DUAL LANE MODULE OVERVIEW CHAPTER 21 DUAL LANE MODULE OVERVIEW Figure 21 1 Front Print Machine Item Description Item Description 1 Rear Pass Through Rail (rail 4) 4 Front Print Rail (rail 1)..............
DUAL LANE MODULE OVERVIEW CHAPTER 21 DUAL LANE MODULE OVERVIEW Figure 21-1 Front Print Machine Item Description Item Description Rear Pass Through Rail (rail 4) Front Print Rail (rail 1) Front Pass Through Rail (rail 3) Rear Print Rail (rail 2) Rising Table M40 Dual Lane Controller Chapter Issue Jul 10 Technical Reference Manual 21.1 DUAL LANE MODULE OVERVIEW Figure 21-2 Rear Print Machine Item 21.2 Description Item Description Rear Print Rail (rail 4) Front Pass Through Rail (rail 1) Front Print Rail (rail 3) Rear Pass Through Rail (rail 2) Rising Table M40 Dual Lane Controller Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE OVERVIEW Transport Rails Board Present Sensor Rear Pass Through Rail Rear Pass Through Rail Belt Motor Front Pass Through Rail Belt Motor Front Pass Through Rail Rear Print Rail Front Print Rail Board at Left Sensor NOTE The pass through and print rails would be reversed on a rear print machine Plan View Rear Print Rail Belt Motor Board at Right Sensor Front Print Rail Belt Motor Figure 21-3 Board Sensors and Motors Chapter Issue Jul 10 Technical Reference Manual 21.3 DUAL LANE MODULE OVERVIEW NOTE The pass through and print rails would be reversed on a rear print machine View on Left Hand Side Figure 21-4 Rail Sensors Item Description Item Description Print Lane Home Sensor Rail Clash Sensor Print Lane Home Vane Pass Through Lane Home Sensor Rail Lift Sensor Pass Through Lane Home Vane Rail Clash Vane The dual lane module consists of two sets of transport rails, one being a print lane and the other being a pass through lane There are two dedicated machine variants: • Front print machine • Rear print machine The front print machine prints the product on the front rails (rails and 2) Rails and (rear) are the pass through rails designed to act as a conveyor passing the product through the machine to the next stage On the rear print machine, rails and (front) are the pass through rails and rails and (rear) are the print rails The machines have a rail clash sensor and vane fitted to rails and which prevents rail being driven into rail The machines may be installed in the following configurations: 21.4 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE OVERVIEW DEK Rear Print Machine DEK Front Print Machine Dual Lane Placement Machine Board Loader Print Lane Pass Through Lane Lane Board Loader Pass Through Lane Print Lane Lane Plan View on Machines Figure 21-5 In-Line Install Chapter Issue Jul 10 Technical Reference Manual 21.5 DUAL LANE MODULE OVERVIEW DEK Standard Machine DEK Front Print Machine Dual Lane Placement Machine Board Loader Print Lane Conveyor Pass Through Lane Lane Board Loader Print Lane Lane Plan View on Machines Figure 21-6 Staggered Install Print Lane The print rails are a programmable width conveyor system, set by the board product file, which transports the board using belts from the upline machine, into this machine, where the board is positioned, clamped and printed After printing the board is transferred using the same belts to the downline machine The front print rail is the fixed rail, rail on the front print machine and rail on the rear print machine The rear print rail homes to the fixed rail The print rails can be fitted with one of the following board clamping arrangements: • 250mm or 500mm Board Clamps • 250mm or 500mm Foil-less Clamps • Board Snugger Assembly • Over the Top Snugger (see Transport Rail Chapter for details) Foil-less clamps are utilized for thin pliable boards where there is a requirement to print close to the board edge The foil-less clamps are assisted with the use of a vacuum box beneath the product board Board snuggers are an alternative to the standard board clamps and are utilized when there is a requirement to print close to the board edge 21.6 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE OVERVIEW Rear Board Clamp Board Transport Belts Board Transport Belts Board Transport Belts Board Clamps Rear Foil-less Clamp Foil-less Clamps Rear Snugger Plate Counterweight Block Board Snuggers NOTE The dual lane machines use narrow board clamps allowing rail and to abut each other Standard DEK board clamps must not be fitted to a dual lane machine With board snuggers fitted, the rail clash sensor becomes inactive Care must be taken to avoid a collision between rails and when setting the board width in the product file and when driving the rails in diagnostics For tooling details see the tooling chapter For over the top snugger details see the transport rails chapter Pass Through Lane The pass through rails are a programmable width conveyor system, set by the M40 Dual Lane Controller, which transports the board unhindered through the machine NOTE The pass through rails are designed to continue running with the front printhead cover in the open position and to stop when the E-Stop is pressed Chapter Issue Jul 10 Technical Reference Manual 21.7 DUAL LANE MODULE OVERVIEW The front pass through rail is the fixed rail, rail on the front print and rail on the rear print machine The rear pass through rail homes to the fixed rail 21.8 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE OVERVIEW Rising Table Manual Tooling Plate Splash Guard Manual Tooling Plate Frame 3mm Allen Key Rising Table Home Sensor and Vane Rising Table Motor Figure 21-7 Front Print Machine Manual Tooling Plate Manual Tooling Plate Frame 3mm Allen Key Splash Guard Rising Table Home Sensor and Vane Rising Table Motor Figure 21-8 Rear Print Machine Chapter Issue Jul 10 Technical Reference Manual 21.9 DUAL LANE MODULE OVERVIEW The rising table on the dual lane machine is identical to the rising table on the standard DEK machine with the exception of the manual tooling plate and the home vane The manual tooling plate is raised by 37mm to prevent the splash guard lifting the pass through lane when the rising table moves to print height To compensate for the extra height, the rising table home vane allows the table to home 37mm lower than a standard machine As no tooling is required for the pass through lane, the manual tooling plate extends below the print rails only A splash guard replaces the manual tooling plate below the pass through rails to prevent print material falling on to the rising table motor assembly NOTE Objects must not be placed on the splash guard as damage may occur to the pass through rails as the rising table moves to print height MMI 21.10 The MMI beacon on the Dual Lane machine incorporates a blue light at the top of the beacon This indicates that a board has failed to reach the board present sensor on the end of the pass through rails within 10 seconds of leaving the upline machine Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE ADJUSTMENTS AND SETTINGS Rising Table Home Setting WARNING HOT SURFACES THE SURFACE OF THIS COMPONENT OR SURROUNDING AREA MAY BECOME HOT DURING PROLONGED OPERATION CARE TO BE TAKEN WHEN WORKING IN THE VICINITY OF THIS COMPONENT Front Print Machine With C Chase Fitted Select Open Cover Commands Select Carriage To Rear Select Unload Screen Open the front printhead cover If the machine is fitted with an auto screen loader, go to Step Remove the four screen depth adjuster securing screws Screen Depth Adjuster Securing Screws Screen Depth Adjuster Securing Screws Screen Depth Adjuster View on Inside Right Hand Side of the C Chase Remove the screen depth adjuster from the machine Move the screen towards the rear of the machine so that the front edge is further back than the front edge of the manual tooling plate Close the front printhead cover 10 Press the System button 11 Select Back 12 Select Maintenance 13 Select Diagnostics 14 Use Next or Previous to highlight Screen Change 15 Select Select Module 16 Ensure Toggle Screen Clamps is highlighted 17 Select Run Diagnost 18 Select Exit 19 Use Next or Previous to highlight Rising Table 20 Select Select Module 21 Ensure Home Rising Table is highlighted 21.58 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE ADJUSTMENTS AND SETTINGS 22 Select Run Diagnost 23 Open the front printhead cover 24 Using a steel rule, check that the distance from the top of the manual tooling plate to the underside of the screen is 209mm ±1mm Screen Steel Rule Manual Tooling Plate View on Left Hand Side of Front Print Machine 25 Remove the steel rule from the machine 26 If adjustment is not required, go to Step 35 27 Close the front printhead cover 28 Press the System button 29 From the left hand side of the machine, slacken the two home vane securing screws Chapter Issue Jul 10 Technical Reference Manual 21.59 DUAL LANE MODULE ADJUSTMENTS AND SETTINGS A Home Vane Rising Table Motor View on Rear Right of Rising Table Rising Table Home Sensor Home Vane Securing Screws View on Arrow A 30 If the rising table needs to be higher, move the home vane downwards and secure the two home vane securing screws 31 If the rising table needs to be lower, move the home vane upwards and secure the two home vane securing screws 32 Select Run Diagnost 33 Open the front printhead cover 34 Repeat Steps 24 to 33 35 If the screen depth adjuster was removed, pull the screen towards the front of the machine, refit the screen depth adjuster and ensure the screen is correctly located against the stop 36 Close the front printhead cover 37 Press the System button 38 Select Exit 39 Select Exit 40 Select Back 41 Carry out the following calibrations: 21.60 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE ADJUSTMENTS AND SETTINGS Rear Print Machine With C Chase Fitted • Vision Height, Camera System Module chapter refers • Print Height, Rising Table Module chapter refers Select Open Cover Commands Select Carriage To Rear Select Unload Screen Open the front printhead cover Move the screen towards the front of the machine so that the rear edge is further forward than the rear edge of the manual tooling plate Close the front printhead cover Press the System button Select Back Select Maintenance 10 Select Diagnostics 11 Use Next or Previous to highlight Screen Change 12 Select Select Module 13 Ensure Toggle Screen Clamps is highlighted 14 Select Run Diagnost 15 Select Exit 16 Use Next or Previous to highlight Rising Table 17 Select Select Module 18 Ensure Home Rising Table is highlighted 19 Select Run Diagnost 20 Remove the left hand side safety cover to gain access to the rear of the screen 21 Using a steel rule, check that the distance from the top of the manual tooling plate to the underside of the screen is 209mm ±1mm Steel Rule Screen Manual Tooling Plate View on Left Hand Side of Rear Print Machine 22 Remove the steel rule from the machine Chapter Issue Jul 10 Technical Reference Manual 21.61 DUAL LANE MODULE ADJUSTMENTS AND SETTINGS 23 If adjustment is not required, go to Step 29 24 From the left hand side of the machine, slacken the two home vane securing screws A Home Vane Rising Table Motor View on Rear Right of Rising Table Rising Table Home Sensor Home Vane Securing Screws View on Arrow A 25 If the rising table needs to be higher, move the home vane downwards and secure the two home vane securing screws 26 If the rising table needs to be lower, move the home vane upwards and secure the two home vane securing screws 27 Select Run Diagnost 28 Repeat Steps 21 to 27 29 Refit the safety cover 30 If the machine is fitted with a screen depth adjuster, relocate the screen against the stop 31 Select Exit 32 Select Exit 33 Select Back 21.62 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE ADJUSTMENTS AND SETTINGS 34 Carry out the following calibrations: Front Print Machine With ASM Fitted • Vision Height, Camera System Module chapter refers • Print Height, Rising Table Module chapter refers Select Open Cover Commands Select Carriage To Rear Select Unload Screen Open the front printhead cover Remove the screen On the left hand side, move the ASM to 550 Using a steel rule, check that the distance from the top of the manual tooling plate to the upper face of the screen guide on the ASM is 209mm ±1mm Steel Rule ASM Width Set To 550 Screen Guide Manual Tooling Plate Remove the steel rule from the machine If adjustment is not required, go to Step 18 Chapter Issue Jul 10 Technical Reference Manual 21.63 DUAL LANE MODULE ADJUSTMENTS AND SETTINGS 10 Close the front printhead cover 11 Press the System button 12 From the left hand side of the machine, slacken the two home vane securing screws A Home Vane Rising Table Motor View on Rear Right of Rising Table Rising Table Home Sensor Home Vane Securing Screws View on Arrow A 13 If the rising table needs to be higher, move the home vane downwards and secure the two home vane securing screws 21.64 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE ADJUSTMENTS AND SETTINGS 14 If the rising table needs to be lower, move the home vane upwards and secure the two home vane securing screws 15 Select Run Diagnost 16 Open the front printhead cover 17 Repeat Steps to 16 18 Refit the screen 19 Close the front printhead cover 20 Press the System button 21 Select Exit 22 Select Exit 23 Select Back 24 Carry out the following calibrations: Chapter Issue Jul 10 • Vision Height, Camera System Module chapter refers • Print Height, Rising Table Module chapter refers Technical Reference Manual 21.65 DUAL LANE MODULE REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES Board Clamp Replacement WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP NOTE The dual lane machines use narrow board clamps allowing rail and to abut each other Standard DEK board clamps must not be fitted to a dual lane machine Remove the board clamp securing screws and remove the board clamp Retain the screws Board Clamp Securing Screws 250mm Board Clamp Mechanism Board Clamp Securing Screws 500mm Board Clamp Mechanism Place the new board clamp in position on the location plates Secure the board clamp in position with the screws removed in Step NOTE The Board Clamp Setting procedure is not required after board clamp replacement 21.66 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE REPLACEMENT PROCEDURES Board Clamp Foil Replacement WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP If the board clamp is fitted to the machine, use the Board Clamp Replacement procedure to remove and refit the board clamps Remove the M2.5 x 6mm pan headed slotted screws securing the foil to the board clamp Discard the foil and retain the screws Board Clamp Foil Securing Screw (in positions) View on Underside of 250mm Board Clamp Mechanism Board Clamp Foil Securing Screw (in positions) View on Underside of 500mm Board Clamp Mechanism Fit the new foil with the screws removed in Step Chapter Issue Jul 10 Technical Reference Manual 21.67 DUAL LANE MODULE REPLACEMENT PROCEDURES Moving Rail Drive Belt Print Lane Select Shut Down Select Continue Switch the mains isolator to OFF At the rear of the rising table, slacken the adjustable idler pulley by means of the nut at the front face of the rail drive plate Rail Drive Plate Moving Rail Drive Pulley (Print Lane) Adjustable Idler Pulley Moving Rail Drive Pulley (Print Lane) Drive Belt View on Rear of Rails and Rising Table Mechanism Slide the adjustable idler pulley to slacken the drive belt Remove the drive belt and discard Fit the replacement drive belt Using a suitable cable tie, engage a forcemeter with the adjustable idler pulley Apply a horizontal force of 6kg Maintaining this force, tighten the adjustable idler pulley securing nut 10 Using a tension meter on the top of the drive belt (mid point between the pulleys), check the tension is between 38Hz to 45Hz 11 Adjust the drive belt tension as necessary to achieve the reading in Step 10 12 Power up and initialise the machine 13 During initialisation, the rails home and drive to the programmed board width This evens out the tension in the belt 14 Repeat Steps 10 and 11 21.68 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE REPLACEMENT PROCEDURES Pass Through Lane Select Shut Down Select Continue Switch the mains isolator to OFF At the rear of the rising table, slacken the adjustable idler pulley by means of the nut at the front face of the rail drive plate Rail Drive Plate Drive Belt Moving Rail Drive Pulleys (Pass-Through Lane) Adjustable Idler Pulley View on Rear of Rails and Rising Table Mechanism Slide the adjustable idler pulley to slacken the drive belt Remove the drive belt and discard Fit the replacement drive belt Using a suitable cable tie, engage a forcemeter with the adjustable idler pulley Apply a horizontal force of 6kg Maintaining this force, tighten the adjustable idler pulley securing nut 10 Using a tension meter on the top of the drive belt (mid point between the pulleys), check the tension is between 33Hz to 40Hz 11 Adjust the drive belt tension as necessary to achieve the reading in Step 10 12 Power up and initialise the machine 13 During initialisation, the rails home and drive to the programmed board width This evens out the tension in the belt 14 Repeat Steps 10 and 11 Chapter Issue Jul 10 Technical Reference Manual 21.69 DUAL LANE MODULE CALIBRATIONS CALIBRATIONS Board Transport Belt Speed Print Lane The front and rear board transport belts are driven independently by two variable speed motors Inevitably one motor drives faster than the other motor It is necessary to calibrate these motors so that they drive at the same speed The motor speed is measured using a tachometer on the input or output pulley and adjusted by a potentiometer control on each motor Remove the right hand side safety cover to gain access to the transport belt motors Select Maintenance Select Diagnostics Use Next or Previous to highlight Rail System Select Select Module Use Next or Previous to highlight Belt Speed Calibration Select Run Diagnost The following window is displayed: Belt Speed Calibration FRONT R TO L SPEED FRONT L TO R SPEED REAR L TO R SPEED REAR R TO L SPEED 50000 50000 63999 63999 NOTE Belt Speed Calibration figures displayed on this page have no relevance to the belt speeds on this machine Select either Incr or Decr to start the belts 21.70 Technical Reference Manual Chapter Issue Jul 10 DUAL LANE MODULE CALIBRATIONS Using a tachometer fitted with the surface speed test wheel, positioned on the input or output pulley of the front belt motor, measure the speed of the motor right to left 10 Ensure that the speed is 29 to 31 metres/min 11 If adjustment is required, remove the belt speed adjuster cap on the appropriate motor and adjust using a suitable trimming tool 12 Repeat Steps to 11 for the rear rail 13 Select Next 14 Select either Incr or Decr to start the belts running left to right Chapter Issue Jul 10 Technical Reference Manual 21.71 DUAL LANE MODULE CALIBRATIONS 15 Ensure that the speed is 29 to 31 metres/min for both the front and rear belts NOTE There is no separate adjustment between left to right and right to left If the above speed is not achievable in both directions, the motor may be faulty 16 Select Exit 17 Select Exit 18 Select Back 19 Refit the safety cover Pass Through Lane 21.72 The board transport belt speeds of the pass through rails are controlled by the M40 Dual Lane controller and are not adjustable The belt speed can be measured using a tachometer on the input or output pulley, check the speed to be approximately 30 metres/min Technical Reference Manual Chapter Issue Jul 10 ... 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