Technical Services

Combi 130

Combi 130

(Release 2)

Operators Manual

Complete Pad Printing Solutions

TRANS TECH AMERICA Inc. An ITW Decorating Company 475 North Gary Avenue Carol Stream, IL 60188-4900 Phone: 630.752.4000 Fax: 630.752.4489 Web Site: www.itwtranstech.com Go to index Page 1

Combi 130

For best results when printing this file, set printer resolution to 300 dpi.

While every effort has been made to ensure the accuracy of this manual, Trans Tech cannot be held responsible for any errors or omissions. We reserve the right to make changes to technical specifications without prior notice.

Page 2

Trans Tech America, Inc. An Illinois Tool Works Company 475 North Gary Avenue Carol Stream, IL 60188-4900 Phone: (630) 752-4000 Revised Dec. 2001

Go to index

Combi 130

Contents
1.1 1.2 1.3 1.4

1 Safety ........................................................................................................................................... 4

2 Installation Instructions .............................................................................................................. 5

2.1 2.2 2.3 2.4 2.5 2.6

Symbols and their Interpretations ............................................................................................................. 4 Liability ...................................................................................................................................................... 4 General Warnings and Cautions ............................................................................................................... 4 Application Restrictions ............................................................................................................................. 4

3 Operating Controls ..................................................................................................................... 7

Warnings and Cautions ............................................................................................................................. 5 Selecting the Location ............................................................................................................................... 5 Leveling the Machine ................................................................................................................................ 5 Connection to power ................................................................................................................................. 6 Connection to air supply ............................................................................................................................ 6 Air pressure regulator ................................................................................................................................ 6

3.1 Front Panel ............................................................................................................................................... 7 3.2 Side Panel ................................................................................................................................................. 7 3.3 Control Descriptions ................................................................................................................................... 8 Control Descriptions (continued) ................................................................................................................. 9 Control Descriptions (continued) ............................................................................................................... 10

4 Preparing to Print ....................................................................................................................... 11 5 Closed Cup Mode ...................................................................................................................... 12

5.1 Assembling the Doctor Cup and Cliche .................................................................................................. 12 Handling of the Ink Cup ........................................................................................................................... 12 5.2 Dismantling of Doctor Cups and Cliche .................................................................................................. 13

4.1 Mounting the Pad .................................................................................................................................... 11 4.2 Workpiece Support ................................................................................................................................. 11

6 Open Well Mode ......................................................................................................................... 14

6.1 Installing the Ink Well .............................................................................................................................. 14 6.2 Installing the Spatula and Doctor Blade .................................................................................................. 15

7 Guidelines for Operating the Printer ....................................................................................... 16 8 Cliche Sizes ............................................................................................................................... 17

8.1 Closed Cup ............................................................................................................................................. 17 8.2 Open Well ............................................................................................................................................... 17

9 Change Over.............................................................................................................................. 18
9.1 Installing Closed Cup Package ............................................................................................................... 19 9.2 Installing Open Well Package ................................................................................................................. 20

10.1 Printer Specifications ............................................................................................................................ 21 10.2 Printer Dimensions ................................................................................................................................ 22 11.1 11.2 11.3 11.4 11.5

10 Technical Information ............................................................................................................. 21 11 Maintenance ............................................................................................................................ 23

Wire Termination ................................................................................................................................... 23 Cam Follower Torque Values ................................................................................................................. 23 Lubrication Schedule ............................................................................................................................. 23 Preventative Maintenance Schedule ..................................................................................................... 24 Troubleshooting Guide .......................................................................................................................... 25 Troubleshooting Guide (continued) ........................................................................................................ 26 11.6 Electrical Schematics ........................................................................................................................... 27 Electrical Schematics (continued)......................................................................................................... 28 11.7 Pneumatic Schematics .......................................................................................................................... 29

Index ................................................................................................................................................ 30
Go to index

Page 3

Combi 130

1 Safety
1.1 Symbols and their Interpretations
WARNING: Neglecting a safety instruction identified with the WARNING symbol may lead to personal injury. CAUTION: Neglecting a safety instruction identified with the CAUTION symbol may lead to property damage. It is strongly recommended to observe instructions identified with a POINTER symbol.

POINTER:

1.2 Liability
In no event will Trans Tech America be responsible or liable for indirect or consequential damages resulting from the use of this equipment. The information contained in this manual is subject to change due to improvements in design. Though this document has been checked for inaccuracies, Trans Tech America does not assume responsibility for any errors contained herein. This manual is provided as an aid when operating the Combi 130 pad printing machine. Prior to operation, it is strongly advised that the user be thoroughly familiar with the Combi 130 operating manual. Trans Tech America is not responsible or liable for any disadvantage occurred for not following the operating instructions. All operators must be adequately trained.

1.3 General Warnings and Cautions

Switch off main disconnect switch (see page 6) prior to connecting/discon necting power.

Disconnect the air supply prior to servicing the machine.

1.4 Application Restrictions

Any use other than described in this manual may cause damage to the equipment, personal injury or property damage.

Page 4

Go to index

Combi 130

2 Installation Instructions
2.1 Warnings and Cautions
The machine operates on 120 volts, single phase AC power.

Switch off main disconnect switch prior to connecting power and air. Be alert and verify that safe start-up conditions exist prior to connecting the air supply and switching on the main disconnect switch as the machine may move when air pressure is applied. Check the water trap daily and drain as required by pressing the drain valve (see page 6). Apply oil or a thin layer of grease to unprotected ferrous parts to prevent rusting, especially after cleaning with solvents.

2.2 Selecting the Location

Choose a well ventilated area away from direct sunlight to install your pad printing machine. The ideal conditions for the inks used in pad printing are approximately 20 C (68 F) and 40 - 60 % humidity. Make sure the machine is positioned away from walls and other obstructions and placed on a flat surface. The guards, operating panel and other machine openings must be accessible. Ensure adequate area for setup tooling and for storage of parts before and after printing. TTemeratureemperature Humidity

2.3 Leveling the Machine

Before operation, the machine must be leveled. The level of the machine is adjusted by four (4) feet, one at each corner of the machine base. Level the machine as follows: 1. Loosen upper jam nuts. 2. Place bubble levels on machine base, one parallel to the long side of the base and another parallel to the short side of the base. 3. Adjust bottom nuts on left front and left rear screws until bubble level on the long side reads level. It may be necessary to follow with the right rear to keep machine stable if big adjustments are required. 4. Adjust bottom nuts equally on right and left rear screws until bubble level on the short side reads level. 5. It may be necessary to repeat steps 3 and 4 several times until both levels read level and the weight is evenly distributed on the four feet. 6. Turn the upper jam nuts clockwise to tighten.

Go to index

Page 5

Combi 130

2.4

Connection to power
The machine is equipped with a Nema 5-15 plug. Power requirement: 120 VAC 20 watts Main disconnect switch Automation interface Power cord

2.5 Connection to air supply

The machine requires clean, dry air. Minimum requirement: 6 bar (90 psi) 5 cfm Air connection is to quick disconnect adapter (included) or to 1/4 NPT female thread. Connection for air supply

2.6 Air pressure regulator

Adjust system pressure to 5.5 bar (80 psi) by lifting the adjusting knob to unlock, then turning the knob clockwise to increase the pressure or counterclockwise to decrease the pressure. Push down on the adjusting knob to lock the regulator after making adjustments. Adjusting knob Pressure gauge Drain valve for water trap

Page 6

Go to index

Combi 130

3 Operating Controls
3.1 Front Panel

Emergency Stop Start Stop Manual Jog Down/Up

Pad Delay Timer

Setup Single/Continuous Double Print Print/Doctor Pad Delay Enable

Part Counter / Rate Indicator Doctor Blade Pressure Regulator

Pad Slide Stop Adjustment

3.2 Side Panel

Flow Controls Doctor Slide CUP / OPEN Mode Selector Flow Controls Pad Ram

Go to index

Page 7

Combi 130

3.3 Control Descriptions

The control buttons are active after the main disconnect is switched on, the Emergency Stop button is reset and the guard doors are closed. Pressing the Emergency Stop button will immediately stop all machine motion. The button must be released (pulled out) and Start must be pressed to re-initialize the machine. The Start button or the foot switch must be pressed to start a new print cycle or to complete an interrupted print cycle. WARNING This button does not shut off power to the machine or in the electrical panel. Switch off the MAIN DISCONNECT SWITCH and disconnect the power cord and air supply before working on the machine. Pressing the Start button will: initiate the control (enables air pressure). start a printing cycle. The indicator lamp is illuminated while the printer is in operation. Pressing the Stop button (while in Continuous Print Mode) will: initiate a cycle stop. The indicator lamp will illuminate and the printer will stop at the end of the active print cycle in the home position. When home, the light will turn off. The Stop button indicator lamp will flash when an alarm condition exists. (see pages 25 and 26) Pressing the Manual button enables the Jog, Down / Up and Setup functions. When selected (pressed), the: automation start pulse is disabled. cycle counter will not count. pad delay is disabled. The Jog function is active only when Manual is selected. The printer will complete one step of the print cycle each time the Jog button is pressed. The Down/Up button is active only when Manual is selected. When Setup is released, the pad ram will complete one cycle (down / up) each time the Down / Up button is pressed. When Setup is selected, the cup lock, doctor blade or spatula will lower or raise each time the Down / Up button is pressed. The Setup function is active only when Manual is selected. When Setup is selected (pressed) while: in CUP mode, the cup lock will lower or raise each time the Down / Up button is pressed. in OPEN WELL mode when the Spatula button is released, the doctor blade will lower or raise each time the Down / Up button is pressed. in OPEN WELL mode when the Spatula button is selected, the spatula will lower or raise each time the Down / Up button is pressed. Page 8
Go to index

Combi 130

Control Descriptions (continued)

The Single/Continuous button is used to select Single or Continuous Cycle or to enable the Spatula function. The button is in the released position (indicator lamp off) for Single Cycle. After pressing Start or the foot pedal, the printer will carry out the number of hits selected and stop in the home position. The button is in the pressed position (indicator lamp on) for Continuous Cycle. After pressing Start or the foot pedal, the printer will cycle continuously until: the Stop button is pressed. The printer will complete the active print cycle and stop in the home position. the Continuous Cycle button is released. The printer will complete the active print cycle and stop in the home position. the foot pedal is pressed. The printer will stop after completing the active step in the print cycle. Press the foot pedal again to coninue the print cycle. By pressing the foot pedal at each step, the printer can be single stepped through the cycle. The Double Print function is active in Single and Continuous print modes. When Double Print is selected, the printer will print each part two (2) times. The cycle counter increments one count after completing two print cycles. Pad delay is enabled if selected. The rate monitor displays the parts per minute based on two print cycles per part. The Print/Doctor Motion is active in Single and Continuous print modes and during Jog functions.

When Print is selected (button released), the printer will carry out a normal print

cycle. When Doctor Motion is selected (button pressed), the printer will run in doctoring mode only (no pad ram motion).

The Pad Delay function is active in Single and Continuous print modes.

When Pad Delay is selected (button pressed), the printer will stop for the
preselected time in the front/up position prior to printing the image.

The Pad Delay Timer. The length of the pad delay is adjustable from .015 to 3.0 seconds.

Go to index

Page 9

Combi 130

Control Descriptions (continued)

Press the SEL button to toggle between Cycle Counter and Rate Display. When Cycle Counter is selected, the number of parts printed is displayed. The count will increase once for each print cycle completed when Double Print is not selected. The count will increase once for every two print cycles completed when Double Print is selected. Press RST to reset the counter to zero. When Rate Display is selected, the number of completed print cycles per minute is displayed. The rate will indicate half the actual printer rate when Double Print is selected (indicates the number of printed parts per minute).

The Foot Pedal is used to start and stop the print cycle. While in single cycle mode: after pressing Start or the Foot Pedal, the printer will carry out the number of hits selected and stop in the home position. While in continuous cycle mode: after pressing Start or the Foot Pedal, the printer will cycle continuously until: the Stop button is pressed. The printer will carry out the number of hits selected and stop in the home position. the Continuous Cycle button is released (indicator light is off). The printer will carry out the number of hits selected and stop in the home position. the Foot Pedal is pressed. The printer will stop after completing the active step in the cycle. Press the Foot Pedal again to continue the printing cycle. The Key Switch is used to select CUP or OPEN WELL operating mode. CUP mode is shown

The Flow Controls are used to adjust the speed of the pad ram and doctor slide movement. Turn clockwise to decrease speed. Turn counterclockwise to increase speed. The Pad Stroke adjustments are used to adjust the compression of the pad at the cliche and part. Adjustment for pad stroke (lower limit) over part. Adjustment for pad stroke (lower limit) over cliche.

The upper pad stroke limit is fixed. Adjust the stroke until the pad is compressed just far
enough to pick up or release the entire image. Too much compression will cause the image to distort. Page 10
Go to index

Combi 130

4 Preparing to Print
4.1 Mounting the Pad
X adjustment lock Y adjustment lock Pad Pad coupler

Attach a suitable pad to the pad coupler using flat head wood screws for wood back pads or flat head cap screws for aluminum back pads.

X, Y and R adjustments (viewed from above part, standing in front of and facing the machine).

The pad adjustment in the X and Y directions is used to adjust the position of the pad over the image on the cliche. The Pad Slide Stop is used to adjust the position of the image in the Y direction on the part. The X-R adjustments on the cliche holder table are used to adjust the position of the image in the X and Radial directions on the part. When setting up and adjusting the pads, care must be taken to ensure that the pad or coupler is not positioned within the limits of the cup travel. Verify that the pad will clear the cup when in the full back position prior to cycling the machine. Failure to do so may allow the pad and/or pad coupler to contact the cup with enough force to damage the cup and machine.

4.2 Workpiece Support

Workpiece support (table) with fixture mounting T-slots Table height adjusting wheel Table lock Lock the table before printing. Failure to do so may result in print distortion.

Go to index

Page 11

Combi 130

5 Closed Cup Mode

5.1 Assembling the Doctor Cup and Cliche
Before operating the printer, the air supply must be on, the main disconnect switch must be on, EStop must be reset and the front and side guards must be closed. If the front or side guards are opened while the printer is running, the printer will stop immediately. The guards must be closed before printer operation can resume. If a printer or automation error is detected, the printer will stop immediately (see Machine Alarm Messages and Troubleshooting Guide pages 25 and 26). The fault condition must be corrected before printer operation can be resumed. 1. Turn on the air supply to the printer. 2. Switch on the main disconnect and press Start button to initialize the control and enable the air supply. 3. Make sure that CUP mode is selected (see page 10) and that the cup driving forks and cliche holder are assembled and locked in position. 4. Verify that the doctor stroke hole matrix is set for the cup size that will be installed (see chart on page 18). 5. Press the Manual button then press the Setup button to raise the cup driving frame and driving forks. 6. Open the safety guard. 7. Fill the first ink cup with properly thinned and mixed ink to an adequate level. Verify the ink consistency before mounting to the cliche. For normal production requirements, fill the cup with ink until the magnets are just covered. If using a steel foil or plastic cliche, care must be exercised to ensure that the magnet plate (used to hold the cliche) and the bottom of the cliche are clean and free from burrs before assembly and that the cliche is properly positioned over the locating pins. (Ask your sales representative for a copy of instruction How To Mount Cliches On Magnet Plates if further explanation is needed.) 8. While holding the cup firmly, place the cup near and parallel to the image end, image side (bottom) of the cliche and slide the ink cup onto the cliche until the image is centered in the ink cup.

Avoid rough handling to prevent accidental separation.

9. Repeat steps seven (7) and eight (8) for each cup to be installed. 10. Turn over the assembled cup(s) and cliche so cup(s) is/are on top. The magnet in the cup will hold the cup and cliche together.

Handling of the Ink Cup Always protect the doctor ring in the ink cup from being damaged. If stored separately, place the ink cup in the protective plastic shipping container. Rotate the cup frequently (steel cliche 2 hrs., polymer cliche 1 hr.) while in operation.

WARNING
Page 12 The doctor ring has a very sharp edge that may cause personal injury if improperly handled. PLEASE HANDLE WITH CAUTION!
Go to index

Combi 130
11. Turn over the assembled cup(s) and cliche so cliche is on bottom. The magnet in the cup will hold the cup and cliche together. 12. Set the cup and cliche assembly in the cliche holder and push cliche against the left side and rear stop pins.

Driving lugs disengaged Cliche lock screw

13. 14. 15. 16.

Tighten the cliche locking screws to secure the cliche in the cliche holder. Rotate the cups and position them until the grooves in the cups are aligned with the lugs on the forks. Close the safety guards. Set the doctor pressure adjustment to 1.5 bar (22 psi) and release the SETUP button to engage the driving fork lugs into the grooves.

Driving lugs engaged Cliche holder lock handle

17. If forks do not lower completely, press SETUP button to raise forks, open the guard and repeat steps fourteen (14) through sixteen (16). 18. Press MANUAL button to return to print mode. 19. Mount pad(s) and adjustable coupler to pad bar (see page 11). 20. The machine is now ready to adjust for printing (see page 16).

5.2 Dismantling of Doctor Cups and Cliche

1. Stop machine at the end of print cycle by pressing STOP pushbutton or by selecting SINGLE CYCLE (see page 9). 2. Press MANUAL button. 3. Press SETUP button to raise cup driving forks. 4. Open safety guard. 5. Loosen cliche locking screws. 6. The cliche and cup assembly can now be removed carefully from the machine. 7. Turn over the cup and cliche assembly so cliche is on top. The magnet in the cup will hold the cup and cliche together. 8. While holding the cliche firmly, slide the cup off the edge of the cliche. The sliding motion will strip the remaining ink from the cliche. 9. Repeat step eight (8) for each cup.
Go to index

Page 13

Combi 130

6 Open Well Mode

6.1 Installing the Ink Well
Before operating the printer, the air supply must be on, the main disconnect switch must be on, EStop must be reset and the front and side guards must be closed. If the front or side guards are opened while the printer is running, the printer will stop immediately. The guards must be closed before printer operation can resume. If a printer or automation error is detected, the printer will stop immediately (see Machine Alarm Messages and Troubleshooting Guide pages 25 and 26). The fault condition must be corrected before printer operation can be resumed. 1. Turn on the air supply to the printer. 2. Switch on the main disconnect and press Start button to initialize the control and enable the air supply. 3. Make sure that OPEN WELL mode is selected (see page 10). 4. Verify that the doctor stroke hole matrix is set for the plate size that will be installed (see chart on page 18). 5. Press the MANUAL button. 6. Press SETUP button, then the PAD DOWN/UP button (CONTINUOUS button must be released) to raise the doctor blade. 7. With the SETUP button pressed, press the CONTINUOUS/SPATULA button, then the PAD DOWN/ UP button to raise the spatula. 8. Open safety guard. 9. Slide the cliche into the cliche holder. Slide the front wedge in from left side and using a ball driver, tighten bottom wedge until the cliche is pressed snugly against the side rails. Do not over-tighten bottom wedge as the clamping force will bend the side rails causing leakage or possibly damaging the rails. If using a steel foil or plastic cliche, care must be exercised to ensure that the magnet plate (used to hold the cliche) and cliche are clean and free from burrs before assembly and that the cliche is properly positioned over the locating pins. (Ask your sales representative for a copy of instruction How To Mount Cliches On Magnet Plates if further explanation is needed.) Front wedge Ink well Rail Cliche Bottom wedge Wedge clamping screw R adjustment micrometer X adjustment micrometer Cliche holder lock The spatula design utilized in your Combi 130 enables the machine to print with a lower ink level than the level required in a machine utilizing a conventional spatula design. Start with the ink well full and adjust the level of ink to satisfy production requirements. 10. Fill the ink well with properly thinned and mixed ink to an adequate level. Verify the ink consistency before mounting to the cliche holder. 11. Set the cliche holder assembly on the X-R table and push the holder against back rail, engaging the pin in the slot and rotate locking handle to secure the clich holder to the table. Page 14
Go to index

Combi 130

6.2 Installing the Spatula and Doctor Blade

1. Install the ink well (see page 14). 2. Select the proper length spatula insert(s) and assemble to the support bar. 3. Mount the spatula assembly into the machine and secure by tightening the lock screw. Spatula lock screw

4. Select the proper type and length doctor blade and install into doctor blade holder. 5. Mount the doctor blade holder into the machine and secure by rotating the cam lock clockwise 1/4 turn. Doctor blade holder cam lock Doctor blade holder

6. Close the safety guards. 7. Set the pad ram down limits to the top of their adjustment slots (see page 10). 8. Set the doctor pressure adjustment to 0.5 bar (7.5 psi) and release the SETUP and SPATULA buttons to return the doctor blade and spatula to their normal operating position. The doctor blade edge should be even with or less than 1 mm below the top of the clich holder top rails. 9. Press the DOCTOR/PRINT button to select doctor mode, then press the MANUAL button. 10. Adjust the front doctor blade lift cam to lift the edge of the doctor blade slightly behind the front edge of the cliche. 11. Press and release the JOG button. The doctor blade will stay down and the slide will move to the back. 12. Adjust the rear doctor blade lift cam to lift the edge of the doctor blade slightly ahead of the back edge of the cliche. The front cam should be adjusted while slide is back and the rear cam should be adjusted while the slide is forward. 13. Press and release the JOG button. The doctor blade will lift, the spatula will dip into the ink well and the slide will move forward, covering the cliche with a thin layer of ink. 14. Press and release the JOG button. The doctor blade will move down and the slide will move to the back cleaning the ink off the cliche, leaving ink in the image. 15. Press and release the JOG button. The doctor blade will lift, the spatula will dip into the ink well and the slide will move forward, covering the cliche with a thin layer of ink. 16. Press the MANUAL button to return to print mode, press CONTINUOUS and press START to initiate the automatic doctoring function. 17. Adjust the doctor blade pressure regulator to achieve a clean doctoring action at the minimum pressure setting on the pressure adjustment. Excessive pressure will result in premature failure of the doctor blade and cliche! 18. Press STOP and press DOCTOR/PRINT to return to printing mode. 19. Mount pad(s) and adjustable coupler to pad bar (see page 11). 20. The machine is now ready to adjust for printing (see page 16).
Go to index

Page 15

Combi 130

7 Guidelines for Operating the Printer

Following is a general guideline for setting up and operating your pad printing machine. Your application may require a different procedure. Please contact Trans Tech to arrange specific training. 1. Verify that machine is connected to adequate air supply and that the regulator is adjusted to the proper pressure (see page 6). 2. Check general condition of machine and ensure proper operation of safety doors. Repair or replace any components found to be defective. 3. Prepare and install the ink cup(s) and cliche or ink well and cliche (see pages 12 and 14). 4. Install suitable pad(s) (see page 11). 5. Mount suitable workpiece holding device to table (see page 11). 6. Close all safety doors. 7. Select MANUAL and press the JOG button to move the slide to the rear position. 8. Press the DOWN/UP button to pick up the image from the cliche with the pad. 9. Adjust pad stroke limit (see page 10) to compress the pad over the image on the cliche just enough to pick up the whole image. Press the DOWN/UP button to jog pad down while making adjustment. 10. Adjust the pad position as required over the image so the center of the pad is near the center of the image but that the actual tip of the pad is not directly in the image (see page 11). 11. Press the JOG button to move the slide to the forward position. 12. Press the DOWN/UP button to transfer the image from the pad to the workpiece. 13. Adjust the height of the workpiece table (see page 11) and the position of the pad stroke limit (see page 10) to compress the pad on the workpiece just enough to release the whole image. 14. If desired, the machine cycle can now be verified in single step mode by pressing the JOG button. The machine will execute one step for each time the button is pressed. Adjust the speed of the print cycle by adjusting flow controls (see page 7). 15. Press the MANUAL button to return to print mode. Select the desired operating modes by pressing CONTINUOUS and/or DOUBLE PRINT buttons. Press START or the footswitch to initiate the print cycle. Press the CONTINUOUS button or the STOP button to stop the print cycle. The printer will stop at the end of the cycle in the home position (see footswitch operation on page 10).

Page 16

Go to index

Combi 130

8 Cliche Sizes
8.1 Closed Cup
Cup Diameter Standard Pitch Standard Cliche Depth 60 mm Cup 3 1/8 pitch 150 mm deep 1 Color 2 Color 3 Color 4 Color 5 Color 90 mm Cup 5 pitch 250 mm deep 1 Color 2 Color 3 Color 4 Color 130 mm Cup 6 1/4 pitch 300 mm deep 1 Color 2 Color 3 Color

Required Cliche Length 80 mm 150 mm 250 mm 350 mm 400 mm 125 mm 250 mm 400 mm 500 mm 150 mm 350 mm 500 mm

8.2 Open Well

Length Depth 100 125 150

12 5 X X

15 0

19 0 X

200

250

260 X

300

350 X

400 X X X

500 X X

X X

X X

X X

Go to index

Page 17

Combi 130

9 Change Over
The doctor stroke is set for the selected cliche depth by inserting the drive pin in the linkage holes as shown in the following chart. Always confirm that the linkage is set for the depth of the cliche that is installed in the printer prior to cycling the machine. If the wrong combination is selected, the doctoring stroke will not be centered on the plate and damage to the machine and/or tooling may occur!

Drive pin

Closed Cup 60 cup 90 cup 130 cup

Page 18

Open Well 5E 4D 3C 100 cliche 125 cliche 150 cliche 2C 2B 1A

Go to index

Combi 130

9.1 Installing Closed Cup Package

1. Switch off main disconnect switch and disconnect power cord. 2. Disconnect air supply. 3. Remove the screws in the top cover and remove the cover. 4. Remove the screws and open the back door. 5. Open the machine guards and remove the cliche holder. 6. Loosen clamp screw and remove cylinder linkage pin. 7. Remove the two (2) screws holding the left hand mounting bracket to the frame. 8. Position the frame in the machine, making sure to guide the connecting rod through the doctor slide frame and place the right hand mounting bracket over the pin. 9. Insert two (2) M8 X 25 mm socket head cap screws and loosely secure the right hand bracket. 10. Place the left hand mounting bracket over the pin and loosely secure the bracket with two (2) M8 X 25 socket head cap screws. 11. Replace the two (2) screws removed in step 7 and tighten all the screws in the left and right mounting brackets. 12. Working from the top opening, raise the cylinder linkage and insert the pin to couple the connecting rod to the cylinder linkage. 13. Clamp the pin by tightening the lock screw. 14. Attach the appropriate mounting bar by placing the bar over the two pins and securing with two M8 X 20 socket head cap screws. 15. Attach the required cup drivers and secure to the mounting bar with the supplied socket head cap screw. 16. Select the proper combination of holes and insert the pin in the stroke adjustment linkage (see page 18). 17. Mount the cliche holder and cliche (see page 12) - Do not install the ink cups at this time! 18. Push the pad slide by hand through the extent of the slide travel to confirm proper setup of the stroke adjustment and verify lack of mechanical interference and binding. 19. Close the machine guards. 20. Close back door and secure with screws. 21. Replace the top cover and secure with screws. 22. Connect air supply. 23. Connect power cord and switch on main disconnect. 24. Select manual mode and press the JOG button to cycle machine through each step of a print cycle to verify proper setup. Cup driver Mounting bracket Connecting rod Frame

Clamping screw Coupling pin

Go to index

Page 19

Combi 130

9.2 Installing Open Well Package

1. Switch off main disconnect switch and disconnect power cord. 2. Disconnect air supply. 3. Remove the screws in the top cover and remove the cover. 4. Remove the screws and open the back door. 5. Open the machine guards and remove the cliche holder. 6. Place the spatula support over the pins and secure with two (2) M8 X 20 socket head cap screws. 7. Pull left and right hand mounting brackets from doctor blade carrier. 8. Insert two (2) M8 X 25 mm socket head cap screws and loosely secure the right hand bracket. 9. Position the doctor blade carrier in the machine, making sure to guide the connecting rod through the doctor slide frame and place on the right hand mounting pin. 10. Slide the left hand mounting bracket pin into the carrier and loosely secure the bracket with two (2) M8 X 25 socket head cap screws. 11. Tighten all the screws in the left and right mounting brackets. 12. Working from the top opening, raise the cylinder linkage and insert the pin to couple the connecting rod to the pivot arm. 13. Clamp the pin by tightening the lock screw. 14. Select the proper combination of holes and insert pin in stroke adjustment arms (see page 18). 15. Mount the ink well and cliche (see page 14) - Do not add ink at this time! 16. Push the pad slide by hand through the extent of the slide travel to confirm proper setup of the stroke adjustment and verify lack of mechanical interference and binding. 17. Close the machine guards. 18. Close back door and secure with screws. 19. Replace the top cover and secure with screws. 20. Connect air supply. 21. Connect power cord and switch on main disconnect. 22. Select manual mode and press the JOG button to cycle machine through each step of a print cycle to verify proper setup (see page 8). Spatula support Mounting brackets

Connecting rod Doctor blade carrier

Clamping screw Coupling pin

Open well accessories installed Page 20

Go to index

Combi 130

10 Technical Information
10.1 Printer Specifications
Single Cycle Multiple Cycles Continuous Cycle Parts Counter Machine Cycle Rate Indicator Infinitely Variable Speed Ink Cup Diameter Maximum Print Diameter Cliche Size Cycles per Hour Pad Print Delay Pad Pressure Drive Power Control Voltage Yes Double print Yes Up-count 6 Digit / Reset Cycles/min. (Cycles/Hours) Yes
(see page 17)

60 = 50, 90 = 80, 130 = 115

(see page 17)

1500 max. continuous 0.15 to 3 sec. 1100 pounds of force at 90 psi. Pneumatic 110 VAC, 1, 2A 24VDC Programmable LOGIC Controller: 24VDC, 24 I/Os Inputs sourcing, Outputs Isolated Relays System expandable by 3 expansion units (48 I/Os) Programmable via PC 1080 lbs.

Control System

Machine Weight
Machine Weight

Go to index

Page 21

Combi 130

10.2 Printer Dimensions

Page 22

Go to index

Combi 130

11 Maintenance
11.1 Wire Termination
The machine is equipped with screwless wire terminals. When connecting or disconnecting wires, please refer to the illustrations below.

Illustration: 2- Wire Insertion/removal Diagrams

Illustration: 2-7. Jumper Insertion Diagram

11.2 Cam Follower Torque Values

When adjusting or replacing cam followers, they must be tightened to the following values to achieve maximum performance and life: Cam Follower Type KR 19 KR 22 KR 26 Torque Value Nm 8 Nm 15 Nm 15 Nm Torque Value ft/lbs 5.9 ft/lbs 11 ft/lbs 11 ft/lbs

11.3 Lubrication Schedule

Cam followers: The cam followers are permanently lubricated at the factory and sealed. Additional lubrication is not required. Cam tracks: The cam tracks are lubricated with a high pressure lithium grease Lubrication Schedule: First Application 200 hr. of operation Consecutive Applications 1000 hr. of operation Recommended Lubricant Manufacturer: Mobil Oil Corp. (or equivalent) Brand name: Mobilux EP2

Pivot arm support bearings: The support bearings are lubricated with lithium grease Lubrication Schedule: First Application 2000 hr. of operation Consecutive Applications 2000 hr. of operation Recommended Lubricant Manufacturer: Mobil Oil Corp. (or equivalent) Brand name: Mobilux 2

Doctor slide & pad ram: The rods are lubricated with light machine oil Lubrication Schedule: First Application 50 hr. of operation
Go to index

Recommended Lubricant Consecutive Applications 50 hr. of operation Manufacturer: Mobil Oil Corp.

(or equivalent) Brand name: DTE 25

Page 23

Combi 130

11.4 Preventative Maintenance Schedule

Description Water Trap Pneumatic Components Safety Guards Maintenance required: Check for accumulation of water. Drain if required. Check for air leaks. Tighten connections, repair or replace components as required Test for proper function. When opening any guard, the machine should stop immediately. Repair all defective guards and switches Test for proper function. When pressing the E-stop pushbutton, the machine should stop immediately. All machine functions are disabled Test for proper functions. Test all buttons for proper machine functions Clean slides of all ink and other residue. Ink and residue build up in the area of the guide rails may lead to excessive friction and premature failure. Inspect guide rails for wear. Oil guide rails with a light machine oil. The cam followers are lubricated for life and are factory sealed. No maintenance is required. Doctor Cams and Cam Followers Inspect the cam followers for wear. Replace if required. Clean cams and cam followers of residue. Inspect for wear or damage (replace if required). Lightly grease contacting surfaces of cams and cam followers with multi-purpose lithium grease. Grease with multi-purpose lithium grease (2 cc each bearing) Every 50 hours of operation Every 1000 hours of operation Every 2000 hours of operation Every 2000 hours of operation (dirty plant air may necessitate more frequent changes)
Go to index

Frequency Every 8 hours of operation Every 8 hours of operation Every 8 hours of operation

E-stop

Every 8 hours of operation

Controls

Every 8 hours of operation Every 8 hours of operation Every 50 hours of operation

Doctor Slide and Pad Ram

Pivot Arm Support Bearings

Air Filter

Replace filter element

Page 24

Combi 130

11.5 Troubleshooting Guide

Symptom Machine wont cycle Possible Cause Low or no air pressure Remedy Provide clean, dry air at 90 psi Adjust system pressure regulator to 80 psi Machine in MANUAL mode Guard door(s) not closed (stop light will flash) Control not initialized Press MANUAL button to release Close all guards The E-Stop button must be released and the START button must be pressed once to initialize the control after applying power Check automation - reset if needed. Check input 105 on PLC - should be high Adjust air pressure regulator to 80 psi Raise pad stroke adjustment - use softer pad Press foot pedal or START button to continue Check automation - reset if needed. Check input 105 on PLC - should be high Provide clean, dry air at 90 psi Adjust system pressure regulator to 80 psi Machine not in MANUAL mode - machine not in SETUP mode Guard doors not closed (stop light will flash) Doctor pressure too low
Go to index

Automation not in position (stop light will flash) Print cycle not completed Low air pressure Pad stroke adjusted too low - pad too hard Foot pedal pressed (machine completes active step in cycle and stops) Automation not in position (stop light will flash) Cup wont lock/unlock Low or no air pressure

MANUAL and SETUP buttons must be pressed to enable cup lock motion, then press DOWN/UP button Close guard doors Adjust doctor blade pressure regulator to at least 20 psi
Page 25

Combi 130

Troubleshooting Guide (continued)

Symptom Doctor blade wont raise/lower

Possible Cause Low or no air pressure

Remedy Provide clean, dry air at 90 psi Adjust system pressure regulator to 80 psi

Machine not in MANUAL mode - machine not in SETUP mode Guard doors not closed (stop light will flash) Doctor pressure too low Spatula wont raise/lower Low or no air pressure

MANUAL and SETUP buttons must be pressed to enable doctor blade motion, then press DOWN/UP button Close guard doors Adjust doctor blade pressure regulator to at least 20 psi Provide clean, dry air at 90 psi Adjust system pressure regulator to 80 psi

Machine not in MANUAL mode - machine not in SETUP mode-SPATULA button not pressed Guard doors not closed (stop light will flash) Machine cycle too slow Pad stroke too long

MANUAL ,SETUP and SPATULA buttons must be pressed to enable spatula motion, then press DOWN/UP button Close guard doors Raise work table Use taller pad

Flow controls set too slow Pad delay enabled Air volume volume/pressure too low

Turn flow control knobs counterclockwise to increase speed Decrease time or disable pad delay Service air filter Verify adequate air supply Adjust system pressure regulator to 80 psi

Page 26

Go to index

Combi 130

11.6 Electrical Schematics

Go to index

Page 27

Combi 130

Electrical Schematics (continued)

Page 28

Go to index

Combi 130

11.7 Pneumatic Schematics

Go to index

Page 29

Index

Combi 130

Index
A
Application Restrictions 4 Automation Interface 6

P
Pad Coupler 11 Pad Delay Enable Pushbutton 7 Pad Delay Timer 7, 9 Pad Slide Stop Adjustment 7 Pad Stroke 10 Part Counter 7 Pionter Symbol 4 Plastic Cliche 12, 14 Power Cord 6 Pressure Gauge 6 Print/Doctor Motion Pushbutton 9 Print/Doctor Pushbutton 7

C
Caution Symbol 4 Cycle Counter 10

D
Doctor Blade Pressure Regulator 7 Doctor Stroke 18 Double Print Pushbutton 7, 9 Down/Up Pushbutton 7, 8 Drain Valve 6

R
Rate Display 10 Rate Indicator 7

E
Emergency Stop 7, 8

F
Flow Controls 10 Flow Controls Doctor Slide 7 Flow Controls Pad Ram 7 Foot Pedal 10

S
Safety 4 Setup Pushbutton 7, 8 Single/Continuous Pushbutton 7, 9 Start Pushbutton 7, 8 Steel Foil 12, 14 Stop Pushbutton 7, 8 Symbols and their Interpretations 4

H
Handling of the ink cup 12 Humidity 5

T
Temperature 5

I
Installation Instructions 5

W
Warning Symbol 4

J
Jog Pushbutton 7, 8

K
Key Switch 10

L
Levelling the Machine 5 Liability 4

M
Machine Weight 21 Main Disconnect Switch 6 Manual Pushbutton 7, 8 Mode Selector 7

Page 30

Go to index