ermengineering DC-200 Use And Maintenance Manual

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ www.ermengineering.com info@ermengineering ✆ (+34)937632525 P a g . 1 (Original) Use and maintenance manual Type: Automatic die cutter 2000mm Model: DC-200 IMPORTANT Read this user manual and follow the instructions and warnings before operating this device. Any modification or transformation performed on this machine may cause loss of the manufacturer’s guarantee and liability. This manual must always remain near to the machine and visible to all the operating and maintenance staff, for any future consultation, forming part of the equipment.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 2 Index: Page - CE Declaration of conformity: ........................................................................................... ¡Error! Marcador no definido. - Description: .................................................................................................................................................................................. 4 - Technical characteristics:........................................................................................................................................................ 4 - Installation and connection .................................................................................................................................................... 4 - Using instructions: ..................................................................................................................................................................... 6 Safety systems and messages. ............................................................................................................................................................................. 7 Programming ............................................................................................................................................................................................................ 8 Belt cutting measures for the different dies: ................................................................................................................................................. 9 DIE CUTTING A-A Direct finger .......................................................................................................................................................................... 9 DIE CUTTING A-A Finger over finger ............................................................................................................................................................. 13 DIE CUTTING A-B for High profile belts at 90º .......................................................................................................................................... 16 DIE CUTTING A-B Diagonal 70º ....................................................................................................................................................................... 18 Changing die head ................................................................................................................................................................................................. 20 - Care and maintenance ........................................................................................................................................................... 21 - Troubleshooting ...................................................................................................................................................................... 22 - Pneumatic drawing ................................................................................................................................................................. 24 - Spare parts ................................................................................................................................................................................. 25 - Electrical drawing ................................................................................................................................................................... 31

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 3 - CE Declaration of conformity WE DECLARE, under our responsibility, that the machine: - Type: Automatic die cutter - Brand: ERM Engineering - Model: DC-200 - Serial No.: xxxxxx - Manufacturer date: 2021 Inspired by the directives of the Official Journal of the European Communities: 2006/42/CE Machinery Directive 2014/35/UE Low Voltage Directive 2014/30/UE Electromagnetic Compatibility Directive Complies with the design and construction specifications of the European Standards on General Machine Safety: EN 349 – EN 614-1 – EN 614-2 – EN 1005-1 – EN 1005-2 – EN 1005-3 – EN 1005-4 – EN 14118 - EN 12100– EN 13850 – EN 13857 – EN 14118 - EN 14120 – EN 60204-1 – EN 11161 – EN 61310-1 - EN 13849-1 – EN 13849-2 – EN 60204-1 General Manager: Eduardo Ramos Martínez Arenys de Munt (Barcelona)-SPAIN Date: 2021/08

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 4 - Description: Pneumatic die cutter with motorised head to cut conveyor belts in zigzag, with ball screw activated by a stepper motor and positioning control. Pressure and die cutting time control. Exchangeable cutting heads for different cutting geometries, with possibility of programming diverse forward steps. Support bench with material positioning guides. This die cutter is especially designed to cut thermoplastic materials with interior tissue. - Technical characteristics: Dimensions 2677x930x1160 (l x w x h) Weight 315 Kg Max. Thickness 8 mm. Voltage 1x230V Power 0.40kW Max. pressure 7 bar - Installation and connection Place the machine near the measuring table, or right after it, in order to avoid the material to be cut coming into contact with the ground. Leave 1 metre free on the four sides to facilitate personnel access when operating.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 5 Level and balance the machine by means of the regulation bolts on the rubber feet. Provide compressed air through a tube with minimum interior diameter of 8 mm. connected to the intake. NOTE: We must bear in mind that air consumption by this die cutter is 220 litres/minute We shall connect the power cable to the control board at 230v. monophasic.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 6 NOTE: It is recommended that the two supplies of air and power be run, hanging from above, to prevent personnel tripping or falling. - Using instructions: WARNING: THIS DEVICE INVOLVES THE HAZARD OF HANDS AND ARMS BEING TRAPPED BY THE MOVEMENT OF THE CUTTING HEAD GREAT CARE MUST ALSO BE TAKEN BETWEEN THE CUTTING HEAD AND THE SUPPORT PLATE, AS THERE IS A DANGER OF CUTTING LIMBS. Once the machine is connected to the mains and provided with air, we shall proceed to start it up using the ON switch.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 7 We shall check that the regulator pressure is between 2 and 6 bar. Safety systems and messages. This die cutter has been equipped with the following safety systems: 1- EMERGENCY STOP This system allows an emergency stop to be performed at any time using the two push buttons located at both ends of the bench. MESSAGE: EMERGENCY BUTTON PRESSED To deactivate it, we must unlock the push button and then press RESET to return the head to the starting point. CLAMP OPEN This device does not allow engagement of the cutting head if the bar holding the belt is not lowered. MESSAGE: CLAMP OPEN To deactivate it, all we need is to lower the bar and press START. 3- DOOR OPEN This device detects that the rear door of the blade head is open. MESSAGE: COVER OPEN

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 8 The door must be closed to deactivate it. 4- CYLINDER DETECTOR This device does not allow displacement of the head because it detects that the cutting cylinder is not raised. This may happen due to lack of air or failure of the detector. MESSAGE: CYLINDRE WRONG To deactivate it, provide the machine with air or replace the detector. Programming We must know the functions of the push buttons on the board to program the die cutter. 1- RESET This must be pressed after an emergency stop or position the head at the starting point after STOP. 2- A-A - Selection of the A-A program This program is used in the majority of cases, to always operate on the left guide rail and cut the belts performing the first end with the coverage on top and the second end with the fabric on top, both for direct finger die cutting as well as finger over finger die cutting. 3- A-B - Selection of the A-B program This program is only used in cases of diagonal belts, or belts with an hi profile, to operate the first end on the left guide rail and the second on the right guide rail, always with the coverage on top.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 9 4- STOP Allows the cutting process to be halted at any moment, to change the time or cutting pressure, for example. On pressing START, it will continue the process without losing the positioning memory 5- START Starts the cutting process or acts to reboot following a stop. 6- WIDTH We shall use this button to program the width of the belt in centimetres with the numerical keyboard, to accept the number entered push ENTER. 7- STEP We shall press this button to program the cutting process by means of the head assembled, with the numerical keyboard, introduce the value in milometers, between 3mm to 50mm, to accept the numerical value, press ENTER 8- TIME We shall press this button to program the cut time using the numerical keyboard the numbers accepted are between 3 to 10, to accept the number press ENTER 9- ESC We shall use this key to correct or delete any wrong number when programming Belt cutting measures for the different dies: 80 x 10 90º………………….......................................……100 mm. Longest 80 x 10 70º…………………….......................................…100 mm. Longest 120 x 15 90º…………………....................................……130 mm. Longest 50 x 20 finger over finger 90º………………………120 mm. Longest DIE CUTTING A-A Direct finger First, we place the first end of the belt on the left side by the guide rail with the coverage on top and position the end of the belt just by the O Ref. mark.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 0 We then mark the measure to input the relevant material with a pencil, according to the die we want to use. We then place the belt under the tread bar until the mark made matches up with 0 Ref. and we make sure it is fully in contact with the guide rail. We lower the tread bar by pressing the down button.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 1 We select function A-A if it is not activated. We press WIDTH to input the numerical value of the width of the belt in centimetres and accept pressing ENTER. We check that the STEP is correct. If it is not, we use the STEP key and input the desired value after ENTER. NOTE: The values programmed shall not be lost, even when the equipment is switched off; the program always memorises the last values input. We press START to begin cutting at the first end. NOTE: During the cutting process, no programmed value may be changed, except the cutting time. To do so, we press STOP and change that value pressing TIME, modifying the cute time and accept pressing ENTER. After we press START to continue. Once the first cut is completed, we release the belt by pressing the raise bar button.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 2 We place the second end of the belt on the left side by the guide rail, but the opposite way, that is, with the coverage down, and position the end of the belt just on the O Ref. mark. Then mark the measurement to feed in the material with a pencil, according to the die one wishes to use. We then feed in the belt under the holding bar until the mark made aligns with 0 Ref. and we make sure it is fully in contact with the guide rail.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 3 We lower the tread bar using the down push button and press START. Once the operation is completed, we release the material by raising the tread bar. DIE CUTTING A-A Finger over finger NOTE: For this type of die cutting, one requires prior separation of the fabrics with the ply separator device PS-15 Separate the fabrics of the 130 mm. belt at both ends. We mount the 50x20 mm die. We check that the A-A function is activated. We program STEP 20 mm. and the required width in centimetres. We shall regulate the pressure to 3 bar, as the cutting pressure is less due to the length of the blades. We place the first end of the belt on the left side, by the guide rail, and place the end of the belt just on the O Ref. mark.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 4 Then pencil mark the two measures to insert the material for the stops STEP-1 and STEP-2. We then insert the material up to the first mark STEP-1. We lower the tread bar using the push button to lower it and press START. Once the first cutting operation has ended, we shall withdraw the surplus material. We shall place the anti-cut plate between the two cloths up to the end of the separator cut.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 5 Once the anti-cut plate has been placed inside, we insert the material up to the second mark STEP-2. We reduce the cutting pressure to 2 bar, as the second cut shall only cut the top fabric. We lower the tread bar and press START. On finishing the second cut, we withdraw the surplus material and the anti-cut plate.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 6 We place the second end of the belt with the opposing face upward on the same left side and repeat the same operations. DIE CUTTING A-B for High profile belts at 90º We select function A-B if it is not activated. We mount the die chosen: 80x10 or 120x15. We program the relevant gauge for the die mounted and program the width in centimetres. We adjust the cutting pressure according to the hardness of the belt and the blade length. First, we place the first end of the belt on the left side by the guide rail and then position the end of the belt just by the O Ref. mark, in order to mark the relevant material insertion measurement according to the die we wish to cut with.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 7 We then place the belt under the holding bar until the mark made aligns with 0 Ref. and make sure that it is fully in contact with the guide rail. We lower the tread bar using the down push button. Using the + / - buttons, we adjust the belt width in centimetres and press OK. We check that the STEP is correct and, if that is not the case, using the MENU key, we jump to the field STEP and input the desired value with + / - and then OK. We press START to start cutting at the first end. Once the first cut has been performed, we observe that the head shall be positioned at point 0 of the end opposite the control board. On reaching that point, we release the belt by pressing the bar up button. We place the second end of the belt on the right side next to the right guide rail and, with the coverage also on top, we position the final end of the belt just at the O Ref. mark, to pencil the mark with the measurement for insertion of the relevant material according to the die we wish to cut with.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 8 We then place the belt under the holding bar until the mark made matches 0 Ref. and we make sure it is fully in contact with the guide rail. We lower the tread bar using the down push button and press START. Once the operation has ended, we release the material by raising the pressing bar. DIE CUTTING A-B Diagonal 70º We select the A-B function if it is not activated. We mount die 80x10 70º. We program the STEP to 10mm. We adjust the cutting pressure to 4 // 6bar We program the width in centimetres 10% wider than the belt width. Example: if the belt is 400mm. wide, we will program 44 instead of 40. We remove de diagonal guide of right side and place in the left side.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 1 9 We place the belt that has already been cut in diagonal at 70º along with the supplementary guide to mark from 0 Ref. with the advance measurement of 80x10 70º. We then insert the belt until it aligns with the mark made at point 0 Ref. We lower the tread bar using the down push button and press START.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 2 0 Once the first cut is complete, we note that the head will be positioned at point 0 of the opposite end of the control board. On reaching that point, we release the belt by pressing the raise bar button. We place the second end of the belt on the right side, by the right diagonal guide and with the coverage also on top, and position the far end of the belt just at the O Ref. mark, to pencil the measurement mark to insert the material, that will be 80x10 70º. We then insert the material till the mark aligns with 0 Ref. and lower the tread bar and press START. Changing die head WARNING: When changing the die, it is recommended to turn off the equipment with the OFF switch for greater safety. We open the rear door. We loosen the 2 bolts using a 13mm Allen key.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 2 1 We remove the die and install the new one. We tighten the 2 bolts again. We close the rear door and program the correct gauge on MENU …. STEP … OK NOTE: We must adjust the cutting pressure for each type of die or material. Otherwise, excess pressure may cause breakage of the blades, or deterioration of the cutting nylon. - Care and maintenance Keep the screw and linear guides dust free and well lubricated with low density, low silicone content, lubricant oil. Replace the blades or the polypropylene bench when imperfect cuts are observed

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 2 2 Periodically move the polypropylene base 2 or 3 mm. to even out the wear Turn or change the polypropylene table when the surface is impaired, to do this, turn off the machine and loosen the knob displacement. After this, open the door and replace this table for a new one. Empty out the water and clean the air intake filter basin if there is condensation in the line. - Troubleshooting The board does not turn on. Check whether the switch LED turns red to determine a possible problem in the electric power line to the machine. The head does not move at all. Check that the cylinder is upward and that the grid (cylinder cutting detector) is on. The head moves but does not cut. Check that the electro-valve is working, and that the connector LED is on. Check that the regulator pressure is above 2 bar. Check that the cutting time is programmed between 05 and 10. The belt is not cut across the full width. Check that the intake pressure does not drop during cutting due to compressed air supply shortage. Check the thickness of the polypropylene plate.

Automatic die cutter Model: DC-200 ____________________________________________________________________________________________________________________ P a g . 2 3 NOTE: In the event of any problem, pay special attention to the messages on the screen to find what is wrong.

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Automatic die cutter Model: DC-200 __________________________________________________________________________________________________________________________________________________________________________ P a g 2 5 - Spare parts 70200 Kn77101 70220 67101 Number Part name Units Kn77101 cuchilla 0.7x122xdoble bisel normal.par 2 70200 Distancial troquel 120 DC.par 1 70220 Pasador troquel.par 2 67101 TROQUEL-120x15.par 1 PUNCHING PLATE 120X15 PUNCHING PLATE 80X10 70200 Kn77102 70220 67102 Number Part name Units Kn77102 cuchilla 0.7x82xdoble bisel normal.par 2 70200 Distancial troquel 120 DC.par 1 70220 Pasador troquel.par 2 67102 TROQUEL-80X10.par 1

Automatic die cutter Model: DC-200 __________________________________________________________________________________________________________________________________________________________________________ P a g 2 6 PUNCHING PLATE 80X10 70º PUNCHING PLATE 50X20 70200 Kn77103 Kn77104 67103 Number Part name Units Kn77103 cuchilla 0.7x79.5-70.par 1 Kn77104 cuchilla 0.7x82.5-70.par 1 70200 Distancial troquel 120 DC.par 1 70220 Pasador troquel.par 2 67103 TROQUEL-80X10-70.par 1 70220 70200 Kn77105 67104 Number Part name Units Kn77105 cuchilla 0.7x52.5.par 2 70200 Distancial troquel 120 DC.par 1 70220 Pasador troquel.par 2 67104 TROQUEL-50x20.par 1 70220

Automatic die cutter Model: DC-200 __________________________________________________________________________________________________________________________________________________________________________ P a g 2 7 70111 70101 70100 70114 70103 70115 70110 70102 70105 70112 70109 70113 70104 70108 70106 70107 Number Part name Units 70100 CDQ2B140TF-40DCZ.asm 1 70101 Cabeza CD1500.asm 1 70102 Patin Hiwin 20.par 2 70103 KQ2L12-03S.par 4 70104 SY9120-5DZ-03.asm 1 70105 Screw_DIN_912_M14x50_v1 0.00.par 4 70106 KQ2S10-03S.par 1 70107 ANA1-02.par 2 70108 Tapa trasera cabezal.par 1 70109 Screw_DIN_912_M6x25_v1 0.00.par 8 70110 Palm_gripDIN_6335_L_20x 15_v10.00.par 1 70111 Bisagra tapa cabezal.par 1 70112 Screw_DIN_912_M5x10_v10 .00.par 2 70113 Screw_ISO_7379_8x16_M6 _v10.00.par 2 70114 D-A93.par 1 70115 Micro puerta.par 1

Automatic die cutter Model: DC-200 __________________________________________________________________________________________________________________________________________________________________________ P a g 2 8 70201 70203 70205 70204 70206 Number Part name Units 70201 Base distancial.par 1 70202 Enlace troquel.par 1 70203 Guia cabezal.par 1 70204 Soporte guia cabeza.par 1 70205 Selfoil 15x20x25.par 2 70206 Tornillo troquel.par 2 70202

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