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Zünd S3 Series User Manual

Zünd S3 Series
214 pages
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Operating Manual
S3 Digital Cutter

Table of Contents

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Zünd S3 Series Specifications

General IconGeneral
Modular ToolingYes
Cutting AreaUp to 3.2 m x 1.6 m
ModulesVarious modules available
Work AreaVaries depending on configuration; sizes range from S3 L-1200 (1.27 x 1.2 m) to S3 XL-3200 (3.2 x 3.2 m)
Power ConsumptionVaries depending on configuration
WeightVaries depending on configuration
Air Pressure6 bar

Summary

Introduction to the S3 Digital Cutter

Using the Operating Manual

Explains how to use the manual effectively for machine operation and maintenance.

Points to Note When Reading the Manual

Provides guidelines for understanding text references, diagrams, and dimensional information.

Publishing Details

Contains information on designation, layout, illustration, print, and copyright.

Product Description of the S3 Digital Cutter

Important Product Information

Highlights tips, important notes, and conventions for understanding product information.

Machine Orientation

Defines directions (front, back, left, right) relative to the operator's view.

Product Identification

Details about the rating plate and its various signs and markings.

Intended Use

Specifies the purposes for which the cutter system is designed and usage restrictions.

Cutter Overview

Visual identification of the main components of the cutter system.

Modules and Tools

Describes the versatility of cutters through interchangeable modules and tools.

Universal Applications

Details universal modules and various tools used for different cutting tasks.

Routing and Engraving

Focuses on router modules and specific tools for routing and engraving applications.

Punching and Perforating

Explains the punch and pricking module for perforating various materials.

Kiss-Cutting

Describes the kiss-cut module for precise film cutting without damaging carriers.

Drawing, Marking, and Labeling

Details marker modules used for drawing, marking, and labeling materials.

Material Handling

Covers methods for handling materials on the cutter, including static and conveyor systems.

Optional Features

Introduces optional features like laser pointers and ICC cameras.

Accessories Box Contents

Lists the tools and materials included in the accessories box for cutter maintenance.

Technical Description of the Cutter

Provides a detailed breakdown of the cutter's base machine, movement systems, and components.

Technical Data and Specifications

Presents specifications including dimensions, weights, electrical connections, and environmental conditions.

Safety Guidelines for S3 Digital Cutter

General Safety Principles

Emphasizes operator safety as the primary concern and state-of-the-art technology.

Proper Use of the Machine

Stresses the importance of correct operation and adherence to safety regulations.

Predictable Unintended Use

Lists examples of misuse and their potential consequences for the machine and user.

Hazard Warnings and Instructions

Explains signal words (Danger, Warning, Caution, Note) and hazard symbols used in the manual.

Areas of Responsibility

Defines responsibilities for the manufacturer, owner, and operating/service personnel.

Personnel Requirements

Outlines necessary qualifications, training, and age for operating and service personnel.

Personal Protective Equipment (PPE)

Specifies required safety equipment such as clothing, goggles, gloves, and hearing protection.

Rules and Occupational Safety

Covers general safety rules, unauthorized modifications, and maintenance procedures.

Conduct During Malfunctions

Provides guidance on actions to take during machine malfunctions and safety devices.

Danger Areas

Identifies general danger areas and specific risks during initialization and cleaning.

Product Warnings and Labels

Illustrates mandatory signs and warning labels found on modules and tools for safety.

Protective Devices

Details safety devices like EMERGENCY STOP buttons and light barriers for machine protection.

Mechanical Hazards

Discusses risks from entanglement, foreign bodies, sharp objects, and burns.

Electrical Hazards and Toxic Dust Risks

Covers risks from electric shock, toxic dust emission, and hazardous material processing.

Environmental and Chemical Hazards

Addresses environmental pollution risks and safe handling of chemicals and operating materials.

Fire and Explosion Risks

Details risks associated with flammable materials, dust explosions, and fire safety measures.

Laser Beam Safety

Provides safety instructions regarding the laser pointer used with the ICC camera.

Operating Personnel Safety Instructions

Emphasizes the importance of training, hazard assessment, and following manual instructions.

Service Personnel Safety Precautions

Outlines safety precautions and expertise required for service and maintenance personnel.

Disposal Instructions

Provides guidelines for the proper disposal of the cutter system and its components.

Controls and Operation of the S3 Cutter

Safe Working Practices

Stresses the critical importance of safe operation to prevent injury and damage.

Machine Controls Overview

Identifies key control elements like the EMERGENCY STOP, control panel, and maintenance units.

Control Panel Details

Details functions of the display, soft keys, navigation keys, and function keys on the control panel.

Emergency Stop Control Devices

Explains the function and location of the two standard EMERGENCY STOP control devices.

Maintenance Unit Functions

Describes the maintenance unit for adjusting air pressure to various modules and options.

Machine Interfaces

Details the data exchange interfaces available on the machine, such as LAN and COM ports.

Menu Navigation

Guides users through navigating menus using navigation keys, help, and info menus.

Menus and Functions

Explains how to select tools, commands, and use function keys for operations.

General Settings Configuration

Covers setting language, display lighting, contrast, and volume for user customization.

User Level Management

Explains user levels, password changes, and defining active user levels after startup.

Malfunction Handling and Troubleshooting

Provides guidance on troubleshooting, error localization, and engaging automatic circuit breakers.

Daily Checks and Startup Procedures

Details pre-startup checks, behavior in emergencies, and machine startup sequences.

Operating Modes

Explains the three operating modes: OFFLINE, STOPPED, and ONLINE.

Manual Beam/Module Movement

Describes how to move the beam and module carriage manually using travel keys.

Handling Modules and Tools

Covers inserting, removing, activating, and marking modules and tools for the cutter.

Material Fixing and Vacuum Settings

Details methods for securing material using vacuum and adjusting vacuum range and intensity.

Material Transport Options

Explains material transport systems, feeding clamps, and feed guide rails for material handling.

Automatic Tool Initialization (AKI)

Guides through the process of automatic tool initialization and height adjustment.

Job Processes and Tandem Operation

Covers job management, tandem operation, and control descriptions for dual workspace use.

Film Handling

Details film handling, cutting strips, and the function of the film end sensor.

Laser Pointer and Reference Point

Explains the use of laser pointers for defining reference points and vacuum width.

ICC Camera and Registration Marks

Describes the ICC camera for automatic registration and requirements for registration marks.

Module Carriage Slot Protection

Discusses the protective plate for module carriage slots to prevent crushing and contamination.

Signal Lights Indicator

Explains the meaning of different signal light colors indicating cutter status and errors.

Tips for Cutting with the S3 Cutter

Selecting the Right Tool

Guides on choosing the correct tool based on material properties and processing methods.

Blade Selection and Types

Details different knife types (drag, oscillating, rotary, circular) and their applications.

Blade Geometry and Cutting Depth

Explains wedge angle, cutting angle, and maximum cutting depth for optimal blade performance.

Overcut Calculation and Correction

Covers understanding, calculating, and correcting overcut for precise cutting results.

Oscillating Cutting Techniques

Details advantages of oscillating cutting and compares EOT/POT tool specifications.

Identifying and Rectifying Quality Problems

Provides solutions for common cutting issues like inaccurate curves, overcuts, and jerky movements.

Maintenance of the S3 Digital Cutter

Maintenance Recommendations

Advises on regular maintenance, annual inspections, and preparation for service.

Safe Maintenance Practices

Outlines general safety instructions for performing maintenance and cleaning work.

Tools, Operating, and Auxiliary Materials

Lists necessary tools, operating materials (cleaning agents, lubricants), and auxiliary materials.

Maintenance Schedule for Operators

Provides a checklist for daily, weekly, and monthly maintenance tasks for trained personnel.

Maintenance Schedule for Service Technicians

Lists annual and special interval maintenance tasks for authorized service technicians.

Cutter Maintenance Mode

Explains how to put the cutter into maintenance mode to ensure safety during work.

Service Flaps and Covers

Details the locations of service flaps and covers and their associated tasks.

Cleaning the Machine and Components

Guides on cleaning the machine, inside of the beam, X/Y axis guide rails, and clamps.

Lubricating Guide Carriages

Provides step-by-step instructions for oiling the front and rear guide carriages on the X axis.

Draining Maintenance Unit Condensate

Details the procedure for draining condensate water from the maintenance unit.

Resetting Vacuum Pump Protection Relays

Explains how to reset motor protection relays for vacuum pumps under various fault conditions.

Replacing the Conveyor Belt

Provides comprehensive instructions for removing and installing a new conveyor belt.

Cleaning the ICC Camera Lens

Details the safe procedure for cleaning the ICC camera lens, including handling isopropanol.

Disposal Instructions

Provides guidelines for the proper disposal of the cutter system and its components.

Starting Up After Standstill

Covers procedures for starting the machine after periods of inactivity, including running-in routines.

Tools

Modules

Material Handling

Additional Specifications

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