Grafisk Maskinfabrik DC330mini

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The provided document is an operating manual for the GM Converting Unit DC330MINI-NANO. This device is a label finishing and converting machine designed for various post-press applications, including varnishing, die-cutting, and lamination. The manual covers the DC330mini and DC330nano models, with the primary distinction being that the DC330nano is for lamination only and does not include a flexo unit. Both models are compact and require a buffer module for inline operation.

Function Description

The GM Converting Unit performs several key functions:

Varnishing: The unit features a varnish station for applying UV-curing ink/lacquer or water-based priming. It supports full-rotation spot varnishing with rollers from 10 to 19 inches. A "slow run" feature is available for non-UV varnish types. The varnish roller can be automatically engaged when the web moves and released when it stops, provided the "Automatic varnish roller" feature is enabled.
Die-cutting: The machine is equipped with a die-cutting station that operates in several modes: "No die-cutting" (cylinder rotates but is not engaged), "Analog die-cutting" (traditional die-cutting with cylinders between 10" and 25"), and "Digital die-cutting" (semi-rotation die-cutting with cylinders between 12" and 25", requiring specially made cylinders). The die-cut station uses a mark reader for registration and can compensate for plate distortion.
Lamination (Optional): The laminating station is a cold foil station, consisting of two spindles, a laminating nip, and a UV lamp. It supports both self-adhesive and supergloss laminates. The laminating nip roller applies pressure to the foil against the web, adjustable via an air pressure regulator.
Web Handling: The unit includes an unwinder, waste rewinder, and two main rewinders (Rewinder 1 and 2). The unwinder can operate in stand-alone mode (with a buffer) or inline mode (fed from another machine). The waste rewinder runs counter-clockwise for easy waste grid mounting. The main rewinders can run in both directions and have adjustable torque ranges (high for heavy webs/non-die-cut webs, low for die-cut/stripped webs).
Slitting: The machine can be equipped with V-knives or slitting knives, which are either air-operated or manually activated. These knives run synchronized with the web at a slightly higher speed (around 5%) to improve cutting quality.

Important Technical Specifications

Web Width (max): 330 mm
Printing Width (max): 310 mm
Print Roller Diameter: 97.5 ± 0.3 mm
Plate Cylinder Diameter: 97.02 mm
Printing Length (min/max): 9" (minimum cylinder) / 19" (maximum cylinder)
UV Lamp: 5000 W (continuously variable between 300 W and 5000 W)
Digital Die Size: 12" to 25"
Analog Die Size: 12" to 25"
Repeat Range: 2"-20.8" (Max repeat = Die size*0.9-40mm, Min. repeat = 2")
Min. Distance between Register Marks: 50mm
Speed (Digital): 40 m/min (depending on repeat and software version)
Speed (Analog): 72 m/min
Offline Speed Limit (without die-cut): 32 m/min
Compressed Air: 4 - 6 bar, 10 l/min (tube Ø8mm)
Die-cut Gap (Standard): 0.48mm (for label) or 0.76mm (for postcards)
Power Supply: 3x400V 32A / phase 50/60 Hz (for converter unit, UV system, cooling system)
Total Machine Weight: 1200 kg

Usage Features

Touch Panel Control: The primary interface is a touch panel, allowing users to enter job values, control machine functions, and monitor status.
Spindle Control: Spindles can be expanded/released by pressing their center on the touch panel. Rotation modes are set via dedicated buttons.
Automatic Stop Features: "Automatic stop at low unwinder diameter" and "Automatic stop at label preset" can be configured to halt the machine based on roll size or label count.
UV Lamp Control: The UV lamp is turned on/off via the 'UV' button. It undergoes a heating sequence and requires proper cooling.
Die-cut Adjustment: The die-cut cylinder can be raised/lowered via the touch panel. Die-cut offset and distortion factor can be adjusted for precise cutting.
Spot Varnish Parameters: Specific parameters for spot varnishing, such as cylinder teeth count or size, are accessible through the Parameter menu.
Web Tension and Scale Print Adjustments: A "tool" icon on the run screen allows adjustment of web tension (1 to 50, default 30), spot varnish scale, and die-cut scaling.
Remote Control Window: A feature for digital press integration, allowing remote stopping of the digital press.
Language and Units Setup: Users can select language (English, German, Danish, Spanish, Dutch) and measurement units (metric or imperial). The UV lamp's operating hours are tracked for replacement prediction.

Maintenance Features

Cleaning: Regular cleaning of nips, rollers, varnish station, anilox/ductor blade, and flexo unit is recommended (daily to weekly).
Lubrication: Bearer rings in the die-cut station should be lubricated every 8 hours. Gearwheels, side shims, and side bearings in the die-cut station require greasing monthly. All die-cut station bearings should be greased every 6 months, with replacement recommended after 4-5 years. The ball bearing on the print cylinder cross-pushing arm needs weekly greasing.
Blade Inspection/Replacement: Doctor blades and CRUSH knives should be checked for sharpness and pressure daily. Damaged blades must be replaced.
Belt Inspection/Tightening: All belts should be inspected and tightened annually.
UV Lamp Maintenance: The UV bulb should be replaced every 1000 hours, and cooling hoses checked.
Print Roller Diameter Check: The print roller diameter should be checked monthly to ensure it's within specifications (Ø97.2 mm, unit stops at Ø96.5 mm).
Water Level in Chiller: Water level in the chiller unit needs monthly refilling if necessary.
Return Filter in Chiller: The return filter in the chiller unit needs monthly cleaning.
Die-cut Bridge Adjustment: A procedure is outlined for adjusting the stroke of the die bridge to ensure correct clearance.
Anilox Roller Handling: Anilox rollers are delicate and require careful handling, especially the ceramic covering. They must be cleaned after use to prevent ink drying and uneven printing.
Ink Roller Handling: Ink rollers should be stored suspended to prevent rubber deformation. Levers for pressure on the anilox roller should be disengaged when not in use.