AGFA APL-106 OPERATING MANUAL
OPERATING MANUAL
(Original operating manual)
Automatic Pallet Loader APL-106
Agfa NV
Septestraat 27
B-2640 Mortsel
Telephone +32 3 444 2111
Internet www.agfagraphics.com
Please keep this manual for future use!
Machine / machine line: Automatic Pallet Loader APL 106A / Agfa Expert Loader
Year of construction:
Manufacturer:
2018 following
Krause-Biagosch GmbH, Paul-Schwarze-Str.5, D-33649
Bielefeld
Version 06
Revision: March 2019
Document history
Version Date Reason for Change Editor Status
3 July 2017 First edition Richter released
4
November 2018
Cassette Loader and Extension
Modul added
Richter released
Agfa name change to Agfa NV
Chapter 5, Installation and Setup
changed,maintanance extended
to the cassette loader,
maintenance materials silicon
spray, cleaning agent and
grease
5
February 2019
Pallet and plate data more
detiled.Cassette safety (5,12),
Richter released
extension module and cassette
operation (44,46ff)
6
r1
March 2019
April 2019
Corrected version numbers.
Maintenance instructions for
cassettes, note for safety
stickers added.
Maintenance intervals changed
Ahlemeyer released
© Agfa NV
This operating manual and all illustrations contained herein are protected by copyright. Any
use beyond the constraints of copyright law without the prior written consent of the publisher
is illegal and punishable by law. This particularly applies to copying, translation, transfer to
microfilm, and saving and processing in electronic systems.
Table of Contents
1 Introduction ............................................................................................................ 1
1.1 Means of representation .......................................................................................... 2
1.2 Warranty and liability ............................................................................................... 3
1.3 Copyright ................................................................................................................. 4
1.4 Terms of guarantee ................................................................................................. 4
1.5 Service / customer service ....................................................................................... 4
2 Safety ...................................................................................................................... 5
2.1 Intended use ............................................................................................................ 5
2.1.1 Constructional modifications to the machine ............................................................ 6
2.1.2 Foreseeable misuse ................................................................................................ 7
2.2 Personnel requirements ........................................................................................... 8
2.2.1 Obligations of the personnel .................................................................................... 9
2.2.2 Unauthorised persons .............................................................................................. 9
2.2.3 Instruction ................................................................................................................ 9
2.3 General safety information ..................................................................................... 10
2.4 Safety measures for environmental protection ....................................................... 10
2.5 Special hazard warnings ........................................................................................ 11
2.5.1 Symbols used on the machine ............................................................................... 11
2.5.2 Safty sticker on the machine .................................................................................. 12
2.5.3 Hazards due to electrical energy ............................................................................ 13
2.5.4 Hazards due to pneumatic energy ......................................................................... 13
2.6 Personal protective equipment .............................................................................. 14
2.7 Information for emergencies .................................................................................. 15
3 Machine description ............................................................................................ 17
3.1 Machine overview .................................................................................................. 17
3.2 Function and operating elements ........................................................................... 18
3.3 Operating panel ..................................................................................................... 19
3.4 Function description ............................................................................................... 20
3.5 Safety device ......................................................................................................... 22
3.5.1 MAIN SWITCH and EMERGENCY STOP. ............................................................ 22
3.5.2 Contact switches on the doors and hoods ............................................................. 22
3.6 Type plate .............................................................................................................. 23
4 Transport and installation site ............................................................................ 25
4.1 Transport ............................................................................................................... 25
4.1.1 Inspection on handover to the customer ................................................................ 25
4.1.2 Scope of delivery ................................................................................................... 25
4.1.3 Information regarding hazards during transport ..................................................... 26
Permissible auxiliary equipment for transport ......................................................... 27
4.1.4
Automatic Pallet Loader APL /Expert Loader I
Table of Contents
4.1.5 Dimensions and weights of the packages .............................................................. 27
4.1.6 Recommended transport equipment ...................................................................... 28
4.1.7 Intermediate storage .............................................................................................. 28
4.1.8 Transport packing .................................................................................................. 28
4.2 Installation site ....................................................................................................... 29
4.2.1 Load-bearing capacity of the installation surface .................................................... 29
4.2.2 Flatness of the installation surface ......................................................................... 29
4.2.3 Safety lighting ........................................................................................................ 29
4.2.4 Air conditioning ...................................................................................................... 29
4.2.5 Regulation of the humidity ..................................................................................... 30
5 Installation and commissioning/first start-up .................................................... 31
6 Operation .............................................................................................................. 33
6.1 Switching on the machine ...................................................................................... 33
6.2 Emptying the paper bin .......................................................................................... 34
6.3 Loading a pallet ..................................................................................................... 37
6.4 Loading a machine with 2nd pallet space............................................................... 44
6.5 Removing a pallet .................................................................................................. 45
6.6 Loading plates to the cassettes (optional) .............................................................. 46
6.7 Removing faulty printing plates .............................................................................. 47
6.8 Switching off the machine ...................................................................................... 48
7 Malfunctions......................................................................................................... 49
7.1 Display of malfunction messages ........................................................................... 49
7.1.1 System error .......................................................................................................... 50
7.1.2 Warnings ............................................................................................................... 50
7.1.3 Sequence error ...................................................................................................... 52
8 Maintenance and cleaning .................................................................................. 53
8.1 Maintenance intervals and maintenance work........................................................ 54
8.2 Cleaning agents and lubricants .............................................................................. 56
9 De-commissioning ............................................................................................... 57
10 Dismantling .......................................................................................................... 59
10.1 Information regarding hazards during dismantling .................................................. 59
10.2 Preparatory measures ........................................................................................... 60
10.3 Dismantling the machine and securing it for transport ............................................ 60
10.3.1 Preparing and securing the machine for transport .................................................. 61
10.3.2 Supply lines ........................................................................................................... 65
10.3.3 Paper bin ............................................................................................................... 66
11 Disposal ................................................................................................................ 67
11.1 Terminology ........................................................................................................... 67
II
Table of Contents
11.2
Overview of the assembly groups .......................................................................... 68
12 Appendix .............................................................................................................. 71
12.1 Technical data ....................................................................................................... 71
12.1.1 Dimensions ............................................................................................................ 71
12.1.2 Weights ................................................................................................................. 72
12.1.3 Electrical connected loads/rating ........................................................................... 72
12.1.4 Compressed air connected values/capacity ........................................................... 72
12.1.5 Ambient conditions ................................................................................................ 73
12.1.6 Airborne noise emitted ........................................................................................... 73
12.1.7 Heat emission ........................................................................................................ 73
12.1.8 Printing plate and pallet sizes ................................................................................ 74
12.2 Other applicable documents .................................................................................. 75
12.3 EC Declaration of Conformity ................................................................................ 75
Automatic Pallet Loader APL / Expert Loader III
1 Introduction
This operating manual provides you with all the information required for problemfree operation of the Automatic Pallet Loader APL-106 /Expert Loader (referred to
as "machine" hereinafter).
The function of the machine is to separate, align and convey printing plates to the
downstream machine line module "Recorder".
This operating manual must be read, understood and applied by all persons
instructed to carry out the
–
transport,
–
installation and assembly,
–
first start-up/commissioning,
–
operation,
–
maintenance and cleaning,
–
malfunction remedy,
–
de-commissioning and dismantling
–
and disposal
of the machine. This applies in particular to the specified safety instructions.
Studying the operating manual will enable you to correctly
–
install,
–
connect,
–
operate,
–
maintain
–
and dispose of the machine.
Observe the regulations generally valid by law and other binding regulations
regarding accident prevention and environmental protection of the country of use
in addition to this operating manual.
Automatic Pallet Loader APL / Expert Loader 1
1.1 Means of representation
Statements in this installation manual intended as information on and direct
warning of hazards are identified as follows:
DANGER
This warning describes a hazard with a high degree of risk, which if
WARNING
not avoided, will lead to death or serious injury.
This warning describes a hazard with a medium degree of risk,
which if not avoided, may lead to death or serious injury.
1 Int roduction
CAUTION
This warning describes a hazard with a low degree of risk, which if
not avoided, may lead to minor or moderate injury.
NO TE
This warning describes a hazard with a low degree of risk, which if
Furthermore, the following text features are used:
– Dashes precede list items.
•
Bullets precede instructions describing actions that are to be carried out in
the specified order.
Text in inverted commas refers to other chapters or sections.
" "
Text in square brackets describes touch buttons to be pressed on the
[ ]
operating panel.
not avoided, may lead to damage to assets.
The information symbol marks useful information.
2
1.2 Warranty and liability
Danger to life due to electric shock
Warning: suspended load
Symbols used in this manual
Particular hazards are additionally marked in warnings as follows:
This symbol warns of the life-threatening hazard of electrical current.
Contact with live components causes imminent danger to life.
This symbol warns of the hazards of standing/working under
suspended loads.
1.2 Warranty and liability
The obligations agreed to in the delivery contract, the General Terms and
Conditions, as well as the machine delivery terms and the legal regulations valid
at the time of the conclusion of the contract apply.
All the information and instructions in this operating manual were compiled taking
the valid standards and regulations, state of the art and our many years of
experience and expertise into consideration.
Warranty and liability claims on the basis of personal injury and damage to assets
are excluded if they can be traced back to one or several of the following causes:
–
Improper use or use other than that intended of the machine;
–
incorrect installation, assembly, operation, maintenance, cleaning,
disassembly;
–
non-observance of the operating manual and information in the operating
manual regarding installation, assembly, operation, maintenance, cleaning,
disassembly, disposal;
–
use of insufficiently qualified or insufficiently instructed/trained personnel;
–
structural changes to the machine (no conversions or any other changes to
the machine may be performed without the prior written consent of Agfa
NV. Any infringement will result in loss of the machine's EC conformity);
–
incorrectly carried out repairs;
–
use of non-approved spare parts and/or use of spare parts that do not meet
the technical requirements;
–
events of catastrophe caused by foreign objects and force majeure.
We reserve all rights to make technical changes within the framework of
improvement of the performance characteristics and further development.
Automatic Pallet Loader APL / Expert Loader 3
1.3 Copyright
This operating manual is protected by copyright and is exclusively intended for
internal purposes.
1 Int roduction
Handing over the operating manual to third parties, making copies of any kind
including excerpts – as well as using and/or disclosing the contents are prohibited
unless expressly consented to in writing by Agfa NV, except for internal
purposes.
Any infringement will result in liability for damages. We reserve the right to assert
further claims.
1.4 Terms of guarantee
The terms of guarantee are contained in the General Business Terms of
Agfa NV.
1.5 Service / customer service
In the event of problems please contact the representative in charge.
–
4
Non
-
observance of the fo
llowing safety information may have
ion to the instructions contained in this operating manual, the
user/owner must adhere to the existing national work, operating and
2 Safety
WARNING
serious consequences:
– Danger to persons resulting from electrical, pneumatic or
mechanical influences;
– failure of important machine functions.
Thoroughly read all the safety and warning information in this
section before commencing with the transport, installation,
connection and commissioning/start-up of this machine.
In addition to the instructions contained in this operating manual,
also observe the universally valid safety and accident prevention
regulations.
In addit
safety regulations. Also adhere to the existing internal works
regulations.
2.1 Intended use
The operational safety of the machine is only guaranteed if it is used in
accordance with its intended use.
The machine is exclusively intended for automatically loading printing plates into
the downstream machine line module "Recorder".
The machine is not intended for any use other than that specified here, any other
use is deemed as non-intended use. The following is forbidden in particular:
–
To transport persons with the machine;
–
to convey products other than those specified;
–
to convey products with different weights than those specified.
The intended use also includes:
–
Using energy supplies in accordance with the valid safety regulations;
–
adhering to the specified operating conditions.
–
adhering to the inspection and maintenance intervals;
Automatic Pallet Loader APL / Expert Loader 5
–
using consumables and auxiliary substances in accordance with the valid
safety regulations;
–
adhering to the specified operating conditions.
The technical specifications specified in the technical data must be adhered to
without exception.
Only use the machine in accordance with its intended use, otherwise safe
operation will not be guaranteed.
The manufacturer declines any responsibility for injuries and damage to
assets resulting from any use other than that intended. The user/owner of
the machine line alone is fully liable in this respect!
2.1.1 Constructional modifications to the machine
2 Saf ety
The design and manufacturer's acceptance are based on the Product Safety Act
(ProdSG). No modifications, attachments to or conversions of the machine may
be carried out without the prior written permission of
Agfa NV.
Non-compliance will result in loss of the machine's EC conformity. The
manufacturer's warranty will become null and void. This also applies to welding
work on load-bearing parts.
Immediately replace components that are not in perfect condition.
Only use original spare parts/wear parts/accessory parts. These parts are
specifically designed for the machine. If non-original parts/parts procured from
other sources are used, it cannot be guaranteed that they are properly designed
and manufactured with regard to stress and safety.
Parts and special equipment not supplied by Agfa NV are not approved for use
on the machine.
6
2.1 Intended use
Any addi
tional use and/or type of use of the machine other than
2.1.2 Foreseeable misuse
WARNING
the intended use can lead to serious injuries!
– Only use the machine in accordance with its intended use.
– Only load the machine with the designated printing plates.
Automatic Pallet Loader APL / Expert Loader 7
Risk of injury in the event of insufficient qualifications!
2.2 Personnel requirements
WARNING
Incorrect handling can cause serious injuries to persons and
Ensure that the machine is only transported, installed, set up and operated by
personnel specifically qualified and/or instructed to do so. These persons must
be familiar with the operating manual and act accordingly. The respective duties
and responsibilities of the personnel must be clearly defined.
damage to assets.
– Therefore restrict all work to suitably qualified personnel.
2 Saf ety
The following qualifications are specified in the operating manual for various
areas of activity:
Instructed personnel
Instructed personnel have been instructed by the user/owner or by qualified
personnel regarding the tasks to be performed and the possible hazards caused
by incorrect behaviour.
Qualified personnel
Qualified personnel, due to their specialist training, knowledge and experience,
and knowledge of the pertinent regulations, are able to perform the work they are
commissioned with and independently recognize and avoid potential hazards.
Electricians
Electricians, due to their specialist training, knowledge and experience, as well as
knowledge of the pertinent standards and regulations, are able to carry out work
on the electrical equipment and independently recognise and avoid potential
hazards.
Qualified electricians are trained for the specific operating site at which they work,
and are familiar with the relevant standards and regulations pertaining to this site.
8
2.2 Personnel requirements
Danger for unauthorised persons!
If in doubt, speak to the unauthorised persons and show them out
Specialist pneumatic personnel
Specialist pneumatic personnel, due to their specialist training, knowledge and
experience are able to monitor and maintain pneumatic equipment and systems.
They can independently recognise and avoid potential hazards.
Specialist pneumatic personnel are trained for the specific operating site at which
they work, and are familiar with the relevant standards and regulations pertaining
to this site.
2.2.1 Obligations of the personnel
Personnel may only include persons who can be expected to carry out their work
reliably. Do not allow persons whose reactions are negatively affected by drugs,
alcohol, medication or similar to work on the machine.
All persons instructed to work on the machine undertake, prior to commencing
work,
–
to observe the basic directives concerning health and safety at work and
accident prevention,
–
to read the safety instructions and the warnings contained in this operating
manual and confirm this with their signature, acknowledging that they have
understood the information.
2.2.2 Unauthorised persons
WARNING
Unauthorised persons who do not meet the requirements described
here with respect to the qualifications are not familiar with the
hazards in the work area.
– Keep unauthorised persons away from the work area.
–
of the work area.
– Interrupt the work while unauthorised persons are in the work
area.
2.2.3 Instruction
The personnel require regular instruction and training by the owner/user. This
instruction and training must be recorded in writing for monitoring purposes.
Automatic Pallet Loader APL / Expert Loader 9
2.3 General safety information
–
The machine may only be transported, installed, set up and
commissioned/started up after the personnel have familiarised themselves
with this operating manual.
–
Only use the machine in accordance with its intended use (see section
"2.1 Intended use").
–
Keep the work area of the machine clean and tidy at all times to avoid
hazards caused by dirt and parts lying around.
–
Keep all safety and hazard information/signs on the machine in legible
condition and replace them when necessary.
–
Restrict all work on the machine to qualified or instructed personnel (see
Section "2.2 Personnel requirements").
2 Saf ety
2.4 Safety measures for environmental protection
Adhere to the regulations for waste avoidance and for correct waste recycling
and disposal.
In particular during installation work as well as during decommissioning,
disassembly and disposal ensure that substances hazardous to groundwater
such as grease, oil, solvent-containing cleaning agents or similar do not
contaminate the ground or enter the sewage system. Collect, transport, store and
dispose of these substances in suitable containers in accordance with the
national regulations.
10
2.5 Special h azard war nings
Danger to life due to electric shock
Warning: danger of hand injury / crushing hazard
This symbol warns of the danger of eye damage from laser radiation.
2.5 Special hazard warnings
2.5.1 Symbols used on the machine
This symbol warns of the life-threatening hazard of electrical current.
Contact with live components causes imminent danger to life.
This symbol warns of the danger of hand injuries.
Your hands could be crushed, pulled in or otherwise injured.
Warning: danger of eye damage / laser radiation
Laser radiation entering the eye can lead to irreparable damage to
the eye.
Warnung: Maloperation
This symbol warns of danger due to maloperation for example when
loading the cassettes.
Keep all safety and hazard information/signs on the machine in legible
condition and replace them when necessary.
Automatic Pallet Loader APL / Expert Loader 11
2.5.2 Safty sticker on the machine
2 Saf ety
Overview
There are safety stickers on the covers of the machine:
A
B
Fig. 2: Safety sticker on the machine
Position Safety Labels meaning
A
Danger to life due to electric
shock.
B
12
Class 1 laser product. No
dangerous laser radiation outside
the machine when all doors and
hatches are shut.
2.5 Special h azard war nings
Contact with live parts causes electric shock.
2.5.3 Hazards due to electrical energy
DANGER
– Always keep electrical components enclosed.
– Only allow an electrician who is specifically trained to carry out
work on electrical equipment and who is able to detect and avoid
the hazards involved to perform work on the electrical equipment.
–
Restrict work on the electrical equipment to a designated qualified
electrician, e.g. company electrician.
–
Have the electrical equipment inspected/tested by an electrician before
installation and set-up of the machine.
–
Any changes made following this inspection must comply with
DIN EN 60204-1.
–
Damaged housings/casings and cables must be immediately repaired or
replaced before installation and set-up of the machine.
2.5.4 Hazards due to pneumatic energy
Air escaping at high pressure can penetrate the skin and cause serious injuries!
–
Only allow expert personnel specially trained and experienced in pneumatic
engineering to work on the pneumatic installations. Ensure that the
machine is switched off and secured against reactivation before
commencing work on the pneumatic installations.
–
Inspect all pneumatic lines, hoses and connections for externally visible
damage prior to installation and set-up of the machine.
–
Always keep pneumatic hoses away from your body.
–
Protect open air connections against the ingress of dirt.
–
Never interchange connections, connectors/plugs or switches. This will
inevitably result in malfunctions.
Automatic Pallet Loader APL / Expert Loader 13
Protective clothing
fitting sleeves and without protruding parts.
Safety footwear
Protective gloves
2.6 Personal protective equipment
It is necessary to wear personal protective equipment during work on the
machine to minimise hazards to health.
–
Always wear the personal protective equipment required for each type of
work.
–
Always follow the instructions regarding personal protective equipment
affixed in the work area.
These symbols have the following meaning:
Protective clothing consists of tight-fitting work clothing with low
tensile strength, with tightThis mainly serves as protection against being caught by moving
machine parts.
2 Saf ety
Do not wear any rings, necklaces, chains or other jewellery.
Wear slip resistant safety shoes to protect against heavy falling parts
and to prevent slipping on smooth surfaces.
Wear protective gloves to protect your hands from friction, abrasion
or deeper injuries.
Personal protective equipment is to be provided by the owner/user and must
meet the pertinent requirements.
In addition, observe the national regulations and any internal instructions laid
down by the owner/user.
14
2.7 Information for emergencies
2.7 Information for emergencies
Preventive measures
–
Be prepared for accidents at any time.
–
Keep the first-aid equipment (first-aid boxes, blankets etc.) ready to hand.
–
Train personnel so that they are familiar with accident reporting and the
first-aid equipment.
–
Keep accesses clear for emergency vehicles.
Measures in the event of accidents
–
Rescue persons from the hazardous area.
–
Immediately administer first aid in the event of cardiac arrest and/or
breathing arrest.
–
In the event of injury/damage to health immediately notify the first-aid
supervisor and an emergency doctor and the emergency rescue service.
–
Clear the accesses for emergency vehicles. Delegate someone to direct
the emergency personnel to the site of the accident if necessary.
Automatic Pallet Loader APL / Expert Loader 15
5
3 Machine description
3.1 Machine overview
1 Pallet compartment Printing plate intake
2 Paper bin Paper removal and double sheet detector
3 Operating panel Operation and status display
4 Transfer table Transfer to CTP exposure unit
5 Extension module Printing plate intake
Model right
Model left
Automatic Pallet Loader APL / Expert Loader 17
6
3.2 Function and operating elements
3 Machine description
1 Door element Access to the pallet compartment and air servicing unit
2 Door element Acess to the paper bin
3 Operating panel Touch panel for operating the machine
4 Main switch ON/OFF switch
5 Folding table Transfer table, can be folded up
6 Cassette compartment
18
3.3 Operating panel
Display of the alarm list with the malfunctions that
3.3 Operating panel
Main menu
1 Display Locking status (pallet compartment hood)
2 Display Locking status (paper bin door)
3 Display Display of the currently loaded material with the
number of plates remaining
4 [Material list] Display of the material list (material database)
6 [Pallets] Display/change the loaded pallets/materials
6 [Setup] System settings
7 [Service] Settings
8 [Empty paper bin] User prompting for emptying the paper bin
(see section "6.2 Emptying the paper bin")
9 [Alarm]
have occurred
10 [Load pallets] User prompting for loading the pallets
(see section "6.3 Loading a pallet")
11 [Home] Return to main menu
Automatic Pallet Loader APL / Expert Loader 19
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