressure control
2. Side regulation (10 mm range)
3. Trolley for magnetic cylinders

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2 1
1
3 3
Figure 16.2 Front loading die station
1. Cart blockade
2. Cart sideways movement blockade
3. Trolley wheels blockade
ATTENTION
Putting magnetic cylinder on cart has to be done with lifting
heavy equipment precautions.
• Putting magnetic cylinder on cart has to be done with lifting

heavy equipment precautions.
• Trolley’s wheels should always been blocked unless trolley have
to be transported.
• Carts movement has to be blocked after changing the position
of cart.
• Safety requirements should always be contained when moving
carts sideways, inserting the cylinder and unloading the
cylinder.

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16.4 Preparing the station
Before and while using the die cutting part of the machine, appropriate lubrication of the
bearings of magnetic cylinder (left and right) should be provided. There are grease nipples for
grease application situated on the front of bearings holders for lubricant application. For
lubrication we can use most of the technical liquid oils available on the market.
The junction of anvil and magnetic cylinder should also be kept lubricated.
The essential thing is to control the station in respect of presence of mechanical impurities,
which can damage die and cylinders, before every use.
The hold down force on the anvil should be the same on both sides of cylinder.
Pressure applied varies between 2 and 250 bars. We adjust the hold down force empirically,
using screws located on the top of the station, beginning with the lowest possible force. When
pressure increase up to 250 bars machine will stop.
Pressure applied to magnetic cylinder unables possibility of unloading the station due to
safety precautions. Hold down force has significant influence on the speed of use up of the die
and anvil.

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16.5 Replacing magnetic cylinder

In order to replace magnetic cylinder, you have to click on main panel “Load magnetic
cylinder” button. Once operator does it, instructions viewed on main operator panel have to be
followed.
First, they have to put trolley with magnetic cylinder inside side loading system.
Once this is done, whole process of loading magnetic cylinder into die-cutting unit will be done
automatically.
Figure 16.3 Cart inside die cut station
INFO
In order to remove magnetic cylinder firstly loose the screw on pressure
clocks, until loose on the screw can be felt! Pressure higher than 4 bars
unables cylinder unloading.

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Operator has to click “Cylinder unload” On main operator panel. Everything will be done
automatically, until operator will be asked to put magnetic cylinder trolley into front-loading
unit.
Carefully check the correct position of the trolley.

You can safely remove the magnetic cylinder using special trolley which came with machine.
After taking out the magnetic cylinder using trolley, there is a possibility to put die plate on
magnetic cylinder.
16.6 Maintenance of the die cutting station

1.Apply approximately 10 drops of oil (type - HLP22) daily just to keep soaking the cleaners.
Figure 16.4 Band’s cleaners
2. One time per month maintenance department need check all tension in belts and regulated
when it is needed.
3. Every 50 workhours add grease (type - NLGI 2 )to magnetic cylinder’s and anvil’s bearings
using grease nipples mounted in the cubes (picture below) till grease flow out.

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Figure 16.5 Grease nipples operator side
Figure 16.6 Grease nipples machine side

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16.7 Menu die cutting station
Figure 16.7 Front loading station menu
Trolley lift: Button used for lifting the trolley when it’s necessary.
Cylinder load: Starts the cylinder load sequence
Cylinder unload: Starts the cylinder unload sequence
Set reference cylinder pressure: Box for setting the pressure applied on the cylinder. Higher
than 5 bars pressure on cylinder sides lights orange. When pressure reach set value cylinder
sides pressure lights green. When pressure reach value higher than 250 bars cylinder set will
light red and machine will stop. Pressure is applied manually.
Register menu: (Only for machine with register options) Opens menu to adjust compensation
button for compensation below.
Button + increase compensation. When you press this button you increase compensation.
Change of 0,1mm and 1mm.
Button - decrease compensation. When you press this button you decrease compensation.
Change of 0,1mm and 1mm.
Compensation - it shows the current value compensation

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2. Rubber roller
5. Auxiliary roller
INFO

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16.8.1 Operation
6
4
3 5
7. Tension – Set value of the tension generating force. Range 0-150 N

unwinding.
bar)

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ATTENTION
Risk of injury

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16.9 Backscore knives

The machine is equipped with trimming knives and allows you to cut the silicone
primer.
1
4
Figure 16.11 Backscore knives
1. Backscore knife – To replace knife unscrew [2] entirely, change the knife and screw it
back.
2. Regulation screw – Screwing in moving the knife towards the material.
3. Counter nut – This nut is used to block the knife.
4. Side adjustment lock – Screw this to block the knife from moving sideways.
5. Side adjustment – Precision side adjustment.

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INFO
Trimming knife in feed
The blade press should be adjusted while the machine is moving at jog
speed or slower. The blade may be pressed too hard and the knife may
break when you start up.
16.9.1 Setting the job
1. Move holders to cut position. Block side adjustment using screw [4].
2. Run the machine using jog button or jog pedal during below points.
3. Gently turn the screw [2] moving knife towards material.
4. Check if knife is cutting only based material. Cutting deeper might damage the knife or
damage the matrix.
5. When cut is good enough block the knife using nut [3]
6. There is a possibility to adjust precise side position using [5].

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Cylinder not pressed in

• Press the cylinder down with the button on the main
panel
• Check that the set press corresponds to the pressure
displayed on the regulator inside the machine
• System pressure too low
not bent.
Solenoid valve control relay failure
Check the switching status of the solenoid valve.
The labels are not die-cut
No pressure
• Check the pressure in the machine
The cylinder is skewed
• The cylinder has been placed on the teeth. If the
pressure drops after movement, press the cylinder
again.
Incorrect die
• Depending on the thickness of the material, the
length of the die knives should be correctly selected
The die is worn out
• The die is worn out, it is necessary to check the
cutting on a different material and use a different
die
All necessary nips open
• Close nips using the main menu
• Correct the replacement of the rubber roller
Play on the material Too low pressure in the roller nip closure system
• Increase system pressure
not bent.

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Cyclic sound
Broken bearings of one of the cylinders
• Replace the bearings with new ones
Operation parameters incorrect
• Re-enter the operating parameters
• Reduce the gap using the gap compensation
Inadequate gap between labels
parameter.
Incorrect dimensions of the die
• Change the die
Hazardous Risk Safety solutions

Number Section Risk probability
situation level applied
Warning in manual,
cover, protection
1. Roller nip Catch point High Low
bar Electrical
protection
Warning in the
Magnetic
2. Catch point High Low manual, sticker,
cylinder
guards
Operator training,
Die loading / restricted access,
3. Impact Low Low
unloading Electrical
protection
Lowering of Guards blocking,

4. Impact Low Low
the covers Stickers
Warning in manual,
Matrix
5. Catch point High Low safety bar, sticker,
dismantlement
restricted access

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17 Semi-rotary cut station

The semi-rotation cutting station is used to die-cut labels in a semi-rotational mode of
operation. The cut, placed under appropriate pressure, imprints the shape on the material
moving longitudinally in two directions. The station can be equipped with loading and unloading
dies and automatic pneumatic press of the cylinder.
Figure 17.1 Semi-rotation station with automatic loading and pneumatic press.

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Figure 17.2 Left side of the semi-rotary station
Figure 17.3 Right side of the semi-rotary station

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1. Front guard
2. Side adjustment
3. Semi-rotary trolley cover
4. Pneumatic clamp
5. Material-driving nips. Located symmetrically on both sides of the station
6. Cut marker sensor in register pin
7. Magnetic cylinder (standard 200T)
8. Die unloading
9. Loading the die
WARNING
Rotating elements.
• Do not put your fingers near the working semi-rotation station!
emergency button
ATTENTION
residue.
ATTENTION
objects.

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17.4 Operation
Figure 17.4 Cut station menu
1. Original Cylinder size in teeth - The size of the rotary die in teeth. E.g. 96T. Changing the
active value requires overwriting it. If the die length in mm is chosen, the gap compensation
will be reset. The program takes into account the value of the die, as currently highlighted
in green.
INFO
Choice of die length in teeth or in mm.
The length of the die measured in the teeth is intended for rotary dies.
The rotary die is made for a cylinder with a specific diameter. When
entering the die length measured in the teeth, the gap compensation is
automatically selected, because the semi-rotating cylinder has a
different diameter than the intended diameter of the rotary cylinder.
The length of the die in mm is intended for semi-self-rotation dies, which
are produced for a cylinder, e.g. 200T. The value is the length of the
reprint format.
2. Cut length in mm - The size of the semi-rotary die in millimeters. E.g. 304.8 mm. Changing
the value requires overwriting it. If the die length in mm is chosen, the gap compensation
will be reset. The program takes into account the value of the die, as currently highlighted
in green.

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3. Die cut plate start offset - The distance from the cylinder baseline to the first cut line
minus half the gap between labels. The baseline for cylinders for automatic loading is
defined according to the cutting line magnetic cylinder. The baseline for the standard semi-
rotary station cylinders is defined as the center of the plate-positioning pins.
Figure 17.5 Distance from the baseline to the beginning of the cutting of cylinder for automatic loading, for the
semi-rotation die.
Figure 17.6 Distance from the baseline to the start of cutting of the standard semi-rotary cylinder, for the
semi-rotary die

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4. Gap compensation - The amount by which the gap between labels can be increased or
decreased. The value is calculated automatically for rotary dies. And automatically reset
to zero if the die length in mm is selected. Range (-3 to 3 mm)
Figure 17.7 Reprint format and window.
6. Marker sensor distance - The distance by which the material will be moved from the place
where the marker is detected when register pin is activated. This value determines the first
cutting line.
INFO
Marker sensor distance.
The repeatability of the first cut line depends on the position of the
marker in relation to the beginning of cutting. Printing a marker at the
same distance from the first cut line will speed up the setup.
7. Registration - Activates the marker sensor and enables cutting of register pin. The button

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8. Label length compensation - The length by which die-cut labels can be lengthened or
shortened. In the range of -3 to 3 mm
10. Init semirotary - When activated, the corresponding cylinder position is calculated. The
use of this function is required after mode change, turning on the machine and after
pressing the emergency button. Starting the work of the station with the register pin
requires pressing the register pin button first. After pressing the button, the cylinder will
position itself to the first cut line and the material will be moved up to the distance entered
in the marker sensor.
ATTENTION
Starting of the station when the cylinder is pressed
down can damage the material or die.
• Start the station when the cylinder is the interlocked, but not
pressed down.
• The material must be rewound through the trolley to initiate the
stations.
11. NIP - Button for activating the station nips. It is turned on automatically during the
initialization of semi-rotary. When bypassing the die station or not using it, the nips should
be open.
12. Rotation mode - The button for starting the rotation mode of the station disables the
operation in the semi-rotation mode. Bypassing the trolley allows you to work in rotary
mode with a rotary die.
13. Cylinder pressure - Button for automatic cylinder positioning.
14. Cylinder press pressure - The value at which the cylinder is pressed down. Range 3-6 bar.
15. Semirotary plate – this option should be activated (green highlighted) when semirotary
plate is in use. When using full rotary plate, button should be grey highlighted.

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17.4.1 Manual die cutting plate loading
Standard version of semirotary die cutting station need to manual die cutting plate
mounting. To proper mount die cutting plate please follow below steps:
9. Unlock magnetic cylinder allowing it to rotate. Unlocking by cylinder lifting by two

pressure clocks. Pressure clocks should be screwed counterclockwise to raise the
cylinder.
10. Rotate cylinder to position like on the photo below. This position is recommended to
mount die cutting plate because of comfortable.
Figure 17.8 Magnetic cylinder position for die cutting plate mounting. Zero line pins marked.
11. Lower the cylinder to block it. When cylinder is block, clock’s screws will be loose,
but clock indicator should show “0 bar”.

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12. Die cutting plate mounting on the magnetic cylinder. Place the plate to touching zero
line plate on whole length.
Figure 17.9 Die cutting plate placing on magnetic cylinder
13. If beginning of die cutting plate is placed on magnetic cylinder, then cylinder should
be raise. When cylinder will be raised, then should free rotate, pulling die cutting
plate.
Figure 17.10 Die cutting plate fitting to zero line plate

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14. After die cutting plate replacement operator should change cutting length (distance
between first and last cutting lines on die cutting plate-check die cutting plate
specification) and first cutting line offset (distance between middle of the zero line
pin and first cutting line on die cutting plate, red line marked “3” on photo below).
INFO
Distance (1) between middle of the pin to zero line plate edge is
12,5mm. It is enough to add this value to distance (2) between edge of
die cutting plate and first cutting line on this plate.
2 3
Figure 17.11 Die cutting plate first cutting line offset measuring

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17.4.2 Manual die cutting plate unloading
To dismount die plate from semi-rotary station follow below steps:
1. Unblock magnetic cylinder by counterclockwise clocks screwing. Unblocked cylinder is

allow to rotate.
2. Rotate the cylinder, put plastic tool between cylinder and die plate.
3. Peel off die plate by pulling.
4. Mount new die plate following steps from previous point.

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17.4.3 Automatic unloading of the die
The automatic die unloading procedure is as follows:
1. Reduce the pressure exerted on the magnetic cylinder by unscrewing the clock clamps or
press the "cylinder clamp" button to lift the cylinder if the machine is equipped with an
automatic pneumatic press. (grey highlight of the button means the cylinder is lifted)
Figure 17.12 Pressure reduction

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2. Go to the unloading menu and follow the instructions displayed. Press the next button if
you want to continue unloading.
Figure 17.13 Die unloading
3. The magnetic cylinder will rotate to the unloading position, to lower the handle press
the handle button.
Figure 17.14 Die unloading 2

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ATTENTION
Risk of injuries.
Positioning pins
• Follow the instructions when unloading the die
• Do not put your hands between the handle and the cylinder during
the die unloading process
Figure 17.15 Standard position for unloading
INFO
Unloading rotary dies
Due to the technology used in the production of rotary dies, the die is
put on the next cut line. The distance between the first cut line and the
start of the die is only half the gap. A rotary die mounted in place of a
semi-rotary die would not have support in the first cut line, which would
significantly affect the quality of cutting. The rotary die must be lifted
manually before reaching the discharge handle.
4. Hold down the jog button until the die is fully removed from the machine.

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Figure 17.16 Using the jog pedal to unload the die
Figure 17.17 The die unloading process

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Figure 17.18 Die unloading process 2
5. Press the finish button when the die is completely discharged
Figure 17.19 Die unloading 3

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17.4.4 Automatic die loading procedure
The automatic die loading procedure is as follows
1. Reduce the pressure exerted on the magnetic cylinder by unscrewing the clock clamps or
press the "cylinder clamp" button to lift the cylinder if the machine is equipped with an
automatic pneumatic press. (grey highlight of the button means the cylinder is lifted)
Figure 17.20 Pressure reduction
INFO
Loading of dies
Due to the technology used in the production of rotary dies, the die is
put on the next cut line. The distance between the first cut line and the
start of the die is only half the gap. A rotary die mounted in place of a
semi-rotary die would not have support in the first cut line, which would
significantly affect the quality of cutting. The rotary die must be lifted
manually before reaching the discharge handle.

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2. Go to the unloading menu and follow the instructions displayed. Press the next button if
you want to continue unloading.
Figure 17.21 Loading the die 1
3. The magnetic cylinder will rotate to the loading position. Place the die on the holder
parallel to the positioning plate.

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Figure 17.23 Die on the holder
4. Make sure that the die is correctly positioned on the holder. Press next to lower and
load the die.

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Figure 17.25 Parallel arrangement of the die
Figure 17.26 Parallel arrangement of the die 2

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5. Confirm if the die has been correctly loaded.

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17.4.5 Die cutting setting

2. Choose the length of the die in teeth or in mm depending on the die and enter the value
in the semi-rotary menu.
3. Measure the distance between the die and the first cut line, subtract half the gap
between the labels and enter this value into the die offset window.
4. Install the die automatically if the machine allows it or install the die by moving the sheet
to the positioning bar.
5. Make sure that the cylinders are correctly interlocked.
ATTENTION
cylinder.
6. Initialize the station. The cylinder will rotate and position the die before cutting begins.
7. Press the cylinder from the main panel or by turning the press screws to the minimum
cutting start value.
8. Run the machine at jog speed, adjust the cylinder with the press screws until the cutting
quality is sufficient.
ATTENTION

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17.4.6 Planning of the functioning of the register pin
To work with the register pin it is necessary to have a printed flag (marker), on the basis
of which it is possible to fit the material and the cylinder to cut it in the right place.
The manufacturer recommends that there are no other prints in the line of markers. If
there are many prints on one line, the distance between the marker and another print should
not be less than 30 mm. The machine will achieve the best working parameters by placing the
marker start halfway from the first cutting line. The marker should be a 6x3mm black rectangle.
Figure 17.28 Marker location

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Figure 17.29 Sick KTM register pin sensor
1. Teaching button
2. Signal LED
3. Power On LED
4. Light beam
KTM sensor learning procedure:
1. Press the teach button (1) on the marker.

3. The sensor has been taught, the LED (2) flashes on the marker.

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Figure 17.30 SICK KT5W register pin sensor
1. Pre-selection switch
2. Teaching button
3. Function LED
KT5W sensor learning procedure if there are more markers in the line:
1. The arrow on the marker (5) must indicate "teach"

3. Move the machine off the marker and press the teaching button (6) on the primer
KT5W sensor learning procedure if there is one marker in the line:

2. Hold down the teach button (6) on the marker while the machine is working for at least
3 seconds.

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Figure 17.31 SICK KTX register pin sensor
1. LEDs status indicators

2. Display
3. Control panel
Sensor static learning procedure:
1 Press SET
2 Use the plus or minus pushbutton to select “tch” and press SET
3 Use the plus or minus pushbutton to select “2P” and press SET
4 Use the plus or minus pushbutton to select “15t”
5 Point the sensor light beam at marker and press SET
6 Use the plus or minus pushbutton to select “2nd”
7 Point the sensor light beam at clean material and press SET
8 Sensor shows quality of teach from 0 (bad) to 100 (excellent) on the display for 3sec
9 After 3sec display shows read contrast value
Sensor dynamic learning procedure:
1. Press SET
2. Use the plus or minus pushbutton to select “tch” and press SET
3. Use the plus or minus pushbutton to select “dyn” and press SET
4. Place the mark or background under the light spot.
The display lights up during repeat length detection. One repeat length is sufficient
for web lengths of between 0 m/s and 2 m/s. At least 2 or 3 repeat lengths are
recommended.
5. Press SET. Sensor displays Quality of Teach value from 0 (bad) to 100 (excellent).

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17.4.8 Setting cutting in register pin
guiding trolley according to the machine's run or at the end of the operating instructions.

2. Choose the length of the die in teeth or in mm depending on the die and enter the value
in the semi-rotary menu.
3. Measure the distance between the die and the first cut line, subtract half the gap
between the labels and enter this value into the die offset window.
4. Install the die automatically if the machine allows it or install the die by moving the sheet
to the positioning bar.
ATTENTION
cylinder.
6. Teach the register nip sensor on the marker.

7. Press the register pin button and start the station. The cylinder will rotate by setting up
the die-cutter before the start of cutting, then the material will be rewound in
accordance with the given distance of the marker sensor entered in the operator panel.
8. Press the cylinder from the main panel or by turning the press screws to the minimum
cutting start value.
9. Run the machine at jog speed, adjust the cylinder with the press screws until the cutting
quality is sufficient.
10. Adjust the accuracy using the side adjustment and the cut alignment buttons.
ATTENTION

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17.4.9 Control of the pressure of the system

marking [bar] [bar]
Die cut
Cut station 2 6
station
Up / down
Cylinder clamp 3 6
cylinder
Nip
Semi-rotary nips 2 6
semirotary

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8. Rubber roller
11. Auxiliary roller
INFO

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17.5.1 Operation
6
4
3 5
13.Tension – Set value of the tension generating force. Range 0-150 N

unwinding.

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bar)

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ATTENTION
Risk of injury

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17.6 Die cut station maintenance


x
label residue
the station
Apply approximately 10 drops of oil
(type HLP22), only to keep the
cleaners soaked from the bottom of x
the station and from the top (press
guides side)
Lubrication of the magnetic and
anvil (type NLGI 2) cylinder
bearings with grease nipples x (every 50
mounted in the cylinder blocks and work hours)
pressure sledge. Lubricate until
grease emerges
Figure 17.35 Web cleaners and grease nipples

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Figure 17.36 Grease fittings from the operator side
Figure 17.37 Grease fittings from the machine side

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Cylinder not pressed in

• Press the cylinder down with the button on the main
panel
• Check that the set press corresponds to the pressure
displayed on the regulator inside the machine
• System pressure too low
not bent.
The labels are not die-cut
No pressure
pressure drops after movement, press the cylinder
again.
Incorrect die
length of the die knives should be correctly selected
The die is worn out
• The die is worn out, it is necessary to check the
die
not bent.

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Cyclic sound
parameter.
• Change the die

Warning in manual,
cover, protection
1. Roller nip Catch point High Low
bar Electrical
protection
Warning in the
Magnetic
2. Catch point High Low manual, sticker,
cylinder
guards
Operator training,
Die loading / restricted access,
3. Impact Low Low
unloading Electrical
protection

4. Impact Low Low
the covers Stickers
Warning in manual,
Matrix
5. Catch point High Low safety bar, sticker,
dismantlement
restricted access
Trolley of the Cover, restricted

6. semi-rotary Impact Medium Low access, electrical
station protection

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18 Sheeter with conveyor

The sheeter station is used to cut the material in pre set sheet length due to flying saw
system. The cut takes place under appropriate pressure. Sheets are transported with conveyor
with adjustable speed.
4
3
5
1
1
Figure 18.1 Sheeter station with conveyor

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Figure 18.2 Left side of the sheeter station
1. Front guard
2. Side adjustment
3. Pressure clocks
4. Sheeting cylinder
5. Movable conveyor
6. Sheeter conveyor with speed adjustment
7. Cut marker sensor in register pin

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WARNING
Rotating elements.
• Do not put your fingers near the working semi-rotation station!
emergency button
ATTENTION
residue.
ATTENTION
objects.

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18.4 Operation
To change sheeter or conveyor adjustment values choose sheeter module from the top of
main panel. Shown below menu will appear.
4 5
1
6
7
3 8 9
Figure 18.3 Sheeter with conveyor menu
1. Nip pressure – window for nip pressure adjustment.

2. Nip rolls icon – button for nip clamping, activated if green highlighted.
3. Vacuum table – button for suction switching on/off, activated if green highlighted.
4. Flying saw menu – tap to enter to “Flying saw menu”. Menu described below.
5. Enable module – tap to enable sheeter with conveyor module.
6. Sheeter table menu – tap to enter to “Sheeter table menu”. Menu described below
in “Conveyor” chapter.
7. Run conveyor – button for conveyor switching on/off, activated if green highlighted.
8. Conveyor normal speed - percentage value of conveyor speed in reference to
machine speed.
9. “+”,”-“ – buttons for conveyor normal speed manual adjustment.

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Figure 18.4 Flying saw menu
1. Flying saw – Activates sheeting in flying saw mode. Flying saw mode enables sheets length
adjustment. To activate flying saw mode, station has to be initialize with flying saw
enabled.
2. Initialization - When activated, the corresponding cylinder position is calculated. The use
of this function is required after mode change, turning on the machine and after pressing
the emergency button. Starting the work of the station with the register pin requires
pressing the register pin button first. After pressing the button, the cylinder will position
itself to the first cut line and the material will be moved up to the distance entered in the
marker sensor. Machine has to run to initialize the station.
ATTENTION
pressed down.
• The material must be rewound through the trolley to initiate the
stations.
3. NIP - Button for activating the station nip. It is turned on automatically during the
initialization of semi-rotary.
4. Cylinder size – Size of the cylinder in teeth, which is currently mounted.
5. Cut length - The size of the sheets in millimeters. E.g. 304.8 mm. Changing the value
requires overwriting it. Working with register requires cut length matching with print
format.
6. Synchro length – Distance at which the cylinder has a linear speed of the web.

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INFO
Synchro length
The parameter depends on the length of the cut and the number of
blades. With more blades, the sync length must be reduced in order for
the cylinder to slow down to synchronous speed.
7. Number of cutting lines– The number of blades currently in the cylinder.
INFO
Number of cutting lines
The blades must be arranged symmetrically. Using a cylinder with four
blade spaces is only possible for one, two or four blades.
Figure 18.5 Reprint format and window.

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9. Marker sensor distance - The distance by which the material will be moved from the place
where the marker is detected when register pin is activated. This value determines the first
cutting line.
INFO
Marker sensor distance.
The repeatability of the first cut line depends on the position of the
marker in relation to the beginning of cutting. Printing a marker at the
same distance from the first cut line will speed up the setup.
10. Register - Activates the marker sensor and enables cutting of register pin. The button
11. Cylinder offset – by changing this value cylinder with flying saw can be turned in reference
to web.

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18.4.1 Planning of the functioning of the register pin
To work with the register pin it is necessary to have a printed flag (marker), on the basis
of which it is possible to fit the material and the cylinder to cut it in the right place.
The manufacturer recommends that there are no other prints in the line of markers. If
there are many prints on one line, the distance between the marker and another print should
not be less than 30 mm. The machine will achieve the best working parameters by placing the
marker start halfway from the first cutting line. The marker should be a 6x3mm black rectangle.
Figure 18.6 Marker location

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Figure 18.7 Sick KTM register pin sensor
1. Teaching button
2. Signal LED
3. Power On LED
4. Light beam


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1. Pre-selection switch
2. Teaching button
3. Function LED
KT5W sensor learning procedure if there are more markers in the line:

3. Move the machine off the marker and press the teaching button (6) on the primer
KT5W sensor learning procedure if there is one marker in the line:

2. Hold down the teach button (6) on the marker while the machine is working for at least
3 seconds.

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Figure 18.9 SICK KTX register pin sensor
1. LEDs status indicators

2. Display
3. Control panel
Sensor static learning procedure:
1. Press SET
2. Use the plus or minus pushbutton to select “tch” and press SET
3. Use the plus or minus pushbutton to select “2P” and press SET
4. Use the plus or minus pushbutton to select “15t”
5. Point the sensor light beam at marker and press SET
6. Use the plus or minus pushbutton to select “2nd”
7. Point the sensor light beam at clean material and press SET
8. Sensor shows quality of teach from 0 (bad) to 100 (excellent) on the display for 3sec
9. After 3sec display shows read contrast value
Sensor dynamic learning procedure:
1 Press SET
2 Use the plus or minus pushbutton to select “tch” and press SET
3 Use the plus or minus pushbutton to select “dyn” and press SET
4 Place the mark or background under the light spot.
The display lights up during repeat length detection. One repeat length is sufficient
for web lengths of between 0 m/s and 2 m/s. At least 2 or 3 repeat lengths are
recommended.
5 Press SET. Sensor displays Quality of Teach value from 0 (bad) to 100 (excellent).

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18.4.3 Setting cutting flying saw mode
The procedure for setting work in flying saw mode is as follows:

2. Choose the length of the sheet in mm and enter the value in the flying saw menu.
4. Enable the flying saw, run the machine with jog speed 5 m/min or lower than jog speed
and init the station.
ATTENTION
cylinder.
5. Adjust the pressure by turning the press screws to the minimum cutting start value.
ATTENTION

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18.4.4 Setting cutting in register
The procedure for setting work of in the flying saw mode is as follows:

2. Choose the length of the sheet in mm and enter the value in the flying saw menu. The
sheet length has to be corresponding with the print format.
4. Teach the register sensor on the marker.
5. Enable the flying saw and register, run the machine with jog speed 5 m/min or lower
than jog speed and init the station.
ATTENTION
cylinder.
7. Adjust the pressure by turning the press screws to the minimum cutting start value.
8. Adjust the accuracy using the side adjustment and the cut alignment buttons.
ATTENTION

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18.4.5 Knife replacement
To exchange the knife, screws holding knife have to be untightened to take out the knife.

marking [bar] [bar]
Die cut
Cut station 2 6
station
Nip sheeter Sheeter nip 2 6
Stacker
Stacker actuators 2 6
actuators

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18.5 Conveyor
Transport tables carry sheets on the stacker module. The table must be correctly leveled
by adjusting the height of the legs, which also allow you to choose the right angle for the seating
of the table. It is only possible to set the speed of the second table, which is located in the menu
under the name of the table menu. Sheets are pressed to maintain parallelism of sheet guidance.
Figure 18.10 Transport table
Figure 18.11 Conveyor table menu
1. Enable making gap – button for gap between stacks enabling, activated if green highlighted
2. Labels in stack – number of stacked labels
3. Gap length – length of gap between stacks
4. Number of cut lines – number of cut lines responding to count of mounted blades on cylinder
5. Table Normal Speed – percentage value of conveyor speed in reference to machine current
speed
6. Table Cut Speed - percentage value of conveyor speed while cutting in reference to machine
current speed
ATTENTION
Table belts are driven by
During work, it is possible to grasp loose parts of
clothes or parts of the body.
• Be careful when working at the transport table
• Do not touch the belt during operation
• Do not put your hands between the belt and the guide rollers

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18.5.1 Dismantling the sheet table
Figure 18.12 Moveable conveyor
The sheeting station can be set to work as a full-seat punch station, but the first transport
table must be removed. Removing the conveyor can only be done when the machine is not
running.
UWAGA
The table is heavy
Dismantling of the table should be carried out only
under supervision.
• Be careful when removing the table
• The locks of the table must always be closed during operation of
the machine.
• After opening the locks, the table must be firmly held

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18.6 Dance system (optional)

The dance system is used to stabilize the tension before sheeting station. Idlers are
moving to the way the material is loose and adjust tension. To enable the dance system click
“dance system” on the sheeter menu.
Figure 18.13 Dance system web path
ATTENTION
Movable parts
Rolls are moving depending on the material tension.
• Don’t put fingers near dance system while machine is running
• Disable the dance system during web guiding through the station

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18.7 Station maintenance


x
label residue
the station
Apply approximately 10 drops of oil
(type HLP22), only to keep the
cleaners soaked from the bottom of x
the station and from the top (press
guides side)
Lubrication of the magnetic and
anvil (type NLGI 2) cylinder
x (every 50
bearings with grease fittings
work hours)
mounted in the cylinder blocks.
Lubricate until grease emerges
Figure 18.14 Web cleaners

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Figure 18.15 Grease fittings from the operator side
Figure 18.16 Grease fittings from the machine side

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No pressure
Sheets are not cut properly pressure drops after movement, press the cylinder
again.
Incorrect blade
thickness of the blades should be correctly selected
The blade is worn out
• The blade is worn out, it is necessary to check the
blade
not bent.
Cyclic sound
parameter.
• Change the die

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Warning in manual,
cover, protection
1. Roller nip Rapture High Low
bar Electrical
protection
Warning in the
Magnetic
2. Rapture High Low manual, sticker,
cylinder
guards

3. Impact Low Low
the covers Stickers
Cover, restricted
access, warning in
4. Conveyors belt Catch point Medium Low
manual, warning
sticker

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19 Digital cross perforation

The digital cross perforation station, abbreviated as DCP, is used to perforate the primer
in rotary or flying saw mode. The perforating die applied under the appropriate pressure,
imprints the line of cuts on the material moving longitudinally. The station is equipped with
semi-automatic loading and unloading of perforating dies. The press of the perforating cylinder
is regulated by screws on both sides of the cylinder.
Figure 19.1 DCP System
WARNING
Rotating elements.
The cylinder system is driven. Pulling the body in may
cause disability.
• Do not put your hands into the working space of the DCP
section!
emergency button

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INFO
Die selection
The die with more perforating lines used in the DCP station must be
produced according to the 96 teeth cut distortion. Perforating lines must
be arranged symmetrically. For example, in the case of two lines, the
distance between them must be 150.2 mm.
19.3.1 Operation
Figure 19.2 DCP menu
1. Flying saw - Button activating the flying saw mode. The button highlighted in green
means that the mode is activated.
2. Init - When activated, the corresponding cylinder position is calculated. The use of this
function is required after mode change, turning on the machine and after pressing the
emergency button. Starting the work of the station with the register pin requires pressing
the register pin button first. After pressing the button, the cylinder will position itself to
the first cut line and the material will be moved up to the distance entered in th marker
sensor.
CAUTION
pressed down.
• The material must be rewound through the station to initiate the
stations.
3. Press – Button activating the adjustment of the perforating cylinder to the opposite
cylinder, adjustable by screws on both sides of the section. The button highlighted in
green indicates the cylinder is clamped.
4. Cut distance in mm – The distance between the specified perforated lines is given in
millimeters.
5. Synchronization distance – The distance at which the magnetic cylinder reaches the
material speed to eliminate misalignment and jerks.

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no other markers on the marker line.
7. Marker sensor distance - The distance by which the material will be moved from the
place where the marker is detected during station initialization in register pin. This value
determines the first perforation line.
8. Number of perforation lines - Set value of perforation lines for the die.
9. Register pin - Activates the marker sensor and enables cutting of register pin. The button
10. Length compensation - The length by which die-cut labels can be lengthened or
shortened. In the range of -3 to 3 mm
11. Compensation - The compensation window displays the values detected by the sensor.
The detected values should stabilize after three revolutions around one value. By moving
the cut line forward and backward, the compensation values will change. After setting
the accuracy appropriate for the operator, the compensation will stabilize around one
value.
Figure 19.3 DCP loading menu
12. Loading mode - Button that activates the loading mode. The button highlighted in green
means that the mode is activated. In the loading mode, it is possible to load and unload
perforating dies.
13. Loading position - The cylinder rotates to the die loading position entered in the loading
position offset window.
14. Unloading position - The cylinder rotates to the die unloading position entered in the
unloading position offset window. The difference between unloading and loading offset
is the length of the die.
15. Rotate Forward - Enables manual cylinder rotation mode. You can turn the cylinder with
the jog mode.
16. Rotate Backward - Enables manual reverse cylinder rotation. You can turn the cylinder
backwards with the jog mode.
17. First cut line distance - Distance from the start of the die to the first cut line.
18. Die length - The length of the entire die. Value appropriate for unloading the die.

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19.3.2 Loading of the perforating die.
The perforation die loading procedure is as follows:
1. Open perforation menu.

2. Make sure the machine is not working
3. Make sure the buttons of the flying saw, init and press are gray.
4. Insert values
5. Start loading mode
6. Press the loading position button so that the cylinder rotates to the starting position.
7. Open the cover and mount the perforation line parallel to the base line of the cylinder
8. Make sure that the perforation line is correctly mounted and load the die by turning the
cylinder with the jog button.
CAUTION
Risk of injury
The die is loaded with the cover open.
• Be careful when loading and unloading. Keep your hands and
loose clothes outside the station's working area.
19.3.3 Unloading the perforation die

The perforation die unloading procedure is as follows:
1. Open perforation menu.

2. Make sure the machine is not working
3. Make sure the buttons of the flying saw, init and press are gray.
4. Start loading mode
5. Press the unload position button to make the cylinder rotate to the unload position
defined by the length of the die.
6. Open the cover and lift the die so as not to scratch the cylinder.
7. Unload the die by turning the cylinder with the jog button.

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Figure 19.4 DCP
20 Auto-set under/back scorer knives

UNFINISHED (in progress)
Figure 20.1 Auto-set scorer knives

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Figure 20.2 Auto-set scorer knives

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21 Cutting section
6E blades are used to cut the material into ready-made rolls. The cutting takes place in the
gap between the labels of the cut material. The shaft on which the blades are mounted is
clamped under pressure to the shaft on which counter-blades are mounted and thus enable the
cutting. The station is equipped with a lateral adjustment range of 10 mm.
Figure 21.1 6E blades
ATTENTION
Risk of mutilation.
The blades and counter-blades are sharp!
• Be careful when working with blades.
• Do not put your hands into the station while the machine is
working.
• Make sure that the counter-blades axle is properly closed
ATTENTION
• Adjusting the station while the machine is at a standstill with the
blades interlocked can break the web.

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Cutting involves the cooperation of the blade and the counter-blade in pairs. The blades
and counter-blades are blocked on the shafts based on the eccentric principle. Putting a blade
or a counter-blade on the axle is possible only when the line is set on the housing marked as 0.
Figure 21.2 Blade 6E
Figure 21.3 Counter-blade 6E

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21.4 Operation
The knife setting procedure is as follows:
• Position the station to the center using the side adjustment.

• Unlock the lower axle by unscrewing the knobs to the left until you can open the shelf
and remove the axle.
Figure 21.4 Unlocking of the axle of the counter blades
Figure 21.5 Counter-blade axle unlocking construction

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INFO
Unlocking of the axle of the counter blades
The axle of the counter-blades is locked with two knobs. Turning the
knob counterclockwise will turn and push the lock up to unlock the axle.
Blocking consists in turning the knob clockwise, which will rotate the
lock and slide the lock down, allowing the counter-blade axle shelf to
engage and close. Pay CAUTION to blocking the axes on both sides so as
not to damage the station.
• Unlock the counter-blades using the wrench provided with the machine.
Figure 21.6 Counter-blade lock key
Figure 21.7 Counter-blade unlocking
• Set the first cut line and block the counter-blade by hand in the direction of the material's
movement so that the material blocks the counter-blade.

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Figure 21.8 The first cut line and locked blades.
INFO
Blocking counter-blades and blades
You can initially lock the counter-blades and blades manually so that the
counter-blade does not move during positioning. It should be
remembered that during operation the blades and counter-blades must
be blocked in the direction of winding using the wrenches supplied with
the machine.
• Place the subsequent counter-blades at a distance equal to the number of cut lines and
block them as described in the previous point.
Figure 21.9 The distances between the cut lines
• Block the counter-blades with the wrench supplied with the machine and check that the
distances between the cut lines are appropriate
• Install the counter-blade axle in the station and block the shelf. Counter-blades should
be felt under the material at the point of the cut line.

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• Install the knife axle and position the blades against the counter-blades. Lock the blade
manually in the direction of the material moving so that the material locks the blade.
Figure 21.10 Locking the blades
Figure 21.11 Blade locking wrench

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INFO
Blade feed
The blades have built-in springs that provide them with springiness. It is
enough to position the blade against the counter-blade without the
spring being compressed and lock it manually. Blocking the knives from
the main panel causes pressure to be applied to the axle, additionally
pressing the blades against the counter-blades. Excessive press of the
blades can cause the blades to wear more quickly.
• Press down the knives using the button on the main panel. The green light of the button
means that the knives are pressed.
• Move the machine at jog speed and adjust the spacing accuracy with the side adjustment.
• The speed can be adjusted up to the set value.
INFO
Trimming the lateral sides
Trimming of thin materials can be a problem for the blade from the side
of the machine. Setting the blades very close to the label and then
adjusting the position with the lateral adjustment towards the trimming
significantly improves the process.

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21.5 Razor blade insert (optional)

The razor blade insert allows you to cut thin materials such as foil or MONO foil. The rules for
using the razor blades are similar to those applicable for circular knives.
The procedure for using the station is as follows:
1. Remove the upper axle of the circular knives and unscrew the screws marked with
arrows.
Figure 21.12 Blades as seen from above
2. Replace the larger plate (located closer to the rubber roller) with a plate with a cutout,
use the same four screws for assembly. Remove the smaller plate and leave a free space
in place of it.
Figure 21.13 Blades after plate replacement
3. Unlock the lower counter-knives cassette.

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Figure 21.14 Counter-blades cassette
4. Take the counter-blade axle out of the lowered cassette and replace it with a reel. After
replacing, raise and close the cassette again.
Figure 21.15 Lowered counter-blades' axle

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Figure 21.16 Roller attached to the counter-blade axle
5. In place of the axle of circular knives, mount the holder with razor knives and lock them
on the idler bar using the knobs.
Figure 21.17 Razor knives in place of the axle of circular knives
ATTENTION
Possible injury and damage to the machine.
The blades are very sharp！
• When changing the blades, be careful not to damage the rubber
rollers

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21.6 Razor knives on the idler

21.6.1 Construction of the station
Figure 21.18 Razor knives on the idler 1 2 3
1. Idler
2. Sliding bar - Serves as a base for mounting knife holders, you can adjust its
displacement with the side adjustment number (4)
3. Guards - An element of protection for the machine operator
4. Knob - Adjusts the position of the knife holders (5) in relation to the web
5. Knife holder - Razor blade attachment
6. Axle rotation - Allows you to rotate the axle on which the knives are mounted
ATTENTION
Risk of mutilation.
working.
• Make sure the knife guard is closed during operation.

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Figure 21.19 Knife holder
By pressing the red button (2), you can insert the razorblade(4) into the holder in the direction
of the black arrow. The knob (1) is used to lock the holder on the sliding bar.
ATTENTION
Risk of mutilation.
• When inserting the razor blade, be careful of its sharp edges

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21.6.2 Equipping razor knife stations
Set up the razor knife station by turning the adjustment knob in the direction of the
arrow. After a few turns, you should feel a clear play when turning.
Figure 21.20 Adjustment knob
Play means that the bar and knob have been disconnected thus allowing the bar to be
ejected from its slot. Now you can slide the holders with knives on the rod, locking them with
the knob marked with a red arrow. After putting the selected number of knives into the
appropriate position, put the bar back into the slot and turn the adjustment knob
counterclockwise to re-lock the bar in the slot.
Figure 21.21 Side view of the station

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21.6.3 Razor knives operation on the web
In order to rotate the sliding bar together with the knives, you need to unlock the clamps
that prevent the bar from rotating around its axle. It can be done by turning the handles shown
in the picture.
Figure 21.22 Unlocking the rotation of the sliding rod
INFO

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Adjusting handles
Raising the lever allows it to be turned freely. The handle must be in the
down position to turn the handle.
Positioning the bar

Unlocking the bar rotation also results in loosening the sleeve (1) in the slot
(2) on the machine side. If it is accidentally pushed out, reinsert it into the
slot before locking the bar.
Figure 21.23 Extended sleeve
After unlocking the rotation axle of the sliding bar, you can rotate it together with the
knives using the knob marked with a black arrow.
Figure 21.24 Arrangement of the razor blades
When you set the bar to the selected position, remember to block it by turning the
adjustable handles clockwise.
INFO

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Positioning the knives

Remember to lock the slots on the sliding bar so they can turn with it.

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1. Gauge dial

marking [bar] [bar]
Knives
Blade clamp 2 4
pressure

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21.7 Vacuum system for edge trim removal (optional)

The vacuum system for edge trim removal is simple in build and operating. Trims edge
should be put into waste removal spring and next into vacuum pipe. Activation and deactivation
by “Suction motor” button on main panel. If green highlighted it is activated.
Figure 21.26 “Suction motor” button
Figure 21.27 Waste removal springs and vacuum pipe

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21.8 Maintenance of the knife station 6E

x
label residue
Blades' condition assessment x
Checking the condition of the
x
expansion rubbers
Shaft lubrication x
the station
Pairs of blades and counter-blades should be replaced when worn!

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Cover open
• Close the cover
Knife guard Cover sensor failure
• Clean the cover sensor
• Check the condition of the cover sensor
Press on the control panel is not activated
• Turn on the press using the button on the panel
Arrangement of the blades
• The blades do not touch the counter blades
The tension is too low
• Increase the web tension
Material is too thin
• The knives are adapted to cut paper or silicone
primer. We suggest cutting thin materials with razor
blades.
Material is too thick
The knives do not cut the
primer.
material
Material curls up without the sides being trimmed
• Start cutting on the label and, while adjusting the
station, move towards the edge of the material
Axle pressure too low
Worn blades and counter blades
• Replace blades and counter-blades with working
pairs
Knives are tearing off the
The material is above or below the point of contact between
material, poor cutting quality
the blade and the counter-blade.
• Check that the worktop in front of the knives is not
bent

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22 Slitting station 6E
6E blades are used to cut the material into ready-made rolls. The cutting takes place in the
gap between the labels of the cut material. The shaft on which the blades are mounted is
clamped under pressure to the shaft on which counter-blades are mounted and thus enable the
cutting. The station is equipped with a lateral adjustment range of 10 mm.
Figure 22.1 Sci Fi knives
7. Top cover
8. Bottom knives cassette
9. Button for opening the lower cassette
10. Side regulation

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WARNING
Automatic mode.
Knives are set automatically. Maintaining while the
machine is running can be harmful to your health.
• Always turn off the power during repair and maintenance.
• Be careful when setting knives.
• Make sure all safety devices are working.
ATTENTION
Possible mutilation.
Knives and stones are sharp!
• Do not put your hands in the station while the machine is in
operation.
• Do not interfere with the machine when unfolding knives.
ATTENTION
Possible damage to the equipment
damage the adjustment.
• The resistance of the adjustment indicates the maximum
adjustment range.
• Adjusting the station while the machine is stationary with knives
attached may interrupt the ribbon.
Cutting involves the cooperation of the blade and the counter-blade in pairs. The blades
and counter-blades are blocked on the shafts based on the eccentric principle. Putting a blade
or a counter-blade on the axle is possible only when the line is set on the housing marked as 0.

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Figure 22.2 Blade 6E
Figure 22.3 Counter-blade 6E

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22.4 Handling
The algorithm for safely setting knives is as follows:
• Position the station in the middle using the side adjustment.

• Open the top cover and push the button to slide out the bottom cassette.
Figure 22.4 Lower cassette button
• Set the counter knives position according to the liner on the station. To lock/unlock use
the wrench provided with the machine. Always block the knives in the same direction as
the web follows.
INFO
Blocking counter-blades and blades
You can initially lock the counter-blades and blades manually so that the
counter-blade does not move during positioning. It should be
remembered that during operation the blades and counter-blades must
be blocked in the direction of winding using the wrenches supplied with
the machine.

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Figure 22.5 Counter knives lock key
INFO
Setting the knives
First line position can be compensated by the side adjustment. Next
counter knives that are cutting between the labels should be set with
the same distance. Mostly as width of the label plus gap.

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Figure 22.6 Setting counter knives
• Slide the bottom cassette inside the station until click is heard and check that the
distances between the cut lines are appropriate.
ATTENTION
Using too much force when sliding the station can
damage the gears
• Be cautious when sliding the cassette in.
• Adjust the gears properly.
• Don’t use to much force when sliding the cassette.
• Click to position. The upper and lower cartridges will place the knives in designated
locations.
• Check that the knives are in the set position.
• When driving at low speed (jog), press the knife lock. The knives will be lowered and
pushed to the opposite side, allowing you to cut.
• Adjust placement accuracy with side adjustment.
• You can increase the speed to the set point.

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INFO
The width between the labels
To set the knives in the middle of the gap, enter the label width plus the
gap width in the distance between labels. The centering of the blade can
be calibrated with the side adjustment knob.
INFO
Cutting off side cuts
Narrow clipping of thin materials can be a problem for the machine side
blade. Setting the blades practically on the label and then adjusting the
position with lateral adjustment significantly improves the process.

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22.4.1 System pressure control
The recommended section pressures refer to the maximum configuration of the machine:

designation [bar] [bar]
Knives
Knives pressure 2 4
pressure

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22.4.2 6E adaptation for razors
Operator can use 6E slitting station with razor blades. This modification needs simple
razors’ holder.
Figure 22.7 Razor slitting station
The holders can be moved after loosening levers marked with green arrow. The rod with
razors is unlocked by loosening screws marked with black arrows, after regulating do not forget
to tighten screws again.

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Figure 22.8 Razor holder
After pressing red button (2) we can put the razor (4) in the holder. Knob (1) blocks the knife
on rod.
ATTENTION
The knives are very sharp!
• Take care when you put the razors in the holder.

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22.4.3 Razor blades in 6E station (optional)
6E station could be equipped in razor blades slitting system. Razor blades could be use
instead 6E blades or used like additional cutting line in cooperation with 6E blades. Also razor
blades could be used when 6E minimal cutting width is too big. In this situation operator could
add one more cutting line by razor blade.
1 2 3
Figure 22.9 Razor blades – build
1. Blockade of razor blades rod

2. Razor blades rod
3. Razor blade holder
ATTENTION
Risk of mutilation.
working.
• Wear protection gloves when cleaning/adjusting cutting station
To change position of razor blade holder make loose on the knob (“1” on the photo
below), move holder to wanted position and tight the knob blocking the holder.
To change whole razor blades rod’s position make loose on rod’s locks (“1” on the picture
above), slide the rod to wanted position or change blade angle by rod rotating and block it by
locks.

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By pressing the red button (2), you can insert the razorblade(4) into the holder in the
direction of the black arrow. The knob (1) is used to lock the holder on the sliding bar.

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22.5 Maintenance of the knives station
Proces daily weekly monthly annualy

x
label residue
belts, general condition of the x
station
23 Cutting section
Crush kinves are used to cut the material into ready-made rolls. The cutting takes place in
the gap between the labels of the cut material. Knives are pushed to the opposite roll under
pressure activated from the main panel. The station is equipped with a lateral adjustment range
of 10 mm.
Figure 23.1 6E blades
ATTENTION

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Risk of mutilation.
The blades are sharp!
working.
• Make sure that the counter-blades axle is properly closed
ATTENTION
• Adjusting the station while the machine is at a standstill with the
blades interlocked can break the web.

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23.4 Operation
The knife setting procedure is as follows:
• Position the station to the center using the side adjustment.

• Make sure that the knives are not pushed
• Unlock the knives using red handle, slide it to the required position and lock it.
Figure 23.2 Unlocking of the axle of the counter blades
• Press down the knives using the button on the main panel. The green light of the button
means that the knives are pressed.
• Start pressing the knives against the roll from the lowest required pressure, increase until
the cut is good.
• Move the machine at jog speed and adjust the spacing accuracy with the side adjustment.
• The speed can be adjusted up to the set value.
INFO
Trimming the lateral sides
Trimming of thin materials can be a problem for the blade from the side
of the machine. Setting the blades very close to the label and then
adjusting the position with the lateral adjustment towards the trimming
significantly improves the process.

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23.5 Razor knives on the idler

23.5.1 Construction of the station
Figure 23.3 Razor knives on the idler 1 2 3
7. Idler
8. Sliding bar - Serves as a base for mounting knife holders, you can adjust its
displacement with the side adjustment number (4)
9. Guards - An element of protection for the machine operator
10. Knob - Adjusts the position of the knife holders (5) in relation to the web
11. Knife holder - Razor blade attachment
12. Axle rotation - Allows you to rotate the axle on which the knives are mounted
ATTENTION
Risk of mutilation.
working.

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By pressing the red button (2), you can insert the razorblade(4) into the holder in the direction
of the black arrow. The knob (1) is used to lock the holder on the sliding bar.
ATTENTION
Risk of mutilation.
• When inserting the razor blade, be careful of its sharp edges

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23.5.2 Equipping razor knife stations
Set up the razor knife station by turning the adjustment knob in the direction of the
arrow. After a few turns, you should feel a clear play when turning.
Figure 23.5 Adjustment knob
Play means that the bar and knob have been disconnected thus allowing the bar to be
ejected from its slot. Now you can slide the holders with knives on the rod, locking them with
the knob marked with a red arrow. After putting the selected number of knives into the
appropriate position, put the bar back into the slot and turn the adjustment knob
counterclockwise to re-lock the bar in the slot.
Figure 23.6 Side view of the station

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23.5.3 Razor knives operation on the web
In order to rotate the sliding bar together with the knives, you need to unlock the clamps
that prevent the bar from rotating around its axle. It can be done by turning the handles shown
in the picture.
Figure 23.7 Unlocking the rotation of the sliding rod
INFO

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Adjusting handles
Raising the lever allows it to be turned freely. The handle must be in the
down position to turn the handle.
Positioning the bar

Unlocking the bar rotation also results in loosening the sleeve (1) in the slot
(2) on the machine side. If it is accidentally pushed out, reinsert it into the
slot before locking the bar.
Figure 23.8 Extended sleeve
After unlocking the rotation axle of the sliding bar, you can rotate it together with the
knives using the knob marked with a black arrow.
Figure 23.9 Arrangement of the razor blades
When you set the bar to the selected position, remember to block it by turning the
adjustable handles clockwise.
INFO

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Positioning the knives

Remember to lock the slots on the sliding bar so they can turn with it.

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1. Gauge dial

marking [bar] [bar]
Knives
Blade clamp 2 4
pressure

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23.6 Maintenance of the crush knives

x
label residue
Blades' condition assessment x
x
expansion rubbers
Shaft lubrication x
the station

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Cover open
• Close the cover
Knife guard Cover sensor failure
Press on the control panel is not activated
• Turn on the press using the button on the panel
Arrangement of the blades
• The blades do not touch the roll
The tension is too low
• Increase the web tension
Material is too thin
primer. We suggest cutting thin materials with razor
blades.
Material is too thick
The knives do not cut the
primer.
material
Material curls up without the sides being trimmed
• Start cutting on the label and, while adjusting the
station, move towards the edge of the material
Axle pressure too low
Knives are tearing off the Worn blades
material, poor cutting quality • Replace blades

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24 Sci-Fi Knives
Sci Fi knives are used to cut material into ready-made roll rollers. Sci Fi knives allow you to
automatically place knives and counter knives colloquially called stones. The upper and lower
carriage system sets the knives with the upper gripper from the operator and machine side and
the lower gripper from the operator and machine side.
Figure 24.1 SciFi knives
WARNING
Automatic mode.
Knives are set automatically. Maintaining while the
machine is running can be harmful to your health.
• Always turn off the power during repair and maintenance.
• Be careful when setting knives.
• Make sure all safety devices are working.
• Do not replace the blades while the machine is on.

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ATTENTION
• Do not put your hands in the station while the machine is in
operation.
• Do not interfere with the machine when unfolding knives.
ATTENTION
damage the adjustment.
• The resistance of the adjustment indicates the maximum
adjustment range.
• Adjusting the station while the machine is stationary with knives
attached may interrupt the ribbon.

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24.4 Handling
The algorithm for safely setting knives is as follows:
• Position the station in the middle using the side adjustment

• The number of all knives physically located on the machine must be entered into the
program (knife and against knife counted in pairs)
• Enter the number of cut lines.
• Determine the position of the first line counting from the end of the roll to the side of
the machine to the first cutting line. The correctness of the parameter can be corrected
by side adjustment.
• Enter the distances between the cutting lines (most often the width of the label plus the
gap)
• Click Calculate Position. When you press the distance of the knives on the panel below
they should update.
• Click to position. The upper and lower cartridges will place the knives in designated
locations.
• Check that the knives are in the set position.
• When driving at low speed (jog), press the knife lock. The knives will be lowered and
pushed to the opposite side, allowing you to cut.
• Adjust placement accuracy with side adjustment.
• You can increase the speed to the set point.
INFO
Knife placement correction
The system may not position the knives precisely with an offset of less
than 2mm. When adjusting for a smaller value, the knives should be
retracted to the base and spread out again..

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Figure 24.2 SciFi knives menu
Number of lines – Pre-set number of material cutting lines.
First line position – Set distance from the end of the guide roller to the first cutting line (from
the machine side, when centring the side adjustment).
Knives quantity – A given number of knives that are physically located on the machine
Distance between lines – Set distance between cutting lines.
Parking machine side – Pre-set number of non-working knives to be positioned on the machine
side.
Calculate the position – The program recalculates the positions of the knives after setting.
To position – The cassettes move the knives to the calculated positions.
Knives lock – The top axis lowers and pushes the knives against the knives to enable cutting
Parking – Cassettes move knives to the base position.
ESTOP – Commissioning of the electronic safety system in which all drives are turned off.
Reset – Button to reset alarms
Expander - Spindle air release button. After evacuating the air, the knives can be moved loosely
on the mandrel.
Gap auto detection (optional) – Push to detect gaps automatically. Labels have to be checked
in the widest part of the label.
Trims off (optional) – Push to include trims cutting in auto gap detection

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INFO
The width between the labels
To set the knives in the middle of the gap, enter the label width plus the
gap width in the distance between labels. The centering of the blade can
be calibrated with the side adjustment knob.
INFO
Cutting off side cuts
Narrow clipping of thin materials can be a problem for the machine side
blade. Setting the blades practically on the label and then adjusting the
position with lateral adjustment significantly improves the process.

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24.4.1 System pressure control
The recommended section pressures refer to the maximum configuration of the machine:

designation [bar] [bar]
SciFi
SciFi actuators 2 4
Actuators
SciFi
SciFi axle lock 2 4
Lock axis
SciFi
Knives SciFi Knife Press 2 4
pressure

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24.5 Replacing knives
ATTENTION
• Do not replace blades while the machine is running.
• Be careful when replacing blades and stones.
To replace the knives and counter knives, open the front cover. Opening the cover while
the machine is running will put the station in the state of the electronic safety system (ESTOP)
which will stop the machine.

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Figure 24.3 SciFi knives station

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After opening the front cover, unscrew the three screws located around the perimeter of the
cap. Removal of the cap is facilitated by inserting one screw in the center and pulling on it.
Figure 24.4 Unscrewing the screws
After removing the cap, it is possible to slide the knives and counter knives off the shafts.
When replacing the knives, they should be spaced 15 mm apart so that the feet do not collide
with the blades

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Figure 24.5 Removed caps
Figure 24.6 Knives sliding

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24.6 Vacuum system for edge trim removal (optional)

The vacuum system for edge trim removal is simple in build and operating. Trims edge
should be put into waste removal spring and next into vacuum pipe. Activation and deactivation
by “Suction motor” button on main panel. If green highlighted it is activated.
Figure 24.7 “Suction motor” button
Figure 24.8 Waste removal springs and vacuum pipe

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24.7 Maintenance of the SciFi knife station
Proces daily weekly monthly annualy

x
label residue
x
expanding rubbers
Oiling the shafts x
belts, general condition of the x
station

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24.8 How to maintenance SciFi station

1. Active ESTOP in the SciFi menu
2. Active EXPANDER OFF in the SciFi menu
3. Open the cover of SciFi station
ATTENTION
Possible equipment damage.
Strong linear magnet!
• Do not wear metal accessories when cleaning
• Do not use metal things to cleaning
• Be careful about unscrewed screws or other metal elements
Figure 24.9 Upper linear magnet
Figure 24.10 Lower linear magnet
4. Using compressed air clean whole station from dust and label residue

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5. Remove cover cap and slide off knives and stones from shafts (more in “Replacing
knives”)
ATTENTION
• Do not replace blades while the machine is running.
• Be careful when replacing blades and stones.
6. Using piece of cloth and cleaning chemicals (e.g. Label Remover or alcohol) clean
knives and stones from glue and label residues
7. Remove lower cover of the SciFi station (4 screws on EACH SIDE)
1 2 3 2 3 4
Figure 24.11 Cover screws on the machine side
8. Using piece of cloth and cleaning chemicals (e.g. Label Remover or alcohol) clean upper
and lower encoder line
Figure 24.12 Upper encoder line

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Figure 24.13 Lower encoder line
9. Install the bottom cover

10. Clean knives shaft and stones shaft using alcohol and piece of cloth
11. Lubricate the shafts by Teflon grease spray to easy knives and stones movement
12. Carefully slide knives and stones on the shafts
13. Attach the cover cap
14. Close SciFi cover
15. Disable ESTOP in the SciFi menu
16. Disable EXPANDER OFF

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Troubleshooting should be carried out by the maintenance department.
Problem/Alarm Solution
Open cover
• Close the cover
Sci Fi Cover Cover sensor failure
• Clean cover sensor
• Check sensor state
Putting knives
Sci Fi not ready • Wait for the knives to spacing
• Reset alarm with "reset" button
Knives set too close, gripper hits knife
• Spread the knives by hand, minimum 20 mm
Shifted end sensor of the gripper actuator (manufacturer's
service)
1. Place the end cap on the gripper actuator at
maximum and minimum tilt. The status of the ends is
displayed on the panel. A green light means that the
Sci Fi pneum or collision
end cap is switched on.
Shifted blade detection sensor (manufacturer's service)
• Move the sensor to detect each knife. The position of
the limit switches is displayed on the panel. The green
light in the center means the sensor is on
• After moving the sensor, recalibration is required,
contact the service department.
The physical number of knives does not match the number
entered on the panel
Sci Fi no knives
• Enter the correct number of knives
• Mount the correct number of knives

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25 Buffer module

The buffer module with the semi turret winder allows for a quick change of the reel without
machine stopping.
Figure 25.1 Buffer module
ATTENTION
Automatic mode
Inserting body parts in the path of the buffer can
cause serious injury.
• When working with a buffer, do not enter the buffer zone!
• Be careful when adjusting the buffer module.
The buffer works in two positions. The first position (top) is the work position, the
tensioned material raises the buffer upwards, shortening the material path. When the set value
of the number of labels or meters is reached, the blade station nip slows down and fills the
buffer. The time of filling the buffer allows for unloading and replacement of the reel. The
buffer is filled with a speed of 20 m / min.
To run continuous mode, turn on continuous mode in the buffer menu or in the rewinder
menu.

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INFO
Working with a buffer
Working with the buffer requires closing the nips of the buffer, blade
station and starting the continuous operation mode in the rewinder
menu.
Below is a list of the alarms that may occur in the buffer module. For a list of servo alarms,
see Troubleshooting chapter in the user manual of the machine.
Buffer filling alarm Information about the buffer that is currently being filled
Incorrectly placed web
• Guide the web in the correct direction (along the
web)
The buffer does not fill Filling pressure too low
• Increase the pressure on the buffer gauge to 1-2 bar.
Loose bolt connecting the servo motor to the buffer
• Tighten the screw
Incorrectly placed web
• Guide the web in the correct direction (along the
The buffer tears off the web web)
Filling pressure too high
• Decrease the pressure on the buffer gauge
Buffer actuator limit switch incorrectly set
• Move the limit switch lower using a flat screwdriver
The buffer hits the top cover
so that when filling, the buffer barely touches the
rubber stopper

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26 Roller nip
The roller nip is used to drive the web to rewind the material. The pressed rubber roller
allows the material to move towards the driven roller. The roller nips control the speed of the
machine and keep the tensions between the sections.
Figure 26.1 Roller nip station
WARNING
Rotating elements.
disability.
emergency button
ATTENTION
residue.

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Figure 26.2 Location of mating gears
26.4 Operation
The roller nip is marked with the same button in the menu or with the word NIP. The green
highlighted button means a NIP roller is locked. The rubber roller will adhere with the entire
width
Selected tension between nips – DCL2 machines are equipped with

strain gauge roller on unwinder module. Put value to adjust tension
inside the machine. Machine will regulate machine tension to set value.
Current tension between nips – Current value of the tension set in

tension between nips window.

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26.4.1 Dismantling the rubber roller
The rubber roller is subject to wear. To replace the rubber roller shaft, unscrew and pull
out the two locking screws on the ends of the grips clamping the rubber roller and then pull the
roller out.
Figure 26.3 Rubber nip roller locking screw
Figure 26.4 Rubber nip roller gear

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marking [bar] [bar]
Roller nip
Roller nip station 2 4
station

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26.5 Maintenance of the roller nip station


x
label residue
the station
Cover open
• Close the cover
Nip cover Cover sensor failure
Play on the material
not bent.
Cyclic sound

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27 Winding spindle
The rewinder is equipped with a servo drive to precisely wind the finished material rolls.
Depending on the configuration of the machine, it can be equipped with one or two winders or
two winders in a semi turret system.
Figure 27.1 Winding system
Figure 27.2 Semi turret

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27.4 Operation
The menu below is for a twin rewinder machine, with the top being the top rewinder and
the bottom being the bottom rewinder. In the case of a machine equipped with a single winder
or semi turret, only the buttons for controlling the top rewinder will be displayed on the panel.
6
2
7
4
1
5
Figure 27.3 Winding menu

diameter of the unwound reel
3. Winding direction - Change the winding direction.
4. Current spindle diameter - Set diameter of the spindle located on the machine. The
value must be updated after the spindle is replaced.
5. Current roll diameter - Current roll diameter calculated by the program during
6. Turn on rewinder - Button for turning on the rewinder. The green highlighted button
means that the rewinder is turned on
7. Shaft expansion - The shaft expansion button to hold the reels on the spindle. The
corresponding button is on the side panel. Green button indicates expanded spindle.
8. Number of rolls - Set number of rolls on the spindle.

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INFO
Q-shaft not ready speed.
If semiturret is in unloading position, then the maximum speed of
winding is 20 m/min. To have full range of speed adjustment it is
neccessery to turn semiturret to working position after roll changing by
clicking “Q-shaft ready” button on side panel.
INFO
Tension
The tension force of the web. The force to be applied depends on the
type of material and its width. The evaluation of the correct tension
depends on the experience of the operator.
27.4.1 Tension force characteristics
INFO
Build-up of the tension force
The interdependence between the tension and the diameter. The
program adjusts the diameter of the unwound / wound roll to the tension
force. The build up system helps to keep the winding force constant.
Unwinding and winding with low parameters may cause that there is play
on the roll inside the machine.
tension characteristics
35 700
100%
30 600
75%
25 500
Tension [N]
50%
Diameter
20 400
[mm]
25%
15 torque flat 300
10 200
5 100
0 0
Diameter
Torque flat
Strenght 25%
Figure 27.4 Characteristics of the relation between the tension and the diameter

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27.4.2 The spindle replacement process
Each winding section is equipped with a replaceable spindle with a diameter of 76mm. The
spindle replacement is possible thanks to the Q-shaft system, which is based on loosening the
screw by 180 degrees and re-locking it.
ATTENTION
Replacing the spindle under pressure may cause injury
to the operator and damage the spindle.
• Before replacing the spindle, make sure that the spindle is not
expanded
• Wear safety shoes.
ATTENTION
Adjusting the hub bolts can jam and damage the
spindle.
• Do not adjust the hub bolts!
• Replace the spindle as described below.
The safe spindle replacement procedure is as follows:
Make sure there is no air in the system by turning off the shaft expansion
Insert the wrench into the bolt so that you can loosen the bolt by turning the allen key
No. 8 180 degrees. (picture below)
Figure 27.5 Rewinder screw

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Turn the key No.8 180 degrees.
Figure 27.6 Turning the key
Pull the shaft out by feeling its center by turning the shaft in both directions
Figure 27.7 Pulling out the shaft
Insert a new spindle and turn it in the direction of winding operation.
INFO
Lubricating the axle shaft
The operator should apply grease to the axle of the shaft to keep the
spindle from jamming in the hub and facilitate subsequent replacement.

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Tighten the screw by turning the key No. 8 by 180 degrees.
Figure 27.8 Spindle lock
Make sure shaft is properly installed before applying pressure

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marking [bar] [bar]
Spindles Winding spindles 2 4
Cutter Autocut 3 6
Lay on roller Press Roller 2 4

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27.5 Autocut
An autocut that works with a semi-turret is available as an option. When the set value for
the number of labels or meters is reached, the semi turret turns, the autocut lowers and cuts
the stretched fabric on the core.
Figure 27.9 Autocut
ATTENTION
Automatic mode.
The autocut lowers automatically while the machine is
working, depending on the parameters entered.
• Be careful in the operating area of the autocut.
• Do not put your hands into the autocut working area while it is
working.

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ATTENTION
Risk of mutilation.
The autocut blade is sharp!
• Be careful in the operating area of the autocut.
• Do not put your hands into the autocut working area while it is
working.
• Be careful when replacing the autocut blade.
• Do not adjust the blade settings while the machine is working.
27.5.2 Operation
Figure 27.10 Circular cutting knife
INFO
Entering parameters
Setting the parameters of the autocut should be performed after
stopping the device. When working with a functioning buffer, the nips
on the buffer module and the winding module must be closed for the
semi turret to work.
Go to the counters menu, set the number of labels or meters and activate the button to
stop the machine. (For more information on counters, see the counters menu.)

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Label offset cut - Correcting the stopping of the machine for cutting in
the gap between labels. After the last label is detected by the label
counter, the machine will run the material according to the value set in
the window, so that the auto cutter can cut the web in the gap.
INFO
Label cut offset
Works only according to label counter.
Activate the autocut by pressing the button available on the operator panel in the rewind
menu, there are two modes of work. Auto cut and turret continuous mode.
Auto-cut mode - Turns on the automatic trimming cycle. The machine stops
when the cutting cycle is complete. Run the material a bit so that after turning
the turret, the material does not break off the reels. Press the Q-shaft button to
rotate the turret to the working position. Press the start button to restart the
cycle.
Continuous automatic cutting mode - If the machine is equipped with a buffer

module (dcl machines only), continuous mode can be turned on. After the cutting
cycle is complete, the machine begins to wind the material onto the current
spindle, creating a time window for the operator to prepare the reels on the
other spindle while the buffer fills with material. Press the Q shaft button to turn
the semi turret to working position after unloading the roll and loading new reels.
The machine is ready for automatic cutting.
If the semi turret is not in the working position, press the Q-shaft button in the winding
menu. The semi turret rotates to the working position. When the machine is in the unloading
position, it allows the machine to run at a maximum speed of 20 m / min.
Manual cut - Cut is only possible when the machine is stopped. Load the reels
onto the disengaged loading spindle. After the roll is wound up in the operating
mode, press the rotation button (2) on the semi turret panel to turn the spindle
to the cu-off position. Press the manual cut-off button. The auto cutter will lower
and cut the web.

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The drawings below show the machine's operating modes, spindle designation is linked to
the drawing.
Figure 27.11 Semi turret working mode
Figure 27.12 Semi turret unloading mode

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2 4
Figure 27.13 Semi turret panel
1. Q-shaft ready - Shaft start button

2. Rotation button - 180-degree semi turret rotation button
3. Winding spindle expansion button - When pressed, the winding spindle will expand,
locking the reel on the spindle.
4. Spindle expansion button for loading - When pressed, the spindle will expand, locking
the reels on the spindle.

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27.5.3 Auto cut knife replacement
To replace the blade, unscrew the blade holder cover (screws marked with number 1)
and unscrew the blade holder from the cutter holder (screws marked with number 2).

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Figure 27.15 Holder
INFO
Knife holder
The blade attachment is adjustable during production, leaving the
attachment point allows the blade to be replaced without additional
adjustments to the blade depth.

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Figure 27.16 Shear knife
ATTENTION
Risk of mutilation
Autocut blade is sharp!
• Be careful in the operating area of the autocut
• Do not adjust the blade settings while the machine is working.

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27.6 Automatic front shaft support

The system requires the use of special Q-shafts with handle for bearings. Device works
automatically cooperating with Autocut and semi turret. If Label Counter or Meter Counter will
reach the set value or if machine operator press Manual Cut it will start roll changing process on
semi turret. At first shaft front support unlock and goes up to allow the turret to rotate. Turret
rotate, Autocut cut the web. The next step is to press the „Q-shaft ready” button. Turret turns
to working position and shaft front support goes down and lock by bearings on front side of shaft.
Figure 27.17 Special Q-Shaft with handle for bearings.
Figure 27.18 Automatic shaft front support on the machine.
ATTENTION
Risk of injury.
Shaft front support works automatically.
• Please take attention for moving elements after reached set
value by label/meter counter
• Make sure reels are mounted properly on shaft
• Please be careful after press “Q-shaft Ready” button

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27.7 Autoholder
This equipment is an option for rewinder module with semi turret. If label or meter
counter reached set value then machine slow down and stop, semi turret turns to unloading
position and autoholder lowers. Its task is to press web to glued cores on the unused shaft. After
manual web cut when there is no tension between shafts (Figure 9.11. point 1), autoholder goes
up automatically and semi turret turns to working position. Its ready to rewind new roll of the
material.
Figure 27.19 Autoholder in the pending position
Figure 27.20 Autoholder in the working position

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CAUTION
Risk of injury
The autoholder lowers automatically depending on the
parameters entered.
• Be careful in the operating area of the autoholder.
• Do not bend over autoholder while cutting web – after cut
autoholder automatically goes up.
• Do not put your hands into the autoholder working area while it
is working.
27.7.2 Operation
To enable the Autoholder option touch the "Turret Auto Holder" button. If it is highlighted in
green it means that it is turned on. The moment of operation of Autoholder depends on the Label
Counter or the Meter Counter settings.
Figure 27.21 Autoholder on/off button
How to set Label Counter or Meter Counter described in “Operator’s panel”->“Counters”.

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2 4
1. Q-shaft - Shaft start button


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27.8 Web advancer

27.8.1 General
Web Advancer is a part of the rewinder which is responsible for even winding of the material
and easy mounting of new cycle.
Figure 27.23 Web Advancer in non working position
ATTENTION
Web advancer pressure.
Risk of injury.
• Do not put your hands between the moving parts
• Make sure there is no collision with somebody or something
when activating
ATTENTION
Rotating elements.
Risk of injury.
• Do not put your hands between the moving parts
• Do not wear loose clothes which can be caught by rotating
elements

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ATTENTION
residue.
27.8.2 Operation
To activate Web Advancer tap the “Web Advancer” button on operator main panel making it
green highlighted. After this operation rubber roll should touch to working Q-shaft.
If want to hold material while cutting and roll changing tap the “Gripper” button making
it green highlighted which activate pneumatic web clamp.

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27.9 Lay on roller
The pressure roller is designed to help improve the winding quality of thin materials, such
as mono-foil. The roll presses the web and pushes the air that may collect between successive
spools.
ATTENTION
Risk of injury
Lay on roller might damage people on the way of
• Make sure that rubber roll will not hurt anyone when starts to fall
down.
• Visually inspect falling down process
• Use safety button in a potentially dangerous situation
Figure 27.24 Lay on roller
To lower the lay on roller active “lay on roller” in rewinder menu.
ATTENTION
residue.

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27.10 Web clamp

The web press is used to hold the web while changing the roll and reloading the reels.
The press is located on the main panel. The green highlighted button means the press is
activated.
Figure 27.25 Web clamp
INFO
Clamp
The press will automatically release when the machine is started and
will tighten when stopping. The application of press speeds up the
process of loading the reels and improves the quality of the first material
winding.

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27.11 Support brush (optional)

The support brush is used to hold the cut ends of the rolled material, thus making it easier for
the operator to secure the finished rolls.
Before starting work, the brush position should be pre-set by the handle.
Figure 27.26 Support brush

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27.12 Label counters

27.12.1 Optical counter
The label sensor is always located between the roller nip and the winding zone.
Figure 27.27 Optical Sensor
Model: Tri-tronics LERC
27.12.2 Optical counter learning procedure

Refer to the sensor manual included with the machine for the learning procedure.
To learn the sensor, hold down the “NORMAL” button in the gap between labels. When
there is a gap between the labels in the sensor zone, the LED light on the sensor should light up
INFO
Sensor adjustment
The material must lightly touch the bottom of the sensor

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27.12.3 Ultrasonic counter
The label sensor is always located between the roller nip and the winding zone.
Figure 27.28 Ultrasonic sensor
27.12.4 Ultrasonic counter learning procedure

Refer to the sensor manual included with the machine for the learning procedure.
To train a sensor for a given material type, press "T" (photo above) until the green and
red lights flash. Run the device until the sensor flashes in the gaps
When there is a gap between the labels in the sensor zone, the LED light on the sensor
should light up
INFO
Sensor adjustment
The material must lightly touch the bottom of the sensor

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Shaft not expanded

No pressure
shaft gauge
Insufficient tension
• Increase the tension
Play on the material
Wrong shaft diameter
• Check and correct
Wrong direction
Inactive spindle
Blade is worn
• Replace the blade with a new one
The auto cutter blade damages Wrongly fitted blades in the holder
/ tears off the material • Check and correct
Dirty blade
• Clean the blade taking all precautions
Material collides with the Incorrectly positioned web tensioning bar
holder when there is a lot of • Place the tension bar in the position corresponding
material still on the reel. to the diameter of the installed shaft.
It doesn't count transparent labels
• Check if the correct type of sensor is installed
Label counter does not work Sensor in wrong position
• Place the sensor in the correct position, train the
sensor again if necessary

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Hazardous Risk Risk

Number Section Safety solutions applied

1. Roller nip Catch point High Low protection bar Electrical
protection

2. Roller nip cover Impact Low Low
sticker
Operator training, guard,

Movement of
safety bar, restricted
3. the SCI-FI blade Impact Medium Low
access, electrical
module
protection
Operator training, guard,

Cutting SCI-FI
4. Cut wounds High Low sticker with restricted
blades
access to bars, Stickers
Cutting of razor
5. Cut wounds High Low guard
blades
Cutting of
6. Cut wounds Low Low guard
circular blades
Operator training, slow

7. Autocut Impact High Low
lowering, sticker
8. Autocut Cut wounds High Low Operator training, sticker,
Warning in the manual

Roll loading / regarding the use of proper
10. Ergonomics Low High
unloading tools to lift the rolls and
operator clothing

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28 Operator's panel
1
2 3 4 5 7 6
Figure 28.1 Main panel
1. Main panel
2. Jog button - When pressed and held, the machine moves at a speed of 5 m / min
3. IDLE button - When pressed, the machine moves at a speed of 5 m / min
4. START button - When pressed, the machine moves at the speed set in the main menu.
5. STOP button - When pressed, the machine slows down and stops.
6. Speed control - Speed control on
7. Emergency button – Emergency stop of the machine.

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2 4
1. Q-shaft ready - Shaft start button


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28.4 Main menu operation

The machine is equipped with a touch panel. The main panel starts when the system
starts. The arrangement of the icons varies depending on the machine configuration. The icons
are arranged to correspond to their physical location on the machine
6 7 7
3
1
2 4
Figure 28.3 Main Menu
The operator panel consists of several sections:

1. Start / stop - Section for starting work in the jog / idle / start / stop mode. The individual
buttons are described in the side panels.
2. Selected speed - Set speed of the machine operation. Speed control using the numeric
keypad.
3. Speed circle - Manual speed control.
4. Current speed - The current operating speed of the machine
5. Roll counter - Roll counting section. Detailed description in the label counters section.
6. Counters section - Counters section. Detailed description in the label counters section.
7. Safety circuit reset - Button for resetting the safety circuit remaining after drive failures.
8. Module lights – Module lighted red indicates of the alarm existing on module lighted (for
example cover opened), red has to be accepted, yellow is a warning.

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28.4.1 Counters
Figure 28.4 Counters menu
Counter reset - To reset the counter, press the gray text field with the current counter status
Meter counter - Shows the current meter counter status. The last icon must be green for the
counter to show values. Green icon means the counter is on.
Label counter - Indicates the current state of the label counter. The counter must be turned on
for the counter to show values. The last icon must be green.
Stop at (text field) - A preset counter value. Range 0-999999.
Stop at (hand icon) - Stops label or meter counter. This function is only possible for one of the
counters.
Figure 28.5 Roll counter
Rolls to be made - Set number of rolls to be made. The number of rolls by which the counter
will increase is equal to the number of rolls on one spindle and is shown in the rewinder menu.
Rolls finished - Number of rolls that have been made. The number of rolls by which the counter
will increase is equal to the number of rolls on one spindle and is shown in the rewinder menu.

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28.4.2 Alarms
By pressing the triangle symbol with the exclamation mark it is possible to go to the alarm history
menu. Alarms highlighted in red are machine errors that are currently occurring.
Figure 28.6 Alarm menu

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28.4.3 Formulas
By pressing on the parchment symbol, you can access the formula menu, which allows
you to save the work settings. Loading previously saved work speeds up the production process.
Figure 28.7 Formulas menu
Create Formula - Creates a formula from the currently entered data
Save formula - Overwrites the currently entered data of a previously created formula.
Load formula - Loads the selected formula.
Delete formula - Deletes the selected formula

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28.4.4 Air pressure control
Air pressure control indicators are located on the main panel in sections corresponding to
their physical location on the machine. For example, the pressure adjustment of the expander
shaft on the unwinder module can be found in the section of the unwinder module on the main
panel, called “Spindle pressure”. To change value of pressure, tap the indicator and enter
wanted value.
Figure 28.8 Example of indicators on unwinder module

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29 Troubleshooting
In the event of a servo error, please contact the manufacturer at service@grafotronic.se
Below is a list of alarms that may appear on the servo power amplifier. Please enter the
error number displayed on the amplifier. This will allow you to diagnose a section error faster
DANGER
High voltage!
• The door must be locked when the machine is working.
• Be careful when inspecting the errors displayed on the amplifier.
• The displayed errors must be inspected by qualified personnel
who is aware of the dangers.
Servo alarm list by: Manufacturer of servo mechanisms.

10. – Undervoltage
16. – Encoder initial communication error
20. – Encoder normal communication error
25. – Absolute position erased
30. – Regenerative error
31. – Overspeed
50. – Overload
51. – Overload 2
52. – Error excessive
54. – Oscillation detection
63. – STO timing error
92. – Battery cable disconnection warning
95. – STO warning
9F. – Battery warning
E0. - Excessive regeneration warning
E1. – Overload warning 1
E2. – Servo motor overheat warning
E6. – Servo forced stop warning
E7. – Controller forced stop warning
E9. – Main circuit off warning

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Manual 220444g Dcl2 550 Eng

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Manual 220444g Dcl2 550 Eng

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USER MANUAL

Applicable harmonized standards:

Machine name: GRAFOTRONIC DCL2

complies with the applicable regulations:

01st-July-2022, Warsaw Vice President / CTO

1.1.1. Correct use and storage of the user manual....................................... 14

1.1.2. Copyrights ............................................................................... 14

1.2. User manual format ............................................................................ 15

1.3. Manufacturer responsibility ................................................................... 15

2.2 Intended use of the machine ................................................................. 16

2.3 Intended use of the machine ................................................................. 16

2.4 Safety symbols .................................................................................. 17

2.5 Main dangers..................................................................................... 18

2.6 Dangers during machine operation .......................................................... 19

2.7 Dangers during repair and maintenance work ............................................. 20

2.8 Requirements for the operator and technical staff. ...................................... 21

2.9 Risk assessment manual ....................................................................... 22

3 Acceptance, positioning and lifting ................................................................. 23

3.1 Transport and acceptance of the machine ................................................. 23

3.2 Placing the machine in a designated, appropriate place ................................ 24

3.3 Machine positioning ............................................................................ 25

3.5 Setting up modular machines. ................................................................ 27

3.6 Connection of the pneumatic system ....................................................... 30

3.7 Electrical Connection .......................................................................... 31

3.7.1 Connecting the machine to the Internet ........................................... 33

3.7.2 Maintenance of the electrical connection system ................................ 33

4 Technical data of the machine ...................................................................... 34

Grafotronic Sp. Z o. o. Phone: +48 22 45 67 400 Service Manager: Hubert Stasiński

5.1 General information ............................................................................ 36

5.2 Operation ........................................................................................ 37

5.2.1 Tension force characteristics ........................................................ 39

5.2.2 Unwind direction ....................................................................... 40

5.3 Reel lifter ........................................................................................ 41

5.3.1 General .................................................................................. 41

5.3.2 Lifter remote ........................................................................... 42

5.4 Roll lifter ......................................................................................... 43

5.4.1 General .................................................................................. 43

5.4.2 Lifter remote ........................................................................... 44

5.4.3 Handling ................................................................................. 45

5.5 Decurler (optional) ............................................................................. 50

5.6 Flag and material splice sensor (optional).................................................. 51

5.6.1 Learning procedure .................................................................... 51

5.7 Maintenance of the unwinder station ....................................................... 52

5.8 Troubleshooting ................................................................................. 53

5.9 Risk assessment ................................................................................. 54

6 Web guiding and worktops ........................................................................... 55

6.1 General information ............................................................................ 55

6.2 Control of the machine ........................................................................ 56

6.3 Troubleshooting ................................................................................. 59

7 Printing station ......................................................................................... 62

7.1 General Information ............................................................................ 62

7.2 Setting up the work station ................................................................... 66

7.3 Print adjustment ................................................................................ 70

7.4 Operation ........................................................................................ 72

Grafotronic Sp. Z o. o. Phone: +48 22 45 67 400 Service Manager: Hubert Stasiński

7.4.2 Teaching the register pin sensor .................................................... 77

7.5 Lamination and Cold foil ...................................................................... 78

7.5.1 Lamination operation.................................................................. 82

7.6 GEW lamp ........................................................................................ 83

7.7 Setting the pressure of the system .......................................................... 84

7.8 Maintenance of the print module ............................................................ 85

7.9 Troubleshooting ................................................................................. 86

7.10 Risk assessment .............................................................................. 87

8 BOBST printing station ................................................................................ 88