4.3 Menu navigation............................................................................................................................. 72
4.4 Menus and functions......................................................................................................................73
3
Page 4
Contents
4.5 General settings..............................................................................................................................75
4.6 User level........................................................................................................................................76
With your decision to purchase our product you are participating in the worldwide success of Zünd
cutter systems.
The modular design of our systems provides the following benefits, among others things:
•A system solution that meets your individual requirements in terms of speed and quality.
•The availability of the most up-to-date technology thanks to continuous development.
Our approach
Constant and intensive cooperation with experienced users is essential for developing innovative
and practical solutions. We are therefore grateful for any comments or suggestions on how we can
improve.
Contact
Zünd Systemtechnik AG
Industriestrasse 8
CH - 9450 Altstätten
Tel: +41 71 757 8181
info@zund.com
www.zund.com
7
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Introduction
1.1 Using the operating manual
The supplied operating manual is intended to enable you to operate the machine safely, perform
routine maintenance and use the machine optimally in every way.
To do this, you need to be able to find what you need in the documentation.
Scope of the operating manual
Volume 1 - Operating instructions
This volume contains information on engineering, commissioning, operation
and maintenance of the machine.
Volume 2 - Service manual
This volume contains information on the design of the machine and on
servicing by authorized service technicians. The service manual is not included
in the scope of delivery of the machine.
Spare parts catalog
The spare parts catalog is not included in the scope of delivery of the machine.
Structure of the operating instructions
The operating instructions consist of separate sections, which are numbered consecutively and
arranged according to the ring binder tabs.
The table of contents provides information on the structure of the individual sections.
Indication of optional accessories
There are many optional accessories available for the machine. Descriptions of optional additional
equipment are labeled in the operating manual with the wording (optional) .
Safekeeping of the documentation
Always keep Volume 1 of the "User manual" close at hand in the vicinity of the workstation.
Current status of the documentation
In order to ensure that the operating manual always remains complete and up to date, the following
must be observed:
•Do not remove individual documents.
•Request copies of missing or illegible pages from the manufacturer, or download them from the
Zünd homepage and print them out.
•If any new documentation is provided as a result of conversions, add it immediately.
•Replace changed documents and destroy the old version.
•If the documentation exists in more than one language, ensure that all languages are kept up to
date.
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Introduction
1.2 Points to note when reading this operating manual
Text references
Chapter headings are numbered consecutively in the chapters, with the first figure corresponding
to the chapter number. Where reference is made to sections outside the current chapter, note the
first figure and turn to the corresponding chapter, which contains the cited section. See chapter 2.4
Cutter; overview, for example, leads to chapter 2 Product description, which contains section 4 Cutter
overview.
Block diagrams and simplified representation
Note that all representations are provided for general information and do not necessarily correspond to
the latest version of the machine.
Dimensional information
Dimensional information is listed in the SI/US units, depending on the installation site.
1.3 Publishing details
Designation
Operating instructions for S3 series cutters.
Layout, illustration, and print
Zünd Systemtechnik AG - Technical Communications Department
This chapter contains information on the following:
•Representation conventions in the operating manual
•Usage possibilities of the machine
•Structure of the main components
•Important technical data
•General technical description of the machine
2.1 Important information about the product
Tip:
"Tip" refers to useful information which enhances the usability and prolongs the service life of the
machine or makes the work process significantly easier.
Tip:
With tips combined with the sheet we give you usage tips and useful information which can
improve the energy efficiency of the machine or optimize its environmental effects.
Important:
Usage tips and important machine operating information are labeled with Important.
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Product description
2.2 Orientation
Directions such as "right, left" or "front, back" relate to the operator's view of the machine during
operation.
1front
2rear
3right
4left
XX-axis
YY axis
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2.3 Product identification
2.3.1 Rating plate
Product description
1Position of the signs10Year of manufacture
2Rating plate11Serial number
3Additional UL sign12UL mark of conformity
4Additional connection values13Nominal voltage
5Additional FCC sign14Rated current
6CE mark of conformity15Frequency
7UL functional safety16Nominal voltage
8Product name17Current consumption
9Type designation18Frequency
2.4 Intended use
The cutter system can be used for the following purposes:
•As an output station for CAD/CAM data.
•For processing and labeling of materials.
The intended use and the usage restrictions are also dependent on the available tool and material
transport system, which are described in the "Tools", "Modules" and "Material handling" chapters.
13
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Product description
2.5 Cutter overview
14
Page 15
1Air supply to maintenance units
2Beam
3Tool/module power supply
4Extractor
5Workstation
6Control panel with optional workstation
7Vacuum pump
8Working area
Product description
15
Page 16
Product description
2.6 Modules, tools
Zünd cutters are highly specialized and can be easily converted to process other materials through the
use of modules and tools.
Two modules can be attached to slots 1 and 2 on the module carriage as standard. Either an
electrically or pneumatically driven marking module can be installed in slot 3 (MAM-SP, MAM-SE).
Tip:
You can find detailed information in section Handling modules/tools on page 88 as well as in
the individual operating manuals of your modules and tools.
16
1Module (e.g., KCM-S, UM-S)
2Tool (e.g. CT, UCT, EOT, POT)
3Tool insert: router, blade, pen
Page 17
2.6.1 Universal applications
Universal modules - UM-S
Universally applicable carrier module for a wide range of tools.
Product description
Tools for use in the UM
Electric Oscillating Tool - EOT
Cutting tool with high oscillation frequency for soft and medium hard
materials.
Electric Oscillating Tool - EOT-250
Robust tool with high-performance electric drive for processing thick
cardboard and leather materials.
Pneumatic Oscillating Tool - POT
Powerful cutting tool with large oscillation stroke for hard and tough
materials of up to 50 mm thickness.
Driven Rotary Tool - DRT
Tool for technically demanding textiles and textile materials. The powered
rotary knife enables a very high processing speed.
Universal Cutting Tool - UCT
Universally usable cutting tool for materials of up to 5 mm thickness.
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Product description
Scoring Cutting Tool - SCT
Combination tool for scoring and cutting cardboard and coating blankets of
up to 5 mm material thickness.
V-Cut Tool - VCT
Tool with five different cutting angles. Creation of complex 3D
constructions from high expansion foam or sandwich boards.
Passepartout Tool - PPT
Exact 45° oblique cuts in constantly high quality.
Perforating Tool - PTT1
Ideal tool for creating precise perforations in corrugated cardboard, solid
board, polypropylene, and foil.
Kiss Cutting Tool - KCT
Kiss-Cutting tool with adjustable pressing pressure for the processing of
numerous vinyl materials.
Universal Routing Tool - URT
Cost-effective routing and engraving tool.
Creasing Tools - CTT1/2
Creasing of various types of materials. The pressing pressure is
separately adjustable laterally and longitudinally along the shaft.
Universal Drawing Tool - UDT
Drawing tool for the use of standard commercial leads in various line
thicknesses.
Raster Braille Tool - RBT
Efficient procedure for the creation of tactile Braille markings (for the
blind).
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2.6.2 Routing, engraving:
Router modules - RM-S
Product description
Universally usable routing system, fitted with a powerful high
frequency spindle.
•Routing depth up to 25 mm
•Effective dust extraction, actively air-cooled
•Surface compensation for precise depth setting
•Optional Minimal Quantity Lubrication- MQL for
processing soft aluminum alloys
•1 kW high-frequency spindle for very high processing
speeds
Tools for use in the RM-S
HF motor spindle 4040 DC-SZ
Motor spindle with 1000 W and manual roll pin.
2.6.3 Punching, perforating
Punch and Pricking Module - PPM-S: Combined high-performance
tool for perforating and punching leather, rubber and textile materials
with up to 8 holes per second. A punching spike is integrated.
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Product description
2.6.4 Kiss-cutting
Punch and Pricking Module - PPM-S: High-performance tool for
perforating leather, rubber and textile materials with up to 8 holes per
second. A marking tool is integrated.
Kiss-cut module - KCM-S
KCM-S: This module cuts films with the highest precision and processing
speed without damaging the carrier material.
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2.6.5 Drawing, marking, labeling
Marker modules - MAM
Marking and labeling of various types of materials. Use of standard
commercial leads.
•MAM-SE: 1 drawing tool, electric
•MAM-SP: 1 drawing tool, pneumatic
•MAM-SPS: 1 drawing tool, pneumatic
•MAM-SPD: 2 drawing tool, pneumatic
Product description
2.7 Material handling
Cutter with static work surface
Loading and removal of the processing material
on the working surface of the cutter. The working
surface is protected against damage using a cutting
board.
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Product description
Cutter with material transport
The material transport is used to pull the processing
materials onto the work surface. The conveyor belt
is used as a cutting base and conveyor belt at the
same time.
During processing, the material to be processed
is fixed in place using a vacuum. After cutting, the
beam moves backwards. The conveyor clamping
elements fix the conveyor belt and the feeding
clamps are pressed onto the material to be pushed
forward. The beam tightens the conveyor belt to the
set position.
The shape of the feeding clamps varies depending
on the material to be processed. An auxiliary drive
is used for larger tables or for transporting heavier
processing materials.
2.7.1 Collection tray
Cutter extensions allow streamlined working. The
material supply/removal is carried out while the
cutter is completing the jobs. Cutter extensions are
available in different sizes.
22
The collection tray is a practical device with which the
cutting waste and cut parts are collected. It ensures a
clean working environment. For emptying, the tray can
be removed from the cutter in just a few steps.
Page 23
2.8 Options
2.8.1 Laser pointer
Product description
The laser pointer is used as an aid for the precise
definition of the reference point. It also serves for
the connection of electrically driven tools.
2.8.2 ICC camera
The ICC camera allows perfect registration in
which the exact position of printed material on the
processing surface is determined.
The integrated laser pointer is used as an aid for
the precise determination of the reference point.
Electrically driven tools can also be connected to
the camera.
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Product description
2.9 Accessories box
The accessories box is delivered with the cutter. The accessories box contains the tools and
operating and auxiliary materials needed for maintaining the cutter. The contents are provided
appropriately for the cutter.
Contents (sample)
AccessoriesQuantityTaskConveyorStaticPU
Allen screwdriver 4 x
170 mm
Torx screwdriver TX101 pc.Assembling/
Special guide rail oil25 mlOil for the X/Y axis
Lubrication set, X axis
guide rails
Staple gun1 pc.Replacing the conveyor
Dosing gun KPM 250
ECON
19 mm tape, doublesided
Teflon grease20 mlServiceXXX
Soldering fluid brush1 pc.ServiceXXX
Glass tube safety guards
(various)
1 pc.Assembling/
disassembling modules
disassembling covers
guide rails, carriage and
bearings
1 pc.Oil for the X/Y axis
guide rails, carriage and
bearings
belt
1 pc.Replacing the conveyor
belt
1 pc.Fixing the cutting boardX
5 pcs.ServiceXXX
XXX
XXX
XXX
XXX
X
X
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Product description
2.10 Technical description
Zünd high performance cutters enable efficient and precise processing of the most varied of
materials. With the modular tool and material handling system, you can adapt your machine to your
individual requirements. Define the production requirements and put together your tailor-made cutter
configuration from the Zünd kit concept.
2.10.1 Base machine
Table design
The cutter consists of a base frame and a beam. Whereas the base frame is produced in the form of
a stable welded structure, the beam consists of a lightweight, torsionally rigid aluminum profile. The
cutter is mounted on vibration-dampening machine feet.
Working area / vacuum plate
The working area is made of stable plastic. The vacuum zones are arranged under the working area
and are controlled using a slider. The vacuum is built up using a powerful vacuum generator.
The vacuum is used for holding down and tightening the material to be processed.
Electronics unit / power box
The power box is housed in the front right-hand side of the cutter and is only accessible via a
removable cover. The power box contains the power supply of the complete cutter and is activated/
deactivated with the main switch. The connection of the individual consumers takes place using
software control, if required.
The electronics unit is arranged behind the power box. The electronics unit can only be accessed
using a special tool. The cutter control is housed in the electronics unit.
Pneumatics
The air pressure for the respective consumers is adjusted via a maintenance unit. The maintenance
unit is accessible via service doors for adjusting settings and carrying out maintenance work.
2.10.2 Movement system
The S3 series has four electronically driven axes:
AxisFunctionMovement system
Movement of the beamDriven via toothed belt
X
Material transport, material transport
extension
Feed clamping elements, feeding clamps
YMovement of the module carriageDriven via toothed belt
ZHeight adjustment of the moduleExample UM-S
TRotary movement of the moduleExample UM-S
X axis - beam
The bar is driven via a toothed belt and a powerful electric motor. The design ensures that it works
without play and it also minimizes wear on the drive system. The beam is supplied with control
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Product description
signals and compressed air via an energy chain. All drive parts are protected against direct access or
contamination using covers.
X axis - material transport
Material transport takes place via conveyor clamp elements and feeding clamps on the bar. Feed
takes place via the bar movement. The conveyor belt is gripped by the conveyor clamp elements and
the processing material is secured against displacement using the feeding clamps.
Y axis - module carriage
The module carriage is driven by a motor via a toothed belt / gear mechanism. The design ensures
that it works without play and it also minimizes wear on the drive system. The module carriage is
supplied with control signals and compressed air via an energy chain. All drive parts are protected
against direct access/contamination using covers.
Z axis - height adjustment of the module
Machine-controlled setting of the processing height (e.g. UM-S).
T axis - rotary movement of the module
Modules with integrated T axis (e.g. UM-S) align the tool insert to the cutting path.
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2.11 Technical data
2.11.1 Dimensions
2.11.1.1 Base cutter (mm)
Product description
The effectively usable working surface (D x E) depends on the tool or module.
Type (mm)ABB1CDE
M-800
M-1200
M-1600
L-1200
L-1600
XL-1200
830
2086
520
2556
3026
1542
1942
2342
1942
2342
194212302270
830
1230
1630
1230
1630
1330
1800
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Product description
2.11.1.2 Base cutter (inch)
The effectively usable working surface (D x E) depends on the tool or module.
Type (in)ABB1CDE
M-800
M-1200
M-1600
L-1200
L-1600
XL-1200
32.7
82.1
20.5
70.9
119.1
60.7
76.5
92.2
48.4
92.2
48.448.489.4
32.7
48.4
64.2
48.4
64.2
52.4
70.9
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2.11.1.3 Cutter extension - CE (mm)
Product description
Type
Length (mm)
M-800x
M-1200x
M-1600x
L-1200x
L-1600x
XL-1200x
CE0800
875
CE1200
1275
CE1600
1674
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Product description
2.11.1.4 Cutter extension - CE (inch)
30
Type
Length (in)
M-800x
M-1200x
M-1600x
L-1200x
L-1600x
XL-1200x
CE0800
34.4
CE1200
50.2
CE1600
65.9
Page 31
Product description
2.11.2 Weights
2.11.2.1 Base cutter (kg)
TypeWeight (kg)max. floor load (kg/m)2)
M-800
M-1200
M-1600
L-1200
L-1600
XL-1200620
2.11.2.2 Base cutter (lbs)
TypeWeight (lbs)max. floor load (lbs/in)2)
M-800
M-1200
M-1600
L-1200
L-1600
XL-12001370
420
490
560
560
610
925
1080
1240
1240
1350
200
440
2.11.2.3 Material weight (kg)
Typemax. material weight (kg)max. material weight (kg/m2)
M-800
M-1200
M-1600
L-1200
L-1600
XL-120027
2.11.2.4 Material weight (lbs)
Typemax. material weight (lbs)max. material weight (lbs/in2)
M-800
M-1200
M-1600
L-1200
L-1600
11
16
21
22
29
24
35
46
49
64
10
22
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Product description
Typemax. material weight (lbs)max. material weight (lbs/in2)
XL-120060
2.11.3 Electrical connection, power consumption
Electrical connection 400 V, 50/60 Hz
Voltage3-phase, 400 VL1, L2, L3, N, PE
Mains frequency50/60 Hz
Power input - 3 phases (without vacuum generator)3.0 kW
Current consumption, 3 phases (without vacuum generator)max. 16 A
Mains fuse, min.
Value
1
16 A
Electrical connection 208 V, 50/60 Hz
Value
Voltage3 phase, 208 V L1, L2, L3, N, PE
Mains frequency50/60 Hz
Power input - 3 phases (without vacuum generator)3.0 KW
Current input, 3 phases (without vacuum generator)max. 16 A
Mains fuse, min.
1)
Applies only to the basic unit. The minimum requirements for the mains fuse increase depending on
1
20 A
the vacuum generator
Vacuum generator
For additional data see rating plate/original operating manual in chapter "Additional specifications."
While the 1.1 kW vacuum pump is supplied with power via the cutter, the other vacuum generators are
connected to a separate power supply.
The vacuum generator is selected according to the following criteria:
•Cutter model
•Desired application
•local mains voltage and frequency
32
1.1 kW vacuum pump
Value
Voltage3-phase, 400 V L1, L2, L3, N, PE
Mains frequency50/60 Hz
Power input - 3 phases1.1 KW
Page 33
Product description
Value
Mains fuse, min.16 A
2.2 kW vacuum pump
Value
Voltage3-phase, 400 V L1, L2, L3, PE
Mains frequency50/60 Hz
Power input - 3 phases2.2 KW
Mains fuse, min.16 A
2.55 kW vacuum pump
Value
Voltage3-phase, 208 V L1, L2, L3, PE
Mains frequency50/60 Hz
Power input - 3 phases2.55 KW
Mains fuse, min.16 A
4 kW vacuum pump
Value
Voltage3-phase, 400 V L1, L2, L3, PE
Mains frequency50/60 Hz
Power input - 3 phases4 KW
Mains fuse, min.16 A
12.5/14.5 kW vacuum pump
Value
Voltage3-phase, 400 V L1, L2, L3, N, PE
Mains frequency50/60 Hz
Power input - 3 phases12.5/14.5 KW
Mains fuse, min.32 A
4.6 kW vacuum pump
Value
Voltage3-phase, 208 V L1, L2, L3, PE
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Product description
Mains frequency50/60 Hz
Power input - 3 phases4.6 KW
Mains fuse, min.20 A
Vacuum turbine 1 - 9 kW
Voltage3-phase, 400 V L1, L2, L3, PE
Mains frequency50/60 Hz
Power input - 3 phases1 - 9 KW
Mains fuse, min.32 A
Value
Value
Vacuum turbine 1 - 9 kW
Value
Voltage3-phase, 208 V L1, L2, L3, PE
Mains frequency50/60 Hz
Power input - 3 phases1 - 9 KW
Mains fuse, min.50 A
2.11.4 Environmental conditions
Value
Operating temperature+10 °C to +35 °C
Storage temperature-20 °C to +55 °C
Relative humidity10 - 80%, non-condensing
2.11.5 Compressed air supply
34
2.11.5.1 Compressed air connection requirements
Important:
The compressed air connection must fulfill the following requirements:
•Air purity: class 2.4.1 according to ISO 8573-1
•Air pressure: 0.6 - 1.0 MPa depending on configuration
Page 35
Product description
•Air consumption: base machine 20 l/min. 20 - 400 l/min depending on configuration
2.11.5.2 Compressed air settings
Compressed air regulator P1
Air pressure [MPa]
Maintenance unitHouse
connection
Punch modules - PUM-S, PMM-S,
PPM-S
Compressed air regulator P2
Electric Oscillating Tool - EOT-25070
Universal Routing Tool - URT60
Marker modules - MAM-SP, MAMSPS, MAM-SPD
Router modules - RM-S40
Sheet feeder feed150
Sheet feeder removal150
0.7 - 0.80.7 - 1.0150
Air pressure [MPa]
Maintenance unitHouse
connection
0.60.6 - 1.0
max. air
consumption [l/min]
max. air
consumption [l/min]
20
Base machine (vacuum elements)
Compressed air regulator P3
Air pressure [MPa]
Maintenance unitHouse
connection
Minimal Quantity Lubrication - MQL70
Material transport (transport
elements, conveyor clamping
elements)
Board loading device
0.450.6 - 1.0
covered with base
consumption
max. air
consumption [l/min]
covered with base
consumption
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Product description
Compressed air regulator P4
Air pressure [MPa]
Maintenance unitHouse
max. air
consumption [l/min]
connection
Pneumatic Oscillating Tool - POT400
0.80.8 - 1.0
Scoring Cutting Tool - SCT
Passepartout Tool - PPT0.6 - 0.80.6 - 1.020
2.11.6 Performance features
Accuracy
ValueUnit
Resolution of measuring system0.0050.0002 mmin
Positioning accuracy at a constant temperature±0.10.004 mmin
Repeat accuracy±0.030.0012 mmin
Evenness of the worktop0.40.016 mmin
20
Cutting performance
ValueUnit
Speed in vector direction1 - 14140.04 - 55.67 mm/sin/s
Max. acceleration in vector direction
max. permissible printing force of the printhead
1
14.14556.9 m/s2in/s
100 N
(creasing)
1
depending on the module equipment and cutter size
2.11.7 Emissions
Noise emission
Cutter noise emission< 75 dB (A)
Depending on the cutting technology used,
the machined material, the vacuum generator
and the environmental conditions, the value
can vary between <75 dB and ~85 dB.
2
36
Electromagnetic emissions
The S3 series meets the requirements of the following technical standards:
•EN 61000-6-2 EMC, interference resistance in industrial environments
•EN 61000-6-4 EMC, emission standard for industrial environments
Page 37
Product description
Please ask the manufacturer if you wish to view to the test reports.
FCC approval
NOTE:
This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference, in which case
the user will be required to correct the interference at its own expense.
NOTE:
Changes or modifications not expressly approved by the party responsible for compliance could void
the user’s authority to operate the equipment.
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Product description
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Safety
3 Safety
This chapter contains information on the following:
•Definition of the intended use of the machine
•Generally applicable safety instructions and safety regulations to be observed
•Explanation of the meaning of symbols and pictograms which are used in this manual and in signs
on the machine
•Overview of protective devices on the machine
•Listing of the required protective equipment
•Information on the applicable requirements for operating and maintenance personnel
Specific handling-related and situation-related safety instructions are given in the corresponding work
steps in the following chapters of this manual and in other parts of the documentation.
3.1 General
Your safety – as the operator, service engineer or otherwise – is the primary concern. Certain
situations, problems or faults that may occur on the machine could put your safety at risk if you are not
aware of the steps you should take to avoid the resulting dangers.
State-of-the-art technology
The supplied machine corresponds to the state-of-the-art at the time of delivery.
However, the equipment may pose dangers if the safety instructions in this guide are not observed and
implemented.
3.2 Proper use
Proper use of the machine is essential for its safe operation.
The equipment supplied is listed and labeled and indicates the usage possibilities of the machine.
The machine is intended for use as an output device for CAD/CAM data for labeling and processing
materials arranged on the table plate. Proper use and the usage restrictions are dependent on the
module and tool system used and the available material transport system. Any other or further use is
deemed improper. The user bears sole liability for any damage arising from improper use!
Use of the machine shall also be regarded as proper when:
•All nationally applicable safety regulations are complied with.
•The safety instructions in this operating manual are observed.
•The operating conditions are adhered to and the prescribed materials are used.
3.3 Examples of reasonably predictable unintended use
Unintended use of the machine can have the following consequences:
•serious injuries
•serious material damage to the machine
•loss of warranty
Examples of reasonably predictable unintended use of the machine include:
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Safety
•Use of materials that are not defined in the contract and in this operating manual.
•Failure to observe the applicable parameters for the processing of the relevant material.
•Maintenance work on an unsafe machine.
•Failure to follow the operating instructions.
•Placing objects on the work surface.
•Processing of materials that are too large or too heavy.
•Processing of materials that are not fixed or are not adequately fixed.
•Processing of unsuitable materials such as steel, for example.
•Usage of a tooling system that is not intended for use with the material or the machine.
•Operating the machine without the designated protective devices.
•Use of modified module and tooling systems.
•Installation of spare parts and use of accessories and resources not approved by the manufacturer.
•Constructional changes to the machine, without subsequent risk assessment.
•Failure to observe the maintenance requirements.
•Failure to react to signs of wear and damage.
•Servicing work performed by untrained or unauthorised personnel.
•Operating the machine even though the operating instructions are incomplete or unavailable in the
local language.
•Deliberate or careless interference with the machine during operation.
•Bridging or altering the protective equipment.
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3.4 Hazard warnings, important instructions
Explanation of the notes
Both in the operating manual and on the device itself, dangers and important instructions are
designated by special symbols and signal words as follows:
Danger:
The safety instruction Danger
•refers to imminent danger
•refers to operational and service risks
•warns of adverse health effects or even life-threatening injuries
Warning:
The safety instruction Warning
•refers to a dangerous situation
•refers to operational and service risks
•warns of adverse health effects or even life-threatening injuries
Safety
Caution:
The safety instruction Caution
•refers to a dangerous situation
•refers to operational and service risks
•warns of minor reversible injuries and other serious material damage and consequential
damage
Note:
The safety instruction Note
•refers to operational and service risks
•warns of serious damage to the machine and other property damage and consequential
damage
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Safety
Tip:
Tip in combination with the light bulb refers to user tips and useful information which enhance the
usability, prolong the service life of the machine and make the work significantly easier.
Tip:
With tips combined with the sheet, we provide usage tips and useful information which can
improve the energy efficiency of the machine or optimize its environmental effects.
Important:
Usage tips and important information
Structure of the hazard warnings
1Hazard symbol with the corresponding signal color
2Signal word corresponding to the danger resulting from the situation
3Description of the danger
4Description of the consequences which could result from this hazardous situation
5Possible actions and codes of conduct to prevent the hazard from occurring or to avert possible
hazardous situations
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Safety
3.5 Areas of responsibility
Manufacturer's areas of responsibility
•The manufacturer is responsible for the safe condition of the machine on delivery, including
operating manual and accessories, according to the sales documentation.
Areas of responsibility of the owner or person authorised by them:
•Ensuring that only adequately trained personnel who have been properly instructed and have read
and understood the content of the safety instructions in this chapter will operate and maintain this
machine.
•Clearly defining the responsibility of the operating and service personnel as required in the
operating manual.
•Checking the personal protective equipment of the operating and service personnel.
•Ensuring a technically safe state of the machine.
•Ensuring that servicing and maintenance are carried out according to the maintenance schedule.
•Notifying the manufacturer of any accident involving the machine that results in serious injury or
substantial material damage.
•Decommissioning the machine immediately if defects arise that affect its operational safety.
Areas of responsibility of the operating and service personnel:
•Wearing the required personal protective equipment.
•Halting operation immediately in the event of faults.
•Reporting any changes which affect operational safety.
•Keeping the machine clean.
•Check the function of the EMERGENCY STOP control devices before starting work.
3.6 Personnel requirements
The operating and service personnel must
•be able to read and understand one of the languages on the command menu (e.g., German,
English, French, Spanish, Italian).
•Be physically and mentally suited.
•Be qualified in the use of the machine by means of thorough training.
•Have read and understood the operating instructions/service manual.
•Be over the age of 16.
•Have knowledge of first aid and the use of fire extinguishers.
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Safety
3.7 Personal protective equipment
The safety equipment required for operating the machine is dependent on the following factors:
•Module and tool system used
•Processing material used
When operating the machine or carrying out maintenance or servicing work, wear tight fitting clothing
and appropriate personal protective equipment.
Warning:
Risk of injury from being caught or trapped in moving machine parts.
•Do not wear loose clothing, scarves, open jackets or open shirt sleeves.
•Remove all jewelry before starting maintenance and servicing work.
Personal protective equipment comprises of:
•Work clothes (service personnel),
•protective goggles (operating and service personnel):
•To provide protection from particles during machining
•To protect the eyes from dangerous radiation
•To protect the eyes from chemicals
•Protective gloves where injury is possible due to:
•burns
•sharp or pointed objects.
•Chemical-resistant protective gloves where injury is possible due to:
•chemicals (cleaning agents)
•Breathing protection when working with poisonous substances
•Hearing protection if the continuous sound pressure level is above 80 dB
Note:
You are personally responsible for:
•wearing the required personal protective equipment
•regular cleaning and maintenance of personal protective equipment;
•replacing damaged and unusable items of protective equipment promptly
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Safety
3.8 Rules and occupational safety
•Operation of the machine is always subject to local regulations regarding work safety and accident
prevention.
•Make sure that there is adequate lighting during operation.
•Check protective devices every time before starting the machine.
•If a hazardous situation arises, activate an EMERGENCY STOP control device to shut down the
machine.
•You are not permitted to make unauthorised modifications or changes to the machine which might
affect the system's safety. Accessories or spare parts made by other manufacturers may only be
used with the machine with the written approval of the manufacturer.
•Only service technicians authorized by the manufacturer are permitted to install, commission,
maintain and repair the machine.
•Before carrying out any maintenance, repair and modification work:
•Switch off the machine using the main switch and secure it with a padlock.
•Prevent the machine being switched on inadvertently by removing the mains supply cables to
the power box (several mains connections available!).
3.9 Conduct in the event of malfunctions
As a matter of principle, all troubleshooting work or inspections on the machine should only be carried
out when it is switched off.
The following must never be bypassed or rendered ineffective:
•Light barriers on beams
•Monitoring sensors
•Safety and control switches of the machine
If malfunctions cannot be remedied by the operating personnel using simple means, inform the
responsible service center!
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Safety
3.10 Danger areas
3.10.1 General danger area
46
1Danger area
The danger area is restricted to the working area or the active area of the drive system. Never reach
into this work area during processing.
3.10.2 Danger area during initialization
Caution:
Risk of injury during manual initialization of the tool!
The safety devices are not active during manual initialization
•Do not reach into the danger area during manual initialization
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•For initialization, use automatic AKI initialization, if the tool allows this.
Safety
1Module (e.g., UM-S)
2Tool (e.g., UCT)
3Danger area
DSafety distance during initialization (25 cm)
The safety distance (d) for operating personnel during manual initialization is 25 cm. Do not reach into
the marked danger area during the initialization phase!
3.10.3 Danger area during cleaning
Caution:
Risk of injury when cleaning the machine!
Blades, router bits and punching inserts have very sharp edges which are sometimes hidden by
moving equipment (spring-loaded gliding disc).
•Before starting to clean, remove all modules and tools from the module carriage.
•Switch off the machine with the main switch and secure it against unauthorised switch-on
using a padlock.
•Disconnect the machine from the mains.
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Safety
•While cleaning work is being performed, attach a sign that says "DO NOT SWITCH ON" that is
prominently displayed on the main control panel of the machine.
1Danger area
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3.11 Warnings on the product
The warnings on the modules and tools are illustrated in the respective operating instructions.
Safety
No.DescriptionVariant 1 (CE)Variant 2 (ANSI)
1Mandatory sign:
Wear protective gloves
Art. no.:
5800412 (50 mm)
Art. no.:
5801106 (65 mm)
2Mandatory sign:
Wear eye protection
Art. no.:
5800467 (50 mm)
Art. no.:
5801058 (65 mm)
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Safety
No.DescriptionVariant 1 (CE)Variant 2 (ANSI)
3Warning sign:
Hand injuries due to
crushing
Art. no.:
5800342 (50 mm)
4Warning sign:
Electrical hazard
Art. no.:
5801338 (50 mm)
Art. no.:
5801059 (65 mm)
Art. no.:
5802331 (95 mm)
5Warning sign:
Electrical hazard
6Warning sign:
Laser beam
Art. no.:
5200367 (110 mm)
Art. no.:
5811418 (50 mm)
Art. no.:
5200367 (110 mm)
Art. no.:
5811418 (50 mm)
50
Art. no.:
5800344 (25 mm)
Art. no.:
5801062 (40 mm)
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3.12 Protective devices
Safety
1EMERGENCY STOP control device
2Safety device (protective trip switch)
3EMERGENCY STOP control device
4Control panel
3.12.1 Safety device
Caution:
The beam may cause serious injuries in case of a collision.
Note that the high level of kinetic energy of the drive results in a significant braking distance.
Light barriers are no guarantee against injuries!
The protective system consists of light barriers on the bar ends and on the module carriage.
The machine is stopped automatically if the light barriers detect an obstacle.
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Safety
Effects for the cutter
•The drive motors (beams, module carriage) are slowed to a standstill.
•The Z-axis remains in the position where it is located when the safety device is triggered (e.g. lower
position).
•The cutter switches to STOPPED mode.
•Safety-relevant units (modules, tools, etc. ) are stopped and switched off.
•Units that are not safetyrelevant or important for the operation of the machine, such as the operating unit, remain switched on.
•An error message is displayed.
•A warning tone sounds.
Effects on the options connected to the cutter
•Synchornised movements are stopped.
•Units that are not safety-relevant or important for the operation of the machine remain switched on.
Recommissioning
•Restore operational safety.
•Free the light barriers of obstacles.
•Acknowledge the error message on the control panel.
Tip:
If the Z-axis is in the upper or lower position when the safety device is triggered, it is now raised to
the park position.
3.12.2 Control panel
Malfunctions are shown on the LCD display.
An acoustic signal sounds in the event of an error or light barrier interruption or activation of an
EMERGENCY STOP control device.
3.12.3 EMERGENCY STOP control devices
Activating an EMERGENCY STOP control device triggers a machine standstill in the event of an
emergency.
Danger:
Risk of injury due to inaccessible EMERGENCY STOP control device!
Machines with inaccessible EMERGENCY STOP control devices are not safe for operation. The
machine cannot be stopped promptly in hazardous situations.
•Ensure that all EMERGENCY STOP control devices are easy to access and not hidden.
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Note:
Risk of damage to the cutter by activating EMERGENCY STOP control devices.
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Safety
Do not use EMERGENCY STOP control devices to switch off the machine under normal
circumstances.
Note:
To unlock an activated EMERGENCY STOP control device after restoring operational safety, turn
the switch clockwise (see Reset EMERGENCY STOP control devicesReset EMERGENCY STOP
control devices on page 82Reset EMERGENCY STOP control devicesReset EMERGENCY
STOP control devices).
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Safety
3.12.4 Shutdown in an emergency
An emergency shutdown allows the machine to be stopped quickly in case of emergency.
Effects for the cutter
•The drive motors (beams, module carriers) are braked to a standstill and are then disconnected
from the energy supply.
•The drive axes are free and can be moved by hand.
•The cutter switches to STOPPED mode.
•Safety-related units (modules, tools, auxiliary drive...) are isolated from the energy supply.
Safety-related units (modules, tools...) are disconnected from the energy supply.
•Units that are not safetyrelevant or important for the operation of the machine, such as the operating unit, remain switched on.
•An error message is displayed.
•A warning tone sounds.
•The EMERGENCY STOP control device remains locked in the off position.
Effects on the options connected to the cutter
•Synchornised movements are stopped.
•Units that are not safety-relevant or important for the operation of the machine remain switched on.
3.12.5 Shutdown in the event of overload
The machine automatically shuts down if an axis (X,Y, T, Z) becomes blocked or overloaded.
Effects for the cutter
•The drive motors (beams, module carriers) are braked to a standstill and are then disconnected
from the energy supply.
•The drive axes are free and can be moved by hand.
•Safety-relevant units (modules, tools, auxiliary drive, etc.) are stopped or switched off.
Safety-relevant units (modules, tools, etc.) are stopped or switched off.
•Units that are not safetyrelevant or important for the operation of the machine, such as the operating unit, remain switched on.
•The cutter switches to the STOPPED operating mode
•An error message is displayed.
•A warning tone sounds.
Effects on the options connected to the cutter
•Synchornised movements are stopped.
•Units that are not safety-relevant or important for the operation of the machine remain switched on.
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3.13 Mechanical hazards
3.13.1 Collection, retraction
Caution:
Risk of injury from entanglement, getting caught and being pulled in!
The machine and the tool system has moving parts.
Possible consequences
•Bruises, crushing, lacerations to fingers or hands
•Bruising to the head and arms
•Pulling out of hair
•Damage to clothing
•Damage to machine
Precautions during initialization and operation in ONLINE mode:
•Do not touch modules and beams
•Do not reach into the working and moving area
•Do not touch the table plate or the material lying on it
•Do not place hands on side covers
•Do not lean with the torso on the work surface
•Avoid untied long hair and loose clothing and ties
These precautions specifically apply if the cutter can be switched into ONLINE operating mode by
the CAD/CAM system.
Safety
3.13.2 Hazards from foreign bodies
Caution:
Injury risk due to objects being ejected!
Foreign bodies on the table plate are collected by the beam or the module/tool/module carriage
and pushed away!
Possible consequences
•Facial injuries and others
•Damage to the machine
Precautionary measures during initialization and operation in ONLINE/OFFLINE mode:
•Do not place any materials, tools, or other objects on the table plate or the side covers.
•Before operation, check whether there are any objects on the table plate or the side covers.
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Safety
3.13.3 Cut and puncture injuries
Caution:
Injury risk from sharp objects!
Blades, router bits and punching inserts have very sharp edges which are sometimes hidden by
moving equipment (spring-loaded gliding disc).
Possible consequences
•Cutting and stabbing injuries to the hands and arms
Precautionary measures
•Change the tool inserts with extreme caution.
•Do not enter the working area during initialization and during operation in ONLINE mode.
3.14 Risk of burns
Warning:
Risk of injury from burning!
Certain materials (metals) or tools (blade, router) reach very high temperatures during processing.
Possible consequences
•Burning injuries to the limbs
Precautionary measures
•Allow workpieces to cool down before removal
•Wear suitable protective gloves when removing freshly processed workpieces
•Allow tools (router, blade) to cool before removing them
3.15 Electrical hazard
Warning:
The machine is operated with a mains voltage of 400/208 V and a mains frequency of 50/60 Hz.
Possible consequences
•Risk of death or injury from electric shock.
Precautionary measures
•Only trained service personnel and authorized service technicians are allowed to open power
boxes, switch boxes and electronics units.
•Ensure that the mains cables are protected against mechanical loads and are laid so that they
are free from strain.
•Ensure damaged cables are replaced immediately.
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Safety
3.16 Risks arising from the emission of toxic dust
Warning:
Risk of poisoning from the emission of toxic dust!
Processing certain materials can lead to the creation of harmful toxic dust.
•Obtain information about the toxicity of the material to be processed from the manufacturer.
•Use a suitable extraction unit or implement other appropriate measures accordingly.
The operator of the system is responsible for making sure that all national regulations concerning
the maximum permissible dust concentrations in the workplace are complied with. When handling
hazardous types of dust, all local safety regulations as well as the manufacturer's instructions must be
observed. When routing or processing hazardous materials, always use dust extractors with special
dust filters designed for the purpose. As an optional accessory, Zünd offers extraction systems that
comply with the following regulations:
•the extraction of hazardous dusts with MAK values up to 0.1 mg/m3and wood dusts conforming to
dust class M
•the extraction of dusts conforming to dust class H
3.17 Risks arising from the processing of toxic materials/materials
hazardous to health
Warning:
Risk of poisoning from emissions when processing toxic materials!
Processing such a wide variety of materials can lead to toxic emissions (gases, dust etc.) that are
hazardous to your health.
•Never process toxic materials/materials hazardous to health!
•Obtain information from the manufacturer of the material to be processed about its toxicity.
Observe the following guidelines when handling toxic/hazardous materials:
•The operator of the system is responsible for determining which processing materials are toxic/
hazardous.
•It is forbidden to process toxic materials on Zünd cutters without appropriate additional safety
measures!
•The operator of the system is responsible for installing appropriate additional safety measures!
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Safety
3.18 Environmental hazards
Warning:
Processing residues, operating materials, cleaning agents etc. can cause damage and pollute the
environment if they enter the soil, waterbodies or the sewage system.
Explanation of the hazard label
Hazard label for substances that are harmful to the environment
Safety regulations and protective measures
•Dispose of waste materials in accordance with current national environmental protection
regulations. In case of doubt, check on the appropriate disposal methods with your local collection
point or recycling center.
•Collect different chemicals in separate containers.
3.19 Handling and storage of chemicals
Warning:
Cleaning agents and operating materials can cause skin irritation and can therefore be hazardous
to your health if handled carelessly.
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Always wear your personal protective gear (protective gloves, goggles, mouth guard etc.) when
handling chemicals.
Explanation of the hazard label
Hazard label for very toxic or toxic substances
Safety
Hazard label for hazardous substances or irritant materials
Hazard label for irritating substances
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Safety
Note:
Chemicals classified as irritants are used to operate and clean this machine (cleaning agents,
operating fluids). Safety datasheets for the substances in question can be downloaded from the
Zünd homepage (www.zund.com).
Safe handling of chemicals
Important:
Dispose of chemicals in accordance with national regulations. Follow the manufacturer's instructions
(MSDS).
•Store chemicals in tightly closed containers in a cool, dry place (between 5 °C and 30 °C).
•Protect the containers from heat and direct sunlight.
•Provide good ventilation, including at floor level.
•Store chemicals in accordance with local regulations.
•Keep containers tightly closed.
•Use chemicals as intended only.
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3.20 Risk of fire and explosion
Warning:
There is a risk of fire when routing and cutting flammable materials
Terminate the routing/cutting and leave the tool to cool off in case of
•smoke emission.
•Discolorations on the router/blade which point to increased heat development
Warning:
Risk of dust explosions
Flying sparks or electrostatic charges result in the risk of dust explosions during the extraction of
different materials.
•Find information about the risk of explosion when processing the type of material that you are
using and, if necessary, do not process it.
•If necessary, adjust the extraction to the required regulations.
Safety
Observe the following safety rules and countermeasures
•Find out the locations where fire extinguishers are kept and familiarize
yourself with their use and operation. The adjacent sign indicates the
location of a fire extinguisher.
•Do not use inflammable cleaning agents to clean the cutter.
•Store all processing materials in the proper manner in accordance with
local guidelines.
Classes of fire
Refer to the following table to find out which type of fire extinguisher is used for each fire class:
Solid materials, mainly organic in nature; e.g. wood, paper, textiles, etc.
Liquid and liquefiable substances; e.g. gasoline, oils, grease, paints etc.
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Safety
Combustible gases: e.g. methane, propane, etc.
Behaviour in the event of a fire
•Turn off the machine using the main switch
•Assess the situation: If there is danger, leave the area
immediately and call the fire department. Only try to extinguish
the fire if your personal safety is not at risk.
•Remove a suitable fire extinguisher (A, B, C) from its bracket
and prepare it for use.
•Locate the source of the fire. Attack the fire with repeated short
bursts from the extinguisher. Always spray the extinguishing
agent from underneath into the source of the fire. In other
words, always aim at the burning material and not at the
flames.
•After using the fire extinguisher, do not return it to its usual
place but have it refilled immediately.
3.21 Danger from laser beam
The optional ICC camera with laser pointer and the laser pointer use a visible laser beam. The laser
beam is considered to be harmless to the human eye in case of short-term exposure (<0.25 s) (class 2
laser).
The ICC camera with laser pointer or the laser pointer are switched on together with the cutter. By
design, the laser beam is directed down onto the material.
Safety instructions
•Do not look into laser beam.
•If a laser beam hits your eye, close your eyes or turn away immediately.
•Keep in mind that certain medications or consuming alcohol may cause a delayed blinking reflex.
3.22 Safety instructions for the operating personnel
This instruction manual cannot cover all possible situations and potential hazards.
It is therefore particularly important that operating personnel
•have been thoroughly trained and are aware of and able to correctly assess the hazards that can
arise from the machine.
•Knows all protective devices on the machine.
•Request information from the manufacturer without delay if an undocumented, hazardous situation
arises in connection with the machine.
In addition to these safety instructions, you must also observe the situation-related safety notes in the
chapters "Controls and operation" and "Maintenance and cleaning".
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Safety
3.23 Safety precautions for service personnel
The reliability, readiness and service life of the machine greatly depend on you carrying out your work
in a conscientious manner.
Note:
Specialist knowledge and expertise are required to service and maintain the machine. The
manufacturer provides this knowledge through training courses which are specially tailored for
service personnel. Only personnel with Zünd certification are permitted to carry out service work
on Zünd cutters.
3.24 Disposal
Information about proper disposal
The symbol has the following functions:
•Marking substances that are toxic and harmful to the environment
•Instructions for disposal of harmful substances
•Warning against disposal with domestic waste or environmental pollution caused by hazardous
substances and objects contaminated with such substances
Measures for disposal
Zünd cutters correspond with the requirements of the German Electrical and Electronic Equipment Act
and generally do not contain any poisonous substances or consumables.
Contact Zünd customer services or your service partner before you dispose of your cutter.
Dispose of cutting waste in accordance with current national environmental protection regulations.
In case of doubt, check the appropriate disposal methods with your local collection point or recycling
center.
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Controls and operation
4 Controls and operation
This chapter familiarizes you with the controls, guides you through the operational procedures and
describes the following operating steps:
•Daily commissioning
•Operation of the main components
•Detailed information on the operation of the machine
•Safe switch-off of the machine
4.1 Safe working practices
Danger:
Operating errors or negligence can put human lives at risk as well as causing serious damage to
the machine!
The machine is fitted with safety devices to minimise risk. However, these safety devices cannot
guard against damage as a result of operating errors or negligent working practices.
Observe the safety requirements from Chapter Safety on page 39 and the situational safety
requirements of the appropriate working step.
Operator personnel are responsible for the safe use of the machine!
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Controls and operation
4.2 Controls
4.2.1 Overview
66
1Rear EMERGENCY STOP control device
2Control panel and workstation (optional)
3Maintenance units (dependent on cutter configuration)
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4.2.2 Control panel
Controls and operation
1Display8ONLINE key
2Soft keys9STOP key
3Navigation keys10VAC (vacuum) key
4Number block and function keys11Router on/off key (optional)
Activating an EMERGENCY STOP control device triggers a machine standstill in the event of an
emergency.
The cutter is fitted with two EMERGENCY STOP control devices as standard. They are located as
follows:
•1 x on control panel
•1 x on side support cover on left
68
Danger:
Risk of injury due to inaccessible EMERGENCY STOP control device!
Machines with inaccessible EMERGENCY STOP control devices are not safe for operation. The
machine cannot be stopped promptly in hazardous situations.
•Ensure that all EMERGENCY STOP control devices are easy to access and not hidden.
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Controls and operation
Note:
Risk of damage to the cutter by activating EMERGENCY STOP control devices.
Do not use EMERGENCY STOP control devices to switch off the machine under normal
circumstances.
Note:
The activated EMERGENCY STOP control device remains locked in the off position.
To unlock an activated EMERGENCY STOP control device after restoring operational safety, turn
the switch clockwise (see Reset EMERGENCY STOP control devices on page 82).
4.2.4 Maintenance unit
The maintenance unit adjusts the air pressure to the switching of the vacuum elements/various
modules and options.
1Maintenance unit, POT*
2, 6Air pressure setting
3, 5Stopcock
4, 7Water separator
8Maintenance unit, basic machine
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Controls and operation
The maintenance unit is preset and adjusted.
Check the air pressure setting at regular intervals. The setting values can be found in the chapter
Basic unit compressed air supply.
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Controls and operation
4.2.5 Interfaces
The machine has data exchange interfaces. These are attached to the electronics unit.
1LAN
2not used
3USB (host) - not used
4Status and error display
5COM 1
6COM 2
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Controls and operation
4.3 Menu navigation
4.3.1 Navigation keys
Functions in the cutter menu
Key
Use these keys to navigate through the menu
•If submenus are available, use this key to change to the next menu level
•Select setting/function
Switching from a sub-menu to the previous menu level
Function in the editor
Key
Use these keys to move the cursor to the right or left
4.3.2 Help
Help texts are available for important menu entries. In order to display a help text, mark the required
menu and press the key.
4.3.3 Info menu
Within the menu the Info menu can be activated with the key.
The info menu also works in online dialog and when an error message is displayed.
72
TabInformation
AssignmentInformation on the module carriage
ModuleInformation about the module
PositionSpecification of the current position of the current tool
BufferInformation about the memory system
JobInformation about the print job
StatusDisplay of the user level, the operating mode...
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Controls and operation
TabInformation
Function keysAllocation of the function keys
CommunicationSettings such as: interface, port, IP address, mask, MAC address
Switch between tabs with the key. Scroll up/down within the tab with the key.
4.3.4 Pop-ups, dialog boxes
Pop-up menus or dialog boxes are displayed for the following actions:
•Error messages (dialog)
•Cutter status display (dialog)
•Menus that are called up using function keys (pop-ups)
The system changes back to the previously active menu when a pop-up or a dialog box is closed.
4.3.5 Layout
SymbolDescription
Menu
Blocked menu (user level)
Command, execute function
Display of a value
4.4 Menus and functions
The cutter has a multitude of functions. The current menu number and the current menu are displayed
in the header.
4.4.1 Navigation in the menu
A
Scroll through the menu with the navigation keys and select a sub-menu with .
B
To return to the previous menu level, press the navigation key. To return to the main menu,
press ESC.
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Controls and operation
4.4.2 Selection
A
Use the navigation keys to select an entry from the list.
B Confirm the selection with OK and cancel by pressing ESC.
4.4.3 Select commands, functions
Mark the required command with the navigation keys and select with .
The command can also be activated directly via the menu number. In order to do this, enter the
menu number using the numeric keypad (see Direct selection of menus on page 74).
Important:
Commands are carried out immediately after entry. An exception to this rule are safety-relevant
commands (e.g., automatic startup). Confirm the selection with OK or cancel with ESC.
4.4.4 Direct selection of menus
Each menu and each function is allocated a unique menu number. It is possible to switch between
menus by entering the menu number.
Two-figure menu numbers (10, 11...) are displayed lower down. Before entering two-digit menu
numbers, press the key and then enter both digits.
4.4.5 Function keys
74
The cutter has function keys (F1 - F8) which can be freely allocated to menu functions.
Allocate function keys directly
To change the function keys, at least the User level on page 76 "Operator" is required.
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Controls and operation
A Simultaneously press the SHIFT key and the function key (F1 - F8) for which you would
like to change the function.
B The function key selection window opens.
C Enter the menu number of the desired menu entry using the number field.
D Confirm the selection with OK or cancel by pressing ESC.
Allocating the function key via the menu
To change the function keys, at least the User level on page 76 "Operator" is required.
A Select the 6-5 Function keys menu.
B Enter the numbers 1 - 8 for the respective function key F1 - F8.
C The function key selection window opens.
D Enter the menu number of the desired menu entry using the number field.
E Confirm the selection with OK or cancel by pressing ESC.
Resetting a function key to the factory settings
To change the function keys, at least the User level on page 76 "Operator" is required.
A Change to the 6-5 Function keys menu.
B Enter the numbers 1 - 8 for the respective function key F1 - F8.
C The function key selection window opens.
D Press the DEF key to load the factory settings.
E Confirm the selection with OK and cancel by pressing ESC.
4.4.6 Entering values
A Select menu (e.g., 1-1-1-2-3 Up Z pos).
B Enter the value using the numeric keypad. The current value is overwritten.
C Check the value and confirm with OK or cancel the entry using ESC.
4.5 General settings
4.5.1 Setting the language
A Select 6-1 Language.
B Select the required language from the list and confirm.
4.5.2 Switch display lighting on/off
Press Shift + ESC to switch the display lighting on/off.
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Controls and operation
4.5.3 Setting the display contrast
KeyDescription
Shift +
Shift +
Increase contrast
Reduce contrast
4.5.4 Setting the volume
KeyDescription
Shift +
Increase/decrease the volume
4.5.5 Clear buffer
Clear the data buffer following the termination or processing of a job.
MenuDescription
2-4-1 Clear bufferAll the data stored in the data buffer is deleted. The file may have to be
resent.
4.6 User level
Access to menus and functions is blocked depending on the user level. The user levels have a
hierarchical structure. This means that the next highest user also has the access rights to the menu
functions of the subordinate user.
User levelDescription
Users 1 - 3All menus and functions needed for the operation of the machine are
accessible
OperatorSimple, uncomplicated adjustments can be made
ServiceCutter settings that may only be adjusted by authorized service
personnel.
Factory-
4.6.1 Changing user levels
A Change to the 4-2 Password menu.
B Enter your user code.
Results
The user level is approved and is displayed under 4-1 User level.
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Controls and operation
4.6.2 Defining active user level after start-up
Tip:
After start-up, it is not possible to define a user level that is higher than your own as an active
user level.
A Change to the 4-3 Start user menu.
B Select the desired user.
Results
The selected user level will be active the next time the cutter is started.
4.6.3 Changing the password for user levels 2 and 3
Tip:
The passwords for user levels 2 and 3 can be changed in the Operator user level or higher.
A Change to the 4-4 Change password menu.
B Select the user.
C Enter the new password for the user.
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Controls and operation
4.7 Malfunctions
4.7.1 Troubleshooting
Caution:
Risk of injury due to incorrectly remedied faults.
•Ensure that the error on the device is remedied correctly.
•Contact your Zünd partner.
Make note of the following information if you need help from the service department to rectify an error
in your cutter:
•The serial number of the machine.
•The error message that is displayed on the operating unit or on the status and error display.
•A description of the circumstances in which the error occurred.
4.7.2 Error localization
Errors can be localized both via the control panel, or, if the control panel is defective, via the Status
and error display on the electronics unit.
4.7.2.1 Error display on the operating unit
The error code is made up of a multi-digit, uniquely allocated combination of numbers and letters.
The signal word before the error code indicates how serious the error is.
1Signal word
2Error codes
3Error description
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Signal word Error code
ends with
Information01Important information for the operating personnel
Warning02Notification of possible problems (overheating). Check status,
Error03Errors that are likely to be remedied - contact the service department if
Alarm04Serious error - contact the service department
Error description
troubleshooting, contact the service department if necessary
necessary
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Controls and operation
4.7.2.2 Error shown on the status and error display
The error is displayed as a sequence. All superfluous digits of the error code will be omitted in this
display!
If several errors occurred one after the other then these are combined together in a group. The error
which occurred first is displayed at the start of the group. All other errors follow in order.
ItemSequenceExplanation
1IntroductionThe error group is introduced by an introductory
sequence
2Error code 1Display of the first recorded error code
3SeparatorDisplay of the error is complete and another error
follows
4Error code 2Display of the next error code
5SeparatorDisplay of the error is complete and another error
follows
6Error code 3Display of the next error code
7ConclusionDisplay of the group has been completed
4.7.3 Error display
If a number of errors have occurred, then the first error of this sequence is always shown on the
display of the operating unit.
All errors which have occurred after confirmation of the last error are collected together in a group.
Displaying the last group
All errors of the last group are displayed with SHIFT+ (2nd soft key).
Display list of unresolved errors
While the first error is shown on the display, with SHIFT+ (1st softkey) a list of all
unresolved errors can be displayed.
4.7.4 Engaging the automatic circuit breaker
Danger:
Hazardous voltage in the power box
Risk of death or injury from electric shock!
•Do not remove the internal power box cover (power unit) under any circumstances.
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Controls and operation
•Contact your service partner if you have any problems with the energy supply.
Note:
Risk of damage to the cutter
If an automatic circuit breaker has been triggered, the cause may be an electrical defect in a
consumer.
•The list shows the consumers who are protected by the triggered automatic circuit breaker.
•Never start up a damaged cutter.
•Work on the electrical system should only be carried out by qualified electricians.
FuseRated currentConsumer
L116 A type CCutter control, compressor, PC
L216 A type CExtractor, various options
L316 A type CAuxiliary drive, router converter
A Stop work.
B Remove the outer cover of the power box (see Remove the power box cover (A10, A21)).
C Push the switch lever upwards when the automatic circuit breaker is triggered.
OptionDescription
The automatic circuit breaker triggers againShut down the cutter. Report the defect to your
service partner.
The circuit breaker can be engaged; after
continuing work, the circuit breaker triggers
again
The automatic circuit breaker can be engaged
and triggers again after continuing to work
D Install the power box cover.
Shut down the cutter. Report the defect to your
service partner.
—
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Controls and operation
4.8 Daily checks prior to start-up
Caution:
There is a risk of injury if the machine is damaged! Machine faults can result in defects and
accidents.
•Never start up a machine if it is damaged.
•Report all defects and faults to your supervisor and arrange for them to be rectified
immediately by qualified personnel.
Ensure that all maintenance and service tasks are performed in accordance with the maintenance
schedule.
Before starting up the machine each day, perform an inspection of the machine and check the
following:
•Visually inspect the machine for damage.
•Remove local dirt caused by processing materials and dust.
•Remove objects from the work surface and the beam.
Remove objects from the work surface and the beam.
•Check whether all maintenance and service covers are installed correctly.
•Ensure that all EMERGENCY STOP control devices are easy to access and not hidden.
4.9 Behavior in dangerous situations
4.9.1 Shutdown in an emergency
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Controls and operation
When a hazard or a possibly hazardous situation occurs, activate an EMERGENCY STOP control
device immediately.
Effects for the cutter
•The drive motors (beams, module carriers) are braked to a standstill and are then disconnected
from the energy supply.
•The drive axes are free and can be moved by hand.
•The cutter switches to STOPPED mode.
•Safety-related units (modules, tools, auxiliary drive...) are isolated from the energy supply.
•Units that are not safetyrelevant or important for the operation of the machine, such as the operating unit, remain switched on.
•An error message is displayed.
•A warning tone sounds.
•The EMERGENCY STOP control device remains locked in the off position.
Effects on the options connected to the cutter
•All potentially hazardous movements are stopped.
•Units that are not safety-relevant or important for the operation of the machine remain switched on.
4.9.2 Reset EMERGENCY STOP control devices
A Restore operational safety.
B Turn the EMERGENCY STOP control device clockwise to unlock.
C Acknowledge the error message on the control panel.
Results
The machine is ready for operation.
82
4.9.3 Commissioning a stopped machine
The cutter automatically shuts down under the following circumstances:
•An object is interrupting the light barrier.
•The safety device on the beam ends is triggered
•An object is interrupting the light curtain (optional).
•The distance between the two beams is too small.
•The drive of an axis is overloaded or blocked
Page 83
A Remove the object and restore operational safety.
B Confirm the error message on the operating unit.
C Bring the machine into ONLINE mode to continue processing.
4.10 Start-up
4.10.1 Switch on the machine
Controls and operation
1Main switch, off position
2Main switch, on position
Switch the main switch to the ON position (Pos. 2)
Results
The cutter switches on. The start page appears on the display.
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Controls and operation
4.10.2 Initialize the machine
Caution:
Risk of injury due to automatic starting of the machine
Following initialization, OFFLINE mode is active. The cutter can receive commands from the
operating software which activate the ONLINE mode.
Do not start the operating software until after initialization of the machine.
Press the function key on the operating unit.
Results
The cutter is initialized.
4.10.3 Switching off the machine
A Switch the cutter to OFFLINE mode.
B
Select the 12 Turn off cutter function from the menu or press the key combination SHIFT +.
C Confirm the dialog with Yes.
D The start page appears on the display.
E Switch off the cutter with the main switch. If necessary, secure the main switch using a lock to
protect the machine against improper startup.
F Clean the machine to remove dust and material residues.
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Controls and operation
4.11 operating mode
The cutter can be put into three operating modes:
•OFFLINE
•ONLINE
•STOPPED
A combination of keys can optionally be used to switch from any operating status to either of the other
two operating modes.
The current operating mode is displayed in the header of the main menu and with the LED of the
ONLINE key.
4.11.1 Change operating status
The following graphic demonstrates how to change from the current operating mode to another mode:
current operating statusinput
4.11.2 OFFLINE
Caution:
Risk of injury due to automatic start-up of the cutter
In OFFLINE mode, the cutter receives commands from the operating software. These commands
can be used to switch to ONLINE mode.
•Activate the STOPPED operating mode during breaks.
•Always perform set-up work on the machine in STOPPED mode.
After the cutter is switched on, OFFLINEmode is active. In this mode, external commands are
received but they are not processed.
Operating software commands can be used to switch to the ONLINE operating mode.
A red flashing LED on the ONLINE key indicates that the OFFLINEoperating mode is
active.
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Controls and operation
4.11.3 STOPPED
Note:
The operating mode STOPPED protects the operator from the machine being set in motion using
remote controls.
In this operating mode, commands are received but they are not processed. Even commands from the
operating software (e.g., to change to the ONLINE operating mode) are ignored.
4.11.4 ONLINE
A red illuminated LED on the ONLINE key indicates that the operating mode
STOPPED is active.
Commands are received and processed in this operating mode.
A green illuminated LED on the ONLINE key indicates that the operating mode
ONLINE is active.
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4.12 Moving the beam/module manually
Controls and operation
The module carriage can be moved using the travel keys in the OFFLINE and STOPPED operating
modes. The assignment of the keys corresponds to the direction of travel.
Pressing the SHIFT key at the same time will make the module carriage move faster.
Pressing a travel key in the X and Y direction at the same time will make the module carriage move
diagonally.
If one or more travel keys are pressed in ONLINE mode, then all movement is stopped and switches
to the OFFLINE status.
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Controls and operation
4.13 Handling modules/tools
Modules are independently recognized by the cutter control unit. Tools, on the other hand, do not have
automatic recognition and must be manually allocated to a module.
Tool-specific parameters (initialization, moving speeds, acceleration) are saved to the corresponding
tool and can be called up again at any time.
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4.13.1 Module/tool/tool insert
Controls and operation
1Module (e.g., KCM-S, UM-S)
2Tool (e.g. CT, UCT, EOT, POT)
3Tool insert: router, blade, pen
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Controls and operation
4.13.3 Inserting/replacing the module
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4.13.3.1 Module carriage
Controls and operation
1Module carriage, slot 1
2Module carriage, slot 2
3Module carriage, slot 3 (reserved for marking module MAM-SE, MAM-SP)
4Pneumatic connections
5Guide pins
6Laser pointer with electrical connections (optional)
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Controls and operation
4.13.3.2 Inserting a module
92
A Select 1-5-1 Change module/tool. The module carriage moves to the module change position.
B Thread the module into the guide pin.
C Lower the module until the stop.
D Screw the module to the module carrier with the 4 mm Allen key (2x).
Results
The module is now mounted and is located by the software.
4.13.3.3 Removing the module
A Select 1-5-1 Change module/tool. The module carriage moves to the module change position.
B Unscrew the module fixation with the 4 mm Allen wrench (2x).
C Raise the module and remove from the guide pin.
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Controls and operation
4.13.4 Activating a module
It is often necessary to activate a module in order to check the settings. This function can only be
carried out in the main menu. The active module can for example be used as a pointer to define the
vacuum width or the reference point.
ModuleKey combination
Module 1
Module 2
Module 3
ICC cameraShift + 8
Laser pointerShift + 9
Shift +
Shift +
Shift +
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Controls and operation
4.13.5 Marking the tool
94
Label all tools of the same type with a consecutive number. Corresponding adhesive labels are
supplied with the equipment.
4.13.6 Tool manager
The tool manager is a user interface to handle tools in combination with a universal module (UM). A
sensor on the module detects the presence of the inserted tool.
The tool manager helps you carry out the following activities:
•Inserting a tool
•Attach/select a tool
•Initialize a tool
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4.13.6.1 Inserting/replacing the tool
A Select 1-5-1 Change module/tool.
B If necessary, select the module/tool change position.
C Insert the tool and - if electrically or pneumatically driven - connect to the power supply.
D Confirm the selection with OK.
The tool manager opens.
Controls and operation
Use to switch to the 1-1-1-1 Select tool menu to select the tool used (see Creating a new
1
tool on page 95 and Selecting a tool already inserted on page 96).
2Use Init to switch to the menu for manual or automatic initialization. After initialization the
parameters are saved. The tool manager closes and the main menu appears.
3Confirm the tool selection with OK. The previously used parameters for this tool will continue to
be used.
4.13.6.2 Creating a new tool
The tool is inserted in the module.
A Select 1-1-1-1 Select tool in the menu.
B Select NEW.
C The Create new entry pop-up menu opens.
D Select the Tool type.
All tool types that can be used in the current module are displayed in the popup menu Tool type.
Select the tool from this list and confirm with OK.
E Enter the appropriate number of the tool in the pop-up menu Tool number and confirm with OK.
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Controls and operation
4.13.6.3 Selecting a tool already inserted
A Insert the tool.
B Select 1-1-1-1 Select tool in the menu.
In the dialog, all tools already assigned to this module are listed.
C Select the tool inserted.
4.13.6.4 Deleting a tool
A 1-1-1-1 Select tool .
All tools already assigned to this module are listed in the tool type dialog.
B Select the tool.
C Delete the selected tool with Delete.
4.13.6.5 Saving tool-specific settings
Use ESC to change to the main menu.
Results
The tool-specific settings that have been made are automatically saved.
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Controls and operation
4.13.7 Connecting powered tools
Driven tools (e.g. EOT, DRT, POT) require an energy supply (electrical, pneumatic). This energy
supply is controlled by the cutter control unit.
Electrically driven tools are connected to the connector control of the laser pointer or the ICC camera
(optional). A port is allocated to each individual connection which must be assigned via the cutter
control unit before the initial commissioning of the respective tool.
Pneumatically driven tools are connected to the pneumatic connections on the module carriage.
4.13.7.1 Connecting electrically driven tools
1Connection 1 (port 1, black) - e.g. EOT
2Connection 2 (port 2, red) - e.g. DRT
3Connection 3 (port 3, blue) - e.g. EOT-250, URT
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Controls and operation
Procedure
The tool is applied and assigned to the module.
A Insert the tool into the color-coded connection provided.
B Allocate the corresponding port to the tool with 1-1-1-3-1-1 Port.
4.13.7.2 Connecting pneumatically driven tools
Pneumatically driven tools and modules are connected to the module carriage via the interface unit.
The pressure is set using a maintenance unit. The air supply is connected to the local installation
or supplied via a compressor. The connection data or the connection procedure can be found in the
operating manual for the respective tool/module.
Note:
Always use a protective plug to protect connection P4 from dirt in the air supply. If particles of
dirt get into the tool, it will be damaged. For more information, see Mount protective stoppers for
pneumatic connection on page 100.
98
1Compressed air hose
2Pneumatically operated tool, e.g. POT
3Interface unit
P1Compressed air connection P1 (e.g., PMM-S, PPM-S)
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P2Compressed air connection P2 (e.g. sealing air EOT-250)
P4Compressed air connection P4 (e.g. POT)
Controls and operation
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Controls and operation
4.13.8 Mount protective stoppers for pneumatic connection
Note:
Always use a protective plug to protect connection P4 from dirt in the air supply. If particles of dirt
reach the tool, it will be damaged.
1Protective plug
2Interface unit
P1Compressed air connection P1
P2Compressed air connection P2
P4Compressed air connection P4
Procedure
A Press down on air pressure connection coupling P4.
B Place the protective plug in the coupling.
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