AFINIA LABEL DLP-2000, User Manual

Page 1: ...Version 1 2 Version 1 2 ...

Page 2: ...000 Digital Label Press 2000 is a digital label press that is powered by quality color at 6 inches per second ible dies up to 12 inches in length allowing for fast accurate die cutting 2000 is compatible with your existing RotoMetrics dies 2000 can also convert stock to blank labels ready for printing With 2000 in full rotary mode which will convert blank labels at a rate of over 140 2000 Digital ...

Page 3: ...edia 14 System Settings Review 15 System settings when converting printed labels from the printer 15 System settings when converting blank labels reciprocating mode 15 System settings when converting blank labels full rotary mode 15 Enable or disable the loop sensor 16 Opening the die lids 17 Using the splicing table 18 Adjusting media 19 Adjusting mark sensor position 20 Teaching the Mark Sensor ...

Page 4: ...ons 32 Adjusting die travel 33 Entering Label Counts 34 Time out safety setting 35 Changing the electronic black mark 36 Troubleshooting 37 Media problems 37 Registration problems 38 Cutting problems 38 Electrical problems 39 Maintenance 41 Maintenance Schedules 41 Buying cutting plates 42 What and how to order 42 Magnetic Cylinder Information 43 ...

Page 5: ...nia L801 printer Simply print your continuous labels with a black registration mark and this remarkable machine makes laminating and die cutting look electronic mark sensor together with a printed board screen and keyboard to ensure an amazing 0 3mm registration accuracy Die cutting is handled by our unique full rotary reciprocating head This system uses a full rotary cutting with a geared recipro...

Page 6: ...or Laser Registration Sensor Adjustment 9 230 mm x 12 304 8 mm Sensor Mark 0 2 x 0 2 5 mm x 5 mm Lateral Paper Adjustment 0 5 12 mm Laminate Economical self wound and supported laminate on a liner Liner removal included for use with high quality liner supported laminate Core Sizes 3 76 mm Dimensions 65 1650 mm x 41 33 1050 mm x 33 840 mm Frame 0 4 10 mm solid aluminum Safety Sensors Magnetic lid x...

Page 7: ... the base panel The DLP 2000 is supplied ready to use Once you have removed the outer part of the crate you will only need to position the machine with a forklift where it is to be used and plug it in Caution This machine is extremely heavy Do not attempt to move the crate or machine without suitable lifting equipment Failure to follow these instructions may result in serious back injury Caution U...

Page 8: ...d The DLP 2000 is supplied with pre set maximum roller settings If the machine is supplied with no nip pressure simply turn the adjustment knob down unit it stops Do not use excessive force PINCH ROLLER ADJUSTERS The laminating roller pressure is set and should not need to be changed Wind the pressure adjusters down until they stop Do not use excessive force ...

Page 9: ...mponents Caution Do not proceed until you have a good understanding of the major components of your machine and their locations Do not attempt to start or run the DLP 2000 before reading the instructions detailed on the following pages ...

Page 10: ... and underneath the die cylinder NIP ROLLERS These rollers are driven by powerful motors Never under any circumstances place fingers hair or clothing near the nip rollers while the machine is running WARNING LABELS These labels indicate important safety considerations for your machine Never remove damage or obscure warning labels DIE ACCESS LID Never open the die access lid while the DLP is operat...

Page 11: ...e voltage text is not correct you must contact your distributor immediately DO NOT attempt to start the DLP 2000 with the wrong voltage selected Attach a power cable to the DLP 2000 machine Connect the cable plug to a standard protective earth electrical socket of the correct voltage You will need a standard computer power cable with the correct power socket for your country Caution Do not proceed...

Page 12: ...its cycle This value cannot be changed CAL This value is preset at the factory Do not change Encoder Mark 1 3 of the distance of the die length ENC Fast Value of zero ENC O Run Value of 000 8 Index T Out Distance the converter will run before stopping because the black mark was not detected Set this value to 1 5 times the repeat value Jump5 Encoder Indexing Always set to 1 Do not change Repeat dis...

Page 13: ...13 Loading media Caution Ensure that the power is disconnected before you begin to load your media for the first time or until you have a good understanding of the general operating procedures ...

Page 14: ...g process the printer is in control of both sections of the machine Simply pause or stop the printer to stop the unwind and the DLP 2000 converter It is also important that the speed of the printer not exceed the speed of the DLP 2000 converter or media will reach the floor When the printer is slower than the converter the converter will stop and start automatically keeping the loops at a constant...

Page 15: ... 0 off Set in Jump 3 Encoder mark ramp down Set to 1 3 of the die length Set in Jump 4 Repeat Distance of the pitch of the die plus the label gap Set in Jump 5 Sense Set to 0 This causes the system not to use the laser Set in Jump 5 System settings when converting blank labels full rotary mode Change the position of the cylinder to full rotary mode See page 24 Die length Length of die does not app...

Page 16: ...setting Disable the sensor by changing the loop sensor setting to 0 by entering 0 and pressing the Enter key Enable the sensor by changing the loop sensor setting to 1 by entering 1 and pressing the Enter key Press the HOME key to return to the front screen If the need arises where the loop sensor needs to be turned off use these instructions to enable or disable the DLP 2000 loop sensor ...

Page 17: ...e RESET button to re home the cutting die Failure to follow these instructions could result in a web break When cleaning the die lids use a window cleaning detergent only The use of strong solvents or chemicals will destroy the transparency of the lids The DLP 2000 lids can be opened partly or fully depending on the access required OPEN ONE LID AT A TIME USING THE HANDLES PROVIDED Caution Ensure t...

Page 18: ...of the new media to the underside of the previous roll making sure to align them as perfectly as possible Undo and lift the top section of the splicing table remove the unwanted cut pieces of media and place another piece of tape across the top of the media at the join If laminate is being applied the top tape is not required Using scissors or a sharp knife cut the excess tape on each side of the ...

Page 19: ...andrel ruler as it winds up on the make the repositioning of new cores Use the lateral web adjuster to move the web across the machine if needed This can be done while the machine is running Wait for a few impressions before moving it again to see how much movement you ha to begin a job with this adjustment in the center of travel to insure movement in either direcions if required The correct line...

Page 20: ...e on the sensor ensor is deliberately set on an angle to avoid excess reflection on glossy materials When setting up your digital print always place the black mark in the center The adjuster for along the web registration is used to advance or retard the print in relation to the clockwise turning will advance the print towards the slitting end of the machine If the above instructions are followed ...

Page 21: ... be used if the sensor needs to be retrained for different media 21 Before carrying out this procedure you should have the sensor already positioned to see the black your media as outlined on the previous page Inch the media forward until the laser is pointing directly onto the black mark Set the small switch on Once you have done this press the orange button on the left once play will flash and c...

Page 22: ...e black mark to the next Sense is the distance before the black mark that the mark sensor will actually look for the mark A 0 in this setting means you are running a blank label with the mark sensor disabled Encoder read is the distance your machine has travelled since the last black mark Encoder cal is the encoder calibration NEVER ALTER THIS SETTING Encoder Mark is the ramp down distance setting...

Page 23: ...cut the labels by registering the printed black mark Try this if the non black mark setting is not accurate enough To access the menu to enable or disable the sensing of a black mark press Jump and 5 Setting any value in the SENSE option will enable the encoder for reading black marks Setting this option to 0 will cause the system to not look for the black mark Warning The mark sense should only b...

Page 24: ...24 Full Rotary Mode Before you being turn off the loop sensor in Jump 3 by setting it to 0 Follow these steps very carefully in reverse to revert to reciprocating mode ...

Page 25: ...e safely While running slowly lead the waste around the rollers and up to the core on the waste r as shown below will keep the waste at a constant stripping angle regardless of the size of the waste matrix roll Make sure your printer is stopped before removing your waste matrix Follow the instructions below for the safe and effective waste removal on the DLP 25 these instructions to remove your me...

Page 26: ... not require the laminate waste mandrel Continue threading the laminate while winding the waste by hand until your laminate reaches the application point in front of the nip rollers Attach the laminate neatly and squarely to your media Locate your laminate guides on either side of the laminate Your laminate should now be threaded as shown Test run your machine as described on page 19 and ensure th...

Page 27: ...re adjusted down until they stop using firm finger pressure The paper clutch must be used It should create a firm tension on the printed media between the paper clutch and the laminating rollers Without a good tension in this area the web may drift from side to side Insure that the paper guides are adjusted so that there is no room for the media to move from side to side Your printed media roll sh...

Page 28: ...r or all three Caution Ensure that the printer is stopped before opening the die access l lid carefully when you have attached your plate 28 Use these instructions to attach a cutting plate to your magnetic cylinder The DLP adjustments for moving the label in relation to the die so that your plate does not need to be i exact position at this stage Concentrate on getting the cutting plate square to...

Page 29: ...moving cutting plates without damaging the surface of the magnetic or instruments or you may damage the face of the magnetic cylinder which will cause serious damage to Open the die access lids and depress the emergency stop button fully to release the brake on inder motor This will allow you to roll the cylinder into a position where you can access a corner of the cutting die plate Using the die ...

Page 30: ...imple to use and effective in their operation Follow the directions below for the correct use of your The knives are most effective when slitting liner only although they can be The tip of the knife can be pushed against the front side of the slitting bar Use the sideways adjuster to move the knives from left to right once set A clockwise movement of the adjustment knob will move the knives away f...

Page 31: ...use your guidelines to split the screen area into two Once you have created the first label design copy the design and place it where the second label will be printed again by using the guidelines Place your black mark which ideally should be about 5mm across the web and 3mm along the web as close as possible to the center of the printed image s as possible This saves a lot of time in set up and r...

Page 32: ...the length of the die travel JUMP 1 To suit longer or shorter dies Changing the length of the paper feed JUMP 5 For different label pitch Changing the length of the encoder ramp down JUMP 4 To ensure registration is maintained regardless of the speed dial setting Changing the mode of cutting JUMP 3 Either reciprocating cylinder or full rotary Enabling Disabling the loop sensor JUMP 3 To suit the f...

Page 33: ...ing operation The longer your cutting die is the greater the setting will be 33 2000 MEASUREMENTS ARE IN MILLIMETERS ONLY To facilitate the most efficient running speed the DLP 2000 should be set to the least amount of equired to perform the cutting action correctly Follow these instructions to set the die Before attaching your cutting die the ideal travel for the cylinder should be ascertained an...

Page 34: ...top line Enter a new value and press Enter to accept the changes NOTE The label count assumes you are cutting one label per black mark If you are cutting more than one label per black mark divide the number of labels required by the number of labels per black mark and enter this value Ensure that the label count value is also set to 0 when entering a new label required count The second line indica...

Page 35: ... machine will stop and prevent printer damage To set the time out value follow these steps Press the Jump key and the number 4 Press the Options key taking you to the time out settings screen Calculate a value to enter into the time out setting Normally it will be the patch of your black mark plus about 20 Enter this amount in millimeters and press Enter If a time out occurs press the emergency st...

Page 36: ...y It is a simple program adjustment to increase the length of the electronic black mark to allow for the ramp down Alternatively the speed can simply be turned down however this may not be desirable as the DLP may be running in line with a printer and the speed of the DLP 2000 should ideally be slightly faster than the running speed of the printer The following steps will allow for the quick and e...

Page 37: ...is clean If you are using an irregular shape you may need to remove the waste at a different angle or position or possibly change the orientation of your cutting die to make stripping easier My cores are slipping on the mandrel Do not use cores with a wall thickness less than 3mm My machine will not start when I press the start button Is your Loop sensor turned on but not seeing media Are your lid...

Page 38: ...age 36 If not slow your machine down or lengthen your electronic black mark setting Your printer s label pitch may be moving Re teach your sensor page 21 Is your machine set to Blank label mode See page 23 The cylinder is blocking the sensor Increase the Die stroke length as described in page 33 The machine is timing out before it reaches the mark Your front drive nip roller may not be pressed fir...

Page 39: ...y My die cuts along the web but not across the web Are you cutting the specified material for which the die was ordered How old is the die If it has been cutting polyester or another abrasive material it may simply be blunt The across the web cuts work a lot harder than the along the web cuts so they are generally the first to wear Double check that you have enough pressure on the die adjusters as...

Page 40: ...ure the motor will not allow more power than its maximum to be used The speed pot should not be run past the point where this happens as it will simply slow the production down Generally this has been altered in the inverter settings I am running full stroke on my die 305mm and the cylinder carriage is hitting the end stops There is a separate speed control for the Die cylinder motor It should nor...

Page 41: ...arriage ends Apply a drop of oil to the thread of the slitter adjustment if applicable Thoroughly clean the clear lids on both sides with a window cleaner and soft cloth DO NOT USE strong solvents to clean the lids Gently clean any paper glue residue from the paper infeed clutch pads with a dry cloth Depress the emergency stop button to release the brake and while rolling the magnetic cylinder bac...

Page 42: ... the label material You will see from this example the following are required when ordering a die Label size Number across and around Gaps between labels across and around Corner radius Specifics of the media to be cut or supply a sample Detailed layout you require including center marks Base plate size you require Web direction Magnetic cylinder circumference Type of machine being used Important ...

Page 43: ...43 Magnetic Cylinder Information Your magnetic cylinder has been products by RotoMetrics US and is manufactured by their standard cylinder gap ...