Zund S3 XL-1200 Operating Manual

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Operating Manual S3 Digital Cutter
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Keep it in a safe place for future use!
Original operating manual
Software/Firmware version: FW1.71 Creation date: 05-2019
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Contents

1 Introduction.......................................................................................................................................7
1.1 Using the operating manual............................................................................................................. 8
1.2 Points to note when reading this operating manual.........................................................................9
1.3 Publishing details..............................................................................................................................9
2 Product description........................................................................................................................11
2.1 Important information about the product........................................................................................ 11
2.2 Orientation.......................................................................................................................................12
2.3 Product identification...................................................................................................................... 13
2.4 Intended use...................................................................................................................................13
2.5 Cutter overview...............................................................................................................................14
2.6 Modules, tools.................................................................................................................................16
2.7 Material handling............................................................................................................................ 21
2.8 Options............................................................................................................................................23
2.9 Accessories box..............................................................................................................................24
2.10 Technical description....................................................................................................................25
2.11 Technical data.............................................................................................................................. 27
3 Safety...............................................................................................................................................39
3.1 General........................................................................................................................................... 39
3.2 Proper use......................................................................................................................................39
3.3 Examples of reasonably predictable unintended use.....................................................................39
3.4 Hazard warnings, important instructions........................................................................................ 41
3.5 Areas of responsibility....................................................................................................................43
3.6 Personnel requirements..................................................................................................................43
3.7 Personal protective equipment.......................................................................................................44
3.8 Rules and occupational safety....................................................................................................... 45
3.9 Conduct in the event of malfunctions.............................................................................................45
3.10 Danger areas................................................................................................................................46
3.11 Warnings on the product..............................................................................................................49
3.12 Protective devices.........................................................................................................................51
3.13 Mechanical hazards......................................................................................................................55
3.14 Risk of burns................................................................................................................................ 56
3.15 Electrical hazard...........................................................................................................................56
3.16 Risks arising from the emission of toxic dust...............................................................................57
3.17 Risks arising from the processing of toxic materials/materials hazardous to health.....................57
3.18 Environmental hazards.................................................................................................................58
3.19 Handling and storage of chemicals..............................................................................................58
3.20 Risk of fire and explosion.............................................................................................................61
3.21 Danger from laser beam.............................................................................................................. 62
3.22 Safety instructions for the operating personnel............................................................................62
3.23 Safety precautions for service personnel.....................................................................................63
3.24 Disposal........................................................................................................................................ 63
4 Controls and operation..................................................................................................................65
4.1 Safe working practices................................................................................................................... 65
4.2 Controls...........................................................................................................................................66
4.3 Menu navigation............................................................................................................................. 72
4.4 Menus and functions......................................................................................................................73
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4.5 General settings..............................................................................................................................75
4.6 User level........................................................................................................................................76
4.7 Malfunctions....................................................................................................................................78
4.8 Daily checks prior to start-up.........................................................................................................81
4.9 Behavior in dangerous situations...................................................................................................81
4.10 Start-up......................................................................................................................................... 83
4.11 operating mode.............................................................................................................................85
4.12 Moving the beam/module manually..............................................................................................87
4.13 Handling modules/tools.................................................................................................................88
4.14 Material fixing..............................................................................................................................102
4.15 Material transport (optional)........................................................................................................110
4.16 Automatic tool initialization - AKI (optional)................................................................................114
4.17 Job processes.............................................................................................................................119
4.18 Film handling.............................................................................................................................. 124
4.19 Laser pointer, reference point (optional).................................................................................... 126
4.20 ICC camera, automatic registration (optional)............................................................................129
4.21 Module carriage slot protective plate......................................................................................... 132
4.22 Signal lights (optional)................................................................................................................ 133
5 Tips for cutting.............................................................................................................................135
5.1 Select tool.....................................................................................................................................135
5.2 Selecting a blade..........................................................................................................................135
5.3 Preparing cutting data.................................................................................................................. 142
5.4 Settings, speed, quality................................................................................................................ 142
5.5 Recognising processing errors.....................................................................................................144
5.6 Oscillating cutting..........................................................................................................................154
5.7 Tips for increasing the rate of production.................................................................................... 156
5.8 Identifying and rectifying quality problems................................................................................... 156
6 Maintenance..................................................................................................................................159
6.1 Safe maintenance of the machine................................................................................................160
6.2 Tools, operating and auxiliary materials.......................................................................................160
6.3 Maintenance list for trained operating personnel......................................................................... 164
6.4 Maintenance list for authorized service technicians.....................................................................166
6.5 Cutter maintenance mode............................................................................................................ 168
6.6 Service flaps and covers..............................................................................................................169
6.7 Visually inspecting the machine for damage................................................................................174
6.8 EMERGENCY STOP control devices function test......................................................................174
6.9 Cleaning the machine...................................................................................................................175
6.10 Cleaning the inside of the beam................................................................................................ 175
6.11 Cleaning the X axis guide rails.................................................................................................. 177
6.12 X axis, oiling the guide carriage.................................................................................................178
6.13 Clean/oil Y axis guide rails.........................................................................................................181
6.14 Cleaning the feeding clamps/feed guide rail.............................................................................. 181
6.15 Draining the maintenance unit condensate water......................................................................183
6.16 Resetting 12.5/14.0 kW vacuum pump motor protection relay...................................................184
6.17 Reset 2.2/2.55 kW, 4.0/4.6 kW, 5.5/6.3 kW vacuum pump, motor protection relay....................185
6.18 Replacing the conveyor belt.......................................................................................................186
6.19 ICC camera, cleaning the lens (optional)...................................................................................204
6.20 Instructions for disposal..............................................................................................................205
6.21 Starting up after periods of standstill..........................................................................................206
7 Tools..............................................................................................................................................207
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8 Modules.........................................................................................................................................209
9 Material handling..........................................................................................................................211
10 Additional specifications...........................................................................................................213
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Contents
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1 Introduction

Introduction

Dear customer,
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
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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
©
Copyright
Zünd Systemtechnik AG
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Introduction
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Product description

2 Product description
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.
1 front
2 rear
3 right
4 left
X X-axis
Y Y axis
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2.3 Product identification

2.3.1 Rating plate

Product description
1 Position of the signs 10 Year of manufacture
2 Rating plate 11 Serial number
3 Additional UL sign 12 UL mark of conformity
4 Additional connection values 13 Nominal voltage
5 Additional FCC sign 14 Rated current
6 CE mark of conformity 15 Frequency
7 UL functional safety 16 Nominal voltage
8 Product name 17 Current consumption
9 Type designation 18 Frequency

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.
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Product description

2.5 Cutter overview

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1 Air supply to maintenance units
2 Beam
3 Tool/module power supply
4 Extractor
5 Workstation
6 Control panel with optional workstation
7 Vacuum pump
8 Working area
Product description
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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.
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1 Module (e.g., KCM-S, UM-S)
2 Tool (e.g. CT, UCT, EOT, POT)
3 Tool insert: router, blade, pen
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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.
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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.
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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)
Accessories Quantity Task Conveyor Static PU
Allen screwdriver 4 x 170 mm
Torx screwdriver TX10 1 pc. Assembling/
Special guide rail oil 25 ml Oil for the X/Y axis
Lubrication set, X axis guide rails
Staple gun 1 pc. Replacing the conveyor
Dosing gun KPM 250 ECON
19 mm tape, double­sided
Teflon grease 20 ml Service X X X
Soldering fluid brush 1 pc. Service X X X
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 board X
5 pcs. Service X X X
X X X
X X X
X X X
X X X
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:
Axis Function Movement system
Movement of the beam Driven via toothed belt
X
Material transport, material transport extension
Feed clamping elements, feeding clamps
Y Movement of the module carriage Driven via toothed belt
Z Height adjustment of the module Example UM-S
T Rotary movement of the module Example 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) A B B1 C D E
M-800 M-1200 M-1600
L-1200 L-1600
XL-1200
830
2086
520
2556
3026
1542 1942 2342
1942 2342
1942 1230 2270
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) A B B1 C D E
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
48.4 48.4 89.4
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-800 x
M-1200 x
M-1600 x
L-1200 x
L-1600 x
XL-1200 x
CE0800
875
CE1200
1275
CE1600
1674
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Product description
2.11.1.4 Cutter extension - CE (inch)
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Type Length (in)
M-800 x
M-1200 x
M-1600 x
L-1200 x
L-1600 x
XL-1200 x
CE0800
34.4
CE1200
50.2
CE1600
65.9
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Product description

2.11.2 Weights

2.11.2.1 Base cutter (kg)
Type Weight (kg) max. floor load (kg/m)2)
M-800 M-1200 M-1600
L-1200 L-1600
XL-1200 620
2.11.2.2 Base cutter (lbs)
Type Weight (lbs) max. floor load (lbs/in)2)
M-800 M-1200 M-1600
L-1200 L-1600
XL-1200 1370
420 490 560
560 610
925 1080 1240
1240 1350
200
440
2.11.2.3 Material weight (kg)
Type max. material weight (kg) max. material weight (kg/m2)
M-800 M-1200 M-1600
L-1200 L-1600
XL-1200 27
2.11.2.4 Material weight (lbs)
Type max. 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
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Product description
Type max. material weight (lbs) max. material weight (lbs/in2)
XL-1200 60

2.11.3 Electrical connection, power consumption

Electrical connection 400 V, 50/60 Hz
Voltage 3-phase, 400 VL1, L2, L3, N, PE
Mains frequency 50/60 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
Voltage 3 phase, 208 V L1, L2, L3, N, PE
Mains frequency 50/60 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
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1.1 kW vacuum pump
Value
Voltage 3-phase, 400 V L1, L2, L3, N, PE
Mains frequency 50/60 Hz
Power input - 3 phases 1.1 KW
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Product description
Value
Mains fuse, min. 16 A
2.2 kW vacuum pump
Value
Voltage 3-phase, 400 V L1, L2, L3, PE
Mains frequency 50/60 Hz
Power input - 3 phases 2.2 KW
Mains fuse, min. 16 A
2.55 kW vacuum pump
Value
Voltage 3-phase, 208 V L1, L2, L3, PE
Mains frequency 50/60 Hz
Power input - 3 phases 2.55 KW
Mains fuse, min. 16 A
4 kW vacuum pump
Value
Voltage 3-phase, 400 V L1, L2, L3, PE
Mains frequency 50/60 Hz
Power input - 3 phases 4 KW
Mains fuse, min. 16 A
12.5/14.5 kW vacuum pump
Value
Voltage 3-phase, 400 V L1, L2, L3, N, PE
Mains frequency 50/60 Hz
Power input - 3 phases 12.5/14.5 KW
Mains fuse, min. 32 A
4.6 kW vacuum pump
Value
Voltage 3-phase, 208 V L1, L2, L3, PE
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Product description
Mains frequency 50/60 Hz
Power input - 3 phases 4.6 KW
Mains fuse, min. 20 A
Vacuum turbine 1 - 9 kW
Voltage 3-phase, 400 V L1, L2, L3, PE
Mains frequency 50/60 Hz
Power input - 3 phases 1 - 9 KW
Mains fuse, min. 32 A
Value
Value
Vacuum turbine 1 - 9 kW
Value
Voltage 3-phase, 208 V L1, L2, L3, PE
Mains frequency 50/60 Hz
Power input - 3 phases 1 - 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 humidity 10 - 80%, non-condensing

2.11.5 Compressed air supply

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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
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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 unit House
connection
Punch modules - PUM-S, PMM-S, PPM-S
Compressed air regulator P2
Electric Oscillating Tool - EOT-250 70
Universal Routing Tool - URT 60
Marker modules - MAM-SP, MAM­SPS, MAM-SPD
Router modules - RM-S 40
Sheet feeder feed 150
Sheet feeder removal 150
0.7 - 0.8 0.7 - 1.0 150
Air pressure [MPa]
Maintenance unit House
connection
0.6 0.6 - 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 unit House
connection
Minimal Quantity Lubrication - MQL 70
Material transport (transport elements, conveyor clamping elements)
Board loading device
0.45 0.6 - 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 unit House
max. air
consumption [l/min]
connection
Pneumatic Oscillating Tool - POT 400
0.8 0.8 - 1.0
Scoring Cutting Tool - SCT
Passepartout Tool - PPT 0.6 - 0.8 0.6 - 1.0 20

2.11.6 Performance features

Accuracy
Value Unit
Resolution of measuring system 0.0050.0002 mmin
Positioning accuracy at a constant temperature ±0.10.004 mmin
Repeat accuracy ±0.030.0012 mmin
Evenness of the worktop 0.40.016 mmin
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Cutting performance
Value Unit
Speed in vector direction 1 - 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.
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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
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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
1 Hazard symbol with the corresponding signal color
2 Signal word corresponding to the danger resulting from the situation
3 Description of the danger
4 Description of the consequences which could result from this hazardous situation
5 Possible 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

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1 Danger 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
1 Module (e.g., UM-S)
2 Tool (e.g., UCT)
3 Danger area
D Safety 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.
1 Danger 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. Description Variant 1 (CE) Variant 2 (ANSI)
1 Mandatory sign:
Wear protective gloves
Art. no.: 5800412 (50 mm)
Art. no.: 5801106 (65 mm)
2 Mandatory sign:
Wear eye protection
Art. no.: 5800467 (50 mm)
Art. no.: 5801058 (65 mm)
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Safety
No. Description Variant 1 (CE) Variant 2 (ANSI)
3 Warning sign:
Hand injuries due to crushing
Art. no.: 5800342 (50 mm)
4 Warning sign:
Electrical hazard
Art. no.: 5801338 (50 mm)
Art. no.: 5801059 (65 mm)
Art. no.: 5802331 (95 mm)
5 Warning sign:
Electrical hazard
6 Warning sign:
Laser beam
Art. no.: 5200367 (110 mm)
Art. no.: 5811418 (50 mm)
Art. no.: 5200367 (110 mm)
Art. no.: 5811418 (50 mm)
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Art. no.: 5800344 (25 mm)
Art. no.: 5801062 (40 mm)
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3.12 Protective devices

Safety
1 EMERGENCY STOP control device
2 Safety device (protective trip switch)
3 EMERGENCY STOP control device
4 Control 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
1 Rear EMERGENCY STOP control device
2 Control panel and workstation (optional)
3 Maintenance units (dependent on cutter configuration)
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4.2.2 Control panel

Controls and operation
1 Display 8 ONLINE key
2 Soft keys 9 STOP key
3 Navigation keys 10 VAC (vacuum) key
4 Number block and function keys 11 Router on/off key (optional)
5 Tool up/down key 12 Front processing approval (optional)
6 Travel keys 13 Switch on front vacuum (optional)
7 SHIFT key 14 EMERGENCY STOP control device
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Controls and operation

4.2.3 EMERGENCY STOP control devices

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
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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.
1 Maintenance unit, POT*
2, 6 Air pressure setting
3, 5 Stopcock
4, 7 Water separator
8 Maintenance 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.
1 LAN
2 not used
3 USB (host) - not used
4 Status and error display
5 COM 1
6 COM 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.
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Tab Information
Assignment Information on the module carriage
Module Information about the module
Position Specification of the current position of the current tool
Buffer Information about the memory system
Job Information about the print job
Status Display of the user level, the operating mode...
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Controls and operation
Tab Information
Function keys Allocation of the function keys
Communication Settings 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

Symbol Description
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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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

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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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4.5.3 Setting the display contrast

Key Description
Shift +
Shift +
Increase contrast
Reduce contrast

4.5.4 Setting the volume

Key Description
Shift +
Increase/decrease the volume

4.5.5 Clear buffer

Clear the data buffer following the termination or processing of a job.
Menu Description
2-4-1 Clear buffer All 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 level Description
Users 1 - 3 All menus and functions needed for the operation of the machine are
accessible
Operator Simple, uncomplicated adjustments can be made
Service Cutter 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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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.
1 Signal word
2 Error codes
3 Error description
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Signal word Error code
ends with
Information 01 Important information for the operating personnel
Warning 02 Notification of possible problems (overheating). Check status,
Error 03 Errors that are likely to be remedied - contact the service department if
Alarm 04 Serious 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.
Item Sequence Explanation
1 Introduction The error group is introduced by an introductory
sequence
2 Error code 1 Display of the first recorded error code
3 Separator Display of the error is complete and another error
follows
4 Error code 2 Display of the next error code
5 Separator Display of the error is complete and another error
follows
6 Error code 3 Display of the next error code
7 Conclusion Display 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.
Fuse Rated current Consumer
L1 16 A type C Cutter control, compressor, PC
L2 16 A type C Extractor, various options
L3 16 A type C Auxiliary 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.
Option Description
The automatic circuit breaker triggers again Shut 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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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.
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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
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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
1 Main switch, off position
2 Main 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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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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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 status input

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
1 Module (e.g., KCM-S, UM-S)
2 Tool (e.g. CT, UCT, EOT, POT)
3 Tool 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
1 Module carriage, slot 1
2 Module carriage, slot 2
3 Module carriage, slot 3 (reserved for marking module MAM-SE, MAM-SP)
4 Pneumatic connections
5 Guide pins
6 Laser 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.
Module Key combination
Module 1
Module 2
Module 3
ICC camera Shift + 8
Laser pointer Shift + 9
Shift +
Shift +
Shift +
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Controls and operation

4.13.5 Marking the tool

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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).
2 Use 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.
3 Confirm 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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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
1 Connection 1 (port 1, black) - e.g. EOT
2 Connection 2 (port 2, red) - e.g. DRT
3 Connection 3 (port 3, blue) - e.g. EOT-250, URT
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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
1 Compressed air hose
2 Pneumatically operated tool, e.g. POT
3 Interface unit
P1 Compressed air connection P1 (e.g., PMM-S, PPM-S)
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P2 Compressed air connection P2 (e.g. sealing air EOT-250)
P4 Compressed 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.
1 Protective plug
2 Interface unit
P1 Compressed air connection P1
P2 Compressed air connection P2
P4 Compressed 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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