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M&R CHALLENGER II Series - User Manual

M&R CHALLENGER II Series
241 pages
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The M&R
111802MS
$75.00
M&R Printing Equipment, Inc.
www.mrprint.com
Toll Free 1-800-736-6431
MAN-CH2

Questions and Answers

M&R CHALLENGER II Series Specifications

General IconGeneral
BrandM&R
ModelCHALLENGER II Series
CategoryIndustrial Equipment
LanguageEnglish

Summary

Introduction

Safety Precautions

FUNDAMENTAL SAFETY INSTRUCTIONS

Core safety instructions and understanding requirements for safe operation.

Obligation of the Equipment Operator

Outlines operator's responsibilities for ensuring staff are trained and understand safety.

Obligation of Personnel

Lists duties for personnel before operating equipment, emphasizing reading manual.

Dangerous Situations during Operation of the Equipment

Highlights potential dangers causing injury or damage despite safety standards.

Defined Purpose

Specifies the intended use of the equipment and prohibits other uses.

Guarantee and Liability

Details exclusions for damages arising from non-compliance or improper use.

Description of Safety Symbols and Instructions

Explains symbols that alert operators to imminent dangers and health consequences.

SAFETY FEATURES

Details safety features like bars, cords, beams, and the importance of not bypassing them.

OPERATOR SAFETY INSTRUCTIONS

Provides general safety considerations and emphasizes reading the manual.

PRACTICE GOOD HOUSEKEEPING

Instructions on maintaining a clean and safe operating environment around the equipment.

AVOID WEARING LOOSE CLOTHING

Advises against loose clothing and recommends safety shoes to prevent entanglement.

Specifications

Standard Features

Lists key features of the Challenger Series II, covering rotation, control, construction, and index systems.

Options & Accessories

Details available optional features and accessories for the printing system.

Screen Frame & Image Size

Installation

Pre-Technician Checklist for Challenger II Installation

A list of requirements to be met before scheduling a technician for installation.

Tri-Loc Pre-Registration System

SYSTEM COMPONENTS

Identifies the key components of the Tri-Loc system for accurate screen registration.

Art Dept. Set-up

Instructions for setting up a layout table to align films with the Pin Bar for accurate registration.

Exposure Unit Set-Up

Details on how to mount the master frame to the exposure unit for the Tri-Loc system.

M&R Press Set-Up

Describes the procedure for registering screens on the press using the Tri-Loc system.

General Setup & Registration

CENTRAL OFF-CONTACT LEVER

Explains the function and adjustment of the central lever for off-contact settings.

Omni;Uni Flash Operation

AUTO FLASH MODE

Instructions for operating the print stations in automatic flash mode.

MANUAL FLASH MODE

Steps for performing manual or test prints using the Omni Flash.

INSTRUCTIONS FOR OMNI;UNI FLASH INSTALLATION

Procedures for installing the Omni/Uni Flash cure unit onto the printing system.

Operation of the Temperature Controller

Details on how to operate and set the temperature controller for flash curing.

Quartz Flash Installation

QUARTZ FLASH INSTALLATION

Steps for correctly installing the Quartz Flash unit onto the printing press.

SIGNAL CABLE INSTALLATION

Instructions for connecting the signal cable from the Quartz Flash unit to the press PLC.

Quartz Flash Unit Operation

How to access and adjust settings for the optional Quartz Flash cure units.

Operator Controls

Cycle Sequence

Describes the step-by-step sequence of a single print cycle on the press.

Control Panel Functions

Overview of the main control console and its various functions and buttons.

Print Station Control Switches

Explains the function of switches and buttons for individual print stations.

Emergency Stop Push Button

Details the function and proper use of the emergency stop button for immediate system shutdown.

Individual Print Station Controls

Describes the specific controls available at each print station for adjustments and operation.

YELLOW CYCLE INTERRUPTION CORDS;BARRIER GATES

Information on safety cords and gates designed to prevent access to hazardous areas during operation.

AC PRINT STATIONS (Optional)

Information on the operation and setup of optional AC drive print stations.

E 300 Operator Interface

E 300 OPERATOR INTERFACE

Description of the operator interface control panel, its layout, and display functions.

L.E.D. STATUS INDICATOR LIGHTS

Explains the meaning of various LED status indicators on the operator interface.

TIMERS

Details how to access and adjust timer settings for index dwell, flash, quartz, and pre-heat.

OPTIONS

Overview of the options menu, including sub-menu items like Revolver, Rotation, and Pallet Size.

OILER

Instructions for adjusting and managing the automatic lubrication system for the index drive.

Ink Dip

Explains the automatic ink dipping feature to supply ink to the screen.

TESTS

Describes the on-board diagnostic program for checking operational integrity of switches and components.

MPR DATA

Information on using the Management Production Report software package for data analysis.

DATE;TIME

Instructions for adjusting the equipment's internal clock and calendar.

M&R INFO

Provides contact information for M&R Printing Equipment, Inc.

E 300 Operator Interface Logic Diagram

MAIN MENU SCREEN

Shows the primary screen displayed on the operator interface, including status indicators.

COUNTERS

Details how to access and interpret production counters like shift, job, and total counters.

TIMERS

Describes the sub-menu items for managing index, flash, quartz, and pre-heat timers.

OPTIONS

Outlines the various options available for configuring the system's operation.

HARDWARE TEST

Describes the diagnostic tests for checking hardware components like proximity switches and motor cards.

Preventive Maintenance Procedure

Recommended Lubricants

Lists recommended lubricants and their M&R part numbers for maintenance.

Recommended Tools

Lists essential tools required for performing maintenance procedures.

Bulletin No. PH1

Details daily maintenance procedures for checking and cleaning the print carriage assembly.

Bulletin No. EL1

Outlines daily procedures for cleaning electrical component enclosure air vents and circulation fan.

Bulletin No. IX1

Describes daily checks and maintenance for the air line moisture trap assembly.

Bulletin No. IX2

Details daily lubrication of indexer assembly bearings using specific grease.

Bulletin No. IX3

Outlines daily checks for Vactra oil level and index drive screw lubrication system.

Bulletin No. PH7

Describes weekly procedures for checking and adjusting print carriage timing belt tension on AC print stations.

Bulletin No. PH4

Details weekly cleaning and lubrication of print carriage stroke cylinders.

Bulletin No. PH5

Outlines monthly lubrication of the index drive capture fork and cam follower bearings.

Bulletin No. IX8

Describes monthly lubrication of registration forks and cam follower bearings on the index table.

Bulletin No. PH6

Details lubrication of micro-registration threaded adjustment shafts every three months.

Bulletin No. IX9

Describes monthly procedures for draining accumulated water and moisture from the compressor tank and air manifold.

Bulletin No. IX10

Outlines semi-annual replacement of the air filter element in the air line moisture trap assembly.

Bulletin No. EL3

Describes the procedure for replacing the PLC battery every three years to preserve memory.

Bulletin No. EL4

Details the process for replacing the Servo Amplifier Unit battery every three years.

Preventive Maintenance Log

Leveling the Pallets

1. Make sure the print station being used to level the pallets is level

Instructions on how to ensure a print station is level using a magnetic level before pallet adjustment.

2. Mount the flood bar on the mounting bar flood position.

Guidance on correctly mounting the flood bar for pallet leveling procedures.

3. Adjust the flood bar for zero angle.

Steps to adjust the flood bar to a zero angle by loosening and tightening specific knobs.

4. Turn the flood pressure knobs clock-wise, to adjust flood bar all the way up.

Procedure for adjusting the flood bar to its highest position using pressure knobs.

5. Pull the print carriage all the way towards the front...

Steps to disconnect the air line from the print head carriage for manual movement.

6. Before raising the table into the registration forks...

Pre-adjustment steps for pallet frame nuts before raising the table.

8. Now go ahead and move the head carriage towards the center...

Procedure for moving the head carriage and adjusting flood pressure knobs to contact the pallet.

9. Bring pallet down by pressing the green reset button...

Using a level to ensure the pallet is level after adjustments, with instructions for correction.

10. Now bring the pallet back up and move the head back and forward...

Adjusting the base pallet frame so the pallet surface is a specific distance from the flood bar edge.

11. Repeat Step #10 with all the remaining pallets.

Instructions to apply the pallet leveling process to all other pallets on the carousel.

Proximity Switch Location & Function

INDEX TABLE UP PROXIMITY SWITCH

Explains the function of the switch that signals the PLC when the index table reaches its raised position.

FORK OFF PROXIMITY SWITCH

Describes the switch that signals the PLC when the index capture fork clevis is dis-engaged.

INDEX “ON” PROXIMITY SWITCH

Details the switch that signals the PLC when the index table aligns with print stations.

DOUBLE INDEX PROXIMITY SWITCH

Explains the switch that signals the PLC when the double index fork is dis-engaged.

FRONT PROX - (On AC Print Station)

Describes the switch that signals the PLC when the print station carriage is at the front of the print head.

REAR PROX - (On AC Print Station)

Explains the switch that signals the PLC when the print station carriage is at the rear of the print head.

HOME PROXIMITY SWITCH

Details the switch used during initial setup to teach the servo drive the optimum starting reference point.

LOWER LIMIT;REVERSE SNAP ACTION SWITCH

Explains the switch that signals the PLC if the index drive assembly overruns its travel range during return.

UPPER LIMIT;FORWARD SNAP ACTION SWITCH

Describes the switch that signals the PLC if the index drive assembly overruns its travel range during forward/index.

Index Lift Cylinder Cushion Adjustments

Idec Relay Identification

Idec Relay Location & Function

Identifies and explains the function of specific Idec relays (K1-K4) within the system.

E 300 Alarm Message Listing

EMERGENCY-PANEL

Details the alarm that appears when the emergency stop button is pressed and how to clear it.

SAFETY CIRCUIT

Explains the alarm related to safety cords not being properly connected.

TIMERS NOT SET

Describes the alarm that occurs when PLC registers are cleared or set to zero.

RESET ERROR

Explains the alarm for a continuous reset input signal not discontinuing.

AIR PRESSURE

Details the alarm triggered by low incoming air pressure to the machine.

LIFT PROX ERROR

Alarm for issues with the lift proximity switch signal staying on or not sending.

INDEX ON PROX ERROR

Alarm for issues with the index on proximity switch signal.

SERVO FWD TIME OUT

Alarm indicating the servo drive failed to send feedback information during forward movement.

LOCK OFF PROX ERR

Alarm for issues with the lock off proximity switch signal.

DBL INDX PROX ERR

Alarm for issues with the double index proximity switch signal.

SERVO RVR TIME OUT

Alarm indicating the servo drive failed to send feedback information during reverse movement.

SERVO NOT HOME

Alarm indicating the servo index drive system is not at its starting position after a reset.

MOTION CARD ALARM

Alarm indicating an error with the PLC motion card, communication, or internal failure.

SRVO AMPLIFIER ALARM

Alarm indicating an error on the servo amplifier, requiring a check of the read-out code.

MOTION CARD NOT READY

Alarm indicating the motion card detected a failure within the servo drive system.

HOME POSITION LOST

Alarm when the servo drive's reference position has been lost.

BATTERY LOW PLC

Alarm indicating the PLC's lithium battery voltage is low or disconnected.

SERVO NOT READY

Alarm when power is turned off/on, or if emergency stop or limit switches are triggered.

ABS COMMUNICATION

Alarm indicating communication failure between the servo amplifier and PLC.

FORWARD LIMIT

Alarm triggered by the limit switch placed away from the servo motor.

REVERSE LIMIT

Alarm triggered by the limit switch placed next to the servo drive motor.

FLASHES NOT SET

Alarm when programmed flashes in MTA E-300 do not match Revolver mode setup.

SYSTEM ERROR - COMM ERROR

Alarm indicating loss or interruption of communication between CPU and E-300 interface panel.

Troubleshooting Procedure

No power to main control panel. Neither print stations or index system operate.

Troubleshooting steps for issues with no power or system operation.

Electrical power is indicated to controls, but nothing operates.

Steps to diagnose issues when power is indicated, but nothing operates.

The indexer does not raise fully into the print position.

Steps to address issues where the indexer does not fully raise into the print position.

The index table lifts and lowers too fast or too slow.

Troubleshooting for index table lift/lower speed being too fast or too slow.

In the automatic mode the press cycles a few times and then stops.

Addresses issues where the press cycles intermittently and then stops in automatic mode.

The indexer raises and the print stations start to print but do not complete the print stroke.

Troubleshooting for indexer raising and starting prints but not completing the stroke.

The indexer over-travels and is so rough that it clanks or the machine moves.

Solutions for indexer over-travel, roughness, or machine movement issues.

Kebco Frequency Drive

Kebco Frequency Drive Error List

Servo Amplifier Alarm List

Recommended Spare Replacement Parts

Ordering Replacement Parts

Replacement Parts

Operator Control Console

Lists replacement parts for the operator control console with corresponding part numbers.

Indexer Electrical Enclosure

Identifies replacement parts for the indexer electrical enclosure components.

Indexer Electrical Enclosure Fuses

Lists replacement fuses for the indexer electrical enclosure with part numbers.

AC PRINT STATION DRIVE CONTROL

Details replacement parts for the AC print station drive control system.

Assembly Diagrams

FRONT FRAME HOLDER;MICRO ASSEMBLY (AC HEAD)

Exploded view and parts list for the front frame holder and micro assembly of the AC head.

HEAD TUBE ASSEMBLY (AC HEAD)

Exploded view and parts list for the AC head tube assembly.

CARRIAGE PROX BRACKET ASSEMBLY (AC HEAD)

Exploded view and parts list for the AC head carriage proximity bracket assembly.

REAR FRAME HOLDER;MICRO ASSEMBLY (AC HEAD)

Exploded view and parts list for the rear frame holder and micro assembly of the AC head.

CHASSIS ASSEMBLY

Exploded view and parts list for the main chassis assembly of the machine.

UPPER;LOWER CAROUSEL ASSEMBLY

Exploded view and parts list for the upper and lower carousel assemblies.

PALLET STOP ASSEMBLY

Exploded view and parts list for the pallet stop assembly.

SPIDER ARM ASSEMBLY

Exploded view and parts list for the spider arm assembly.

DOUBLE INDEX ASSEMBLY

Exploded view and parts list for the double index assembly.

MAIN CONTROL PANEL ASSEMBLY

Exploded view and parts list for the main control panel assembly.

CLEVIS PLATE ASSEMBLY

Exploded view and parts list for the clevis plate assembly.

DRIVE MOTOR;BALL SCREW ASSEMBLY

Exploded view and parts list for the drive motor and ball screw assembly.

INDEX BASE ASSEMBLY

Exploded view and parts list for the index base assembly.

INDEX LUBRICATOR ASSEMBLY

Exploded view and parts list for the index lubricator assembly.

Glossary

LIMITED WARRANTY M&R TEXTILE EQUIPMENT

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