UV Setter 400-800 Installation en V03 Draft

INSTALLATION MANUAL
UV-SETTER SERIES 400 & 800

GENERATION 5
VERSION 03
Date: 9. September 2009
SAP 135403
IMPORTANT NOTICE
This book supersedes all previously dated versions. The material in this book is for informational
purposes and is subject to change without notice. No responsibility is assumed for any errors which may
appear in this book, nor for its use.
Copyright © 2008 Punch Graphix International nv

No parts of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means,
electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Punch Graphix
International nv. Punch Graphix makes no warranties or representation, expressed or implied, with respect to accuracy,
completeness, or usefulness of the information contained in this manual and specifically disclaims warranties of fitness for any
particular purpose. In no event will Punch Graphix be liable for damages arising from the use or inability to use any
information, apparatus, method or process disclosed in this manual. Punch Graphix reserves the right to make changes to this
manual without prior notice.
Printed in Belgium.
All Rights Reserved.
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Tiger - TOC.1
Chapter 1: Introduction 1.1

Version 1 1.1
About 1.1
About ................................................................................................................................... 1.1
Chapter 2: Pre Installation 2.1

Overview 2.1
Overview 2.1
Introduction ........................................................................................................................ 2.1
In this chapter ...................................................................................................................... 2.1
Version 1 2.2
Dimensions and Required Space 2.2
Plate Output Height ............................................................................................................ 2.2
Manual Machine 4UP/8UP ................................................................................................. 2.3
Single Cassette 4UP/8UP ..................................................................................................... 2.4
Multiple Cassette 4UP/8UP ................................................................................................. 2.5
Cooler .................................................................................................................................. 2.6
Flooring Requirements 2.6

Weights of the Different Machines Types ............................................................................ 2.6
Floor conditions ................................................................................................................... 2.7
Support feet Manual Machine .............................................................................................. 2.7
Support feet Single Cassette Machine ................................................................................... 2.8
Support feet Multiple Cassette Machine ............................................................................... 2.8
Environmental Specifications 2.8

Temperature and Relative Humidity .................................................................................... 2.8
Noise Emission .................................................................................................................... 2.9
Dust and Vibrations ............................................................................................................. 2.9
Altitude ................................................................................................................................ 2.9
Cooler .................................................................................................................................. 2.9
Room Requirements 2.9

Heat Dissipation .................................................................................................................. 2.9
Ventilation ........................................................................................................................... 2.9
Connections 2.10
Power Supply ..................................................................................................................... 2.10
Power Consumption .......................................................................................................... 2.10
Compressed Air .................................................................................................................. 2.10
Press Air Consumption ...................................................................................................... 2.10
Network Connections ........................................................................................................ 2.11
TeamViewer Connection ................................................................................................... 2.11
Cooler Connections ........................................................................................................... 2.12
Locations Manual Machine ................................................................................................ 2.12
Locations Single Cassette Machine ..................................................................................... 2.13
Locations Multiple Cassette Machine ................................................................................. 2.13
Chapter 3: Safety 3.1

Overview 3.1
TOC.2
Overview 3.1
Introduction ........................................................................................................................ 3.1
In this chapter ...................................................................................................................... 3.1
Version 1 3.2
General 3.2
Reading the Safety precautions ............................................................................................. 3.2
Specific Safety Information 3.2

Plate Outlet .......................................................................................................................... 3.2
Chapter 4: Transport of the Crates 4.1

Overview 4.1
Overview 4.1
Introduction ........................................................................................................................ 4.1
In this chapter ...................................................................................................................... 4.1
Version 1 4.2
Overview 4.2
Introduction ........................................................................................................................ 4.2
In this chapter ...................................................................................................................... 4.2
Handling the Crates 4.2

Special Concerns .................................................................................................................. 4.2
Transport Notifications ........................................................................................................ 4.3
Returning the Crates ............................................................................................................ 4.3
The Crates 4.3

About the Crates .................................................................................................................. 4.3
Overview .............................................................................................................................. 4.3
Units on pallet ..................................................................................................................... 4.4
Breakdown 4.5
Dimensions .......................................................................................................................... 4.5
Shipping and Storage of the Engine 4.5

Storage Location .................................................................................................................. 4.5
Environmental Specifications ............................................................................................... 4.5
Chapter 5: Installation of Manual Module 5.1

Version 1 5.1
Overview 5.1
Introduction ........................................................................................................................ 5.1
Plate Outlet .......................................................................................................................... 5.1
In this chapter ...................................................................................................................... 5.1
Uncrating and Positioning the Elements 5.1

Shock and tilt indicators. ...................................................................................................... 5.1
Uncrating Procedure ............................................................................................................ 5.2
Tiger - TOC.3
Unlocking the Elements 5.6

Procedure ............................................................................................................................. 5.6
Leveling the Elements 5.7

Procedure ............................................................................................................................. 5.7
Chapter 6: Installation of the Loading Module 6.1

Overview 6.1
Overview 6.1
Introduction ........................................................................................................................ 6.1
In this chapter ...................................................................................................................... 6.1
Version 1 6.2
Introduction ........................................................................................................................ 6.2
Shock and tilt indicators. ...................................................................................................... 6.2

Procedure ............................................................................................................................. 6.6

Procedure ............................................................................................................................. 6.8
Electrical and Pneumatical Connection 6.8

Procedure ............................................................................................................................. 6.8
Chapter 7: Installation of the Single Cassette 7.1

Overview 7.1
Overview 7.1
Introduction ........................................................................................................................ 7.1
In this chapter ...................................................................................................................... 7.1
Version 1 7.2
Introduction ........................................................................................................................ 7.2
Adjusting the Elements 7.2

Procedure ............................................................................................................................. 7.3
Chapter 8: Installation of the Multiple Cassette Module 8.1

Overview 8.1
TOC.4
Overview 8.1
Introduction ........................................................................................................................ 8.1
In this chapter ...................................................................................................................... 8.1
Version 1 8.2
Introduction ........................................................................................................................ 8.2

Procedure ............................................................................................................................. 8.4

Procedure ............................................................................................................................. 8.5
Electrical and Pneumatical Connection 8.6

Procedure ............................................................................................................................. 8.6
Chapter 9: Installing the Cooler 9.1

Overview 9.1
Overview 9.1
Introduction ........................................................................................................................ 9.1
In this chapter ...................................................................................................................... 9.1
Version 1 9.2
Uncrating and Positioning 9.2
About ................................................................................................................................... 9.2
Positioning ........................................................................................................................... 9.2
Installation 9.2
About ................................................................................................................................... 9.2
Procedure ............................................................................................................................. 9.2
Filling Up 9.3
Procedure ............................................................................................................................. 9.3
Chapter 10: Performing the Main Electrical Connection 10.1

Overview 10.1
Overview 10.1
Introduction ...................................................................................................................... 10.1
In this chapter .................................................................................................................... 10.1
Version 1 10.2
Electrical Connection of the UV-Setter Series 400&800
Tiger - TOC.5
10.2
Electrical Safety .................................................................................................................. 10.2
Regulations ........................................................................................................................ 10.2
Mains Supply Cable Specifications ..................................................................................... 10.2
Procedure ........................................................................................................................... 10.2
Chapter 11: Performing the Press Air Connection 11.1

Overview 11.1
Overview 11.1
Introduction ...................................................................................................................... 11.1
In this chapter .................................................................................................................... 11.1
Version 1 11.2
Pneumatic Connection 11.2
Regulations ........................................................................................................................ 11.2
Specifications ..................................................................................................................... 11.2
Procedure For Automatic Machines ................................................................................... 11.2
Procedure For Manual Machines ....................................................................................... 11.3
Chapter 12: Connecting the Peripheral Devices 12.1

Overview 12.1
Overview 12.1
Introduction ...................................................................................................................... 12.1
In this chapter .................................................................................................................... 12.1
Version 1 12.2
Ethernet Connection 12.2
About ................................................................................................................................. 12.2
Procedure ........................................................................................................................... 12.2
Processor 12.2
About ................................................................................................................................. 12.2
Plug Pinout ........................................................................................................................ 12.2
Procedure ........................................................................................................................... 12.3
Chapter 13: Commisioning and Safety Check 13.1

Overview 13.1
Overview 13.1
Introduction ...................................................................................................................... 13.1
In this chapter .................................................................................................................... 13.1
Version 1 13.2
TOC.6
Commisioning 13.2
Safety ................................................................................................................................. 13.2
Procedure ........................................................................................................................... 13.2
About - 1.1
Chapter 1: Introduction
Version 1
About
About This manual describes the transport and installation process of the UV-Setter series 400&800. Only
service technicians trained by Punch Graphix or its service partners may do this work described in here.
Read the following instructions carefully and be aware of the hints and tipps in this manual.
1.2 - Chapter 1: Introduction
Introduction - 2.1
Chapter 2: Pre Installation

Overview
Introduction In this chapter among other things you can find the instructions of the flooring and room requirements
and how to connect the equipment with the UV-Setter.
In this \ Overview ..................................................................................................2.1

chapter X Overview..............................................................................................2.1
Z Introduction .....................................................................................2.1
Z In this chapter..................................................................................2.1
\ Version 1 .................................................................................................2.2
X Dimensions and Required Space............................................................2.2
Z Plate Output Height ..........................................................................2.2
Z Manual Machine 4UP/8UP ................................................................2.3
Z Single Cassette 4UP/8UP ..................................................................2.4
Z Multiple Cassette 4UP/8UP ...............................................................2.5
Z Cooler..............................................................................................2.6
X Flooring Requirements ..........................................................................2.6
Z Weights of the Different Machines Types ............................................2.6
Z Floor conditions................................................................................2.7
Z Support feet Manual Machine ............................................................2.7
Z Support feet Single Cassette Machine.................................................2.8
Z Support feet Multiple Cassette Machine..............................................2.8
X Environmental Specifications ................................................................2.8
Z Temperature and Relative Humidity....................................................2.8
Z Noise Emission.................................................................................2.9
Z Dust and Vibrations ..........................................................................2.9
Z Altitude ...........................................................................................2.9
Z Cooler..............................................................................................2.9
X Room Requirements .............................................................................2.9
Z Heat Dissipation ...............................................................................2.9
Z Ventilation .......................................................................................2.9
X Connections.......................................................................................2.10
Z Power Supply .................................................................................2.10
Z Power Consumption ........................................................................2.10
Z Compressed Air ..............................................................................2.10
Z Press Air Consumption ....................................................................2.10
Z Network Connections ......................................................................2.11
Z TeamViewer Connection ..................................................................2.11
Z Cooler Connections .........................................................................2.12
Z Locations Manual Machine ..............................................................2.12
Z Locations Single Cassette Machine...................................................2.13
Z Locations Multiple Cassette Machine................................................2.13
2.2 - Chapter 2: Pre Installation
Version 1
Dimensions and Required Space
Plate Output
Height
Figure 2.1: Plate Output (all values in mm)
The height of the plate output is depending of the height setting of the machine 920mm, measured
from the ground surface to the plate outlet. In the image above the height setting of an SCA machine is
shown. For MCA and manual machines the height of the leveling feet is 90mm which results in a
height of the plate output of 950mm.
Manual Machine 4UP/8UP - 2.3
Manual
Machine
4UP/8UP 4050
1400
Processor
1000
2658
500
Figure 2.2: footprint of the manual machine (all values in mm)
To ensure trouble-free operation of the machine as well as to provide adequate access for the
performance of maintenance and repair work, the minimum clearances must be observed during
installation and operation, as shown on the diagram.
Proper air circulation for carrying off the heat at the installation site must be ensured.
Single
Cassette 4050
4UP/8UP
Processor
1400
1000
3942
1000
Figure 2.3: footprint of a single cassette machine (all values in mm)
Multiple Cassette 4UP/8UP - 2.5
Multiple
Cassette 4050
4UP/8UP 1400
Processor
1000
4088
1000
Figure 2.4: footprint of a multiple cassette machine (all values in mm)
Cooler
Figure 2.5: Position of the cooler
Proper air circulation for carrying off the heat at the installation site must be ensured. See operating
manual of the cooler from Rittal chapter 5 „Assembly and connection“.
Position the cooler on a flat, solid surface. The maximum permissible deviation from the vertical is 2°.
Make sure that the cooling unit is always erected at the same floor level as the UV-Setter.
The maximum distance between the UV-Setter and the cooler is depending on the type of tubes:
• Standard Flexible: Tube max. 2x5m - DN13 (Delivered with the machine).
• Optional Flexible: Tube max 2x20m - DN13. Hoses that are 5m or longer must be provided with
cold insulation. Operating pressure according to DIN20024, Safety factor 4:12bar.
• Rigid: Cu-pipe max. 2x50m - Cu 18x1; thermal insulation.
REMARK
The amount of coolant is calculated for the standard tubes of 5m.
If you use other tubes, order more coolant.
More information can be found in the operating manual of the cooler.
Flooring Requirements
Weights of The table below gives an overview of the weights of the different machine types:
the Different
Machines Machine Type Weight
Types kg lbs
Manual Machine 1490 3278
Single Cassette Machine* 2035 4477
Multiple Cassette Machine* 2400 5280
Cooling Unit Check cooler manual
*With no plates loaded
Floor conditions - 2.7
It’s imperative that the floor of the site is capable of supporting the weight of the equipment. Note that
the machine is supported on support feet with a diameter of 78mm or 3,1 inch.
The position of the support feet can be found in:
“Support feet Manual Machine” on page 2.7
“Support feet Single Cassette Machine” on page 2.8
“Support feet Multiple Cassette Machine” on page 2.8
The floor should not be subject to excessive vibration from other sources, as this may disturb the
operation of the system.
Floor Wooden floor or raised computer floors are forbidden.

conditions The floor covering selected should be one that not attract dust, is easy to clean and doesn’t produce
static electricity (e.g. carpets should be avoided).
No vinyl, carpet or similar covering should be used underneath the engine. The engine should always
be installed directly on a solid, concrete floor.
The floor may have a slope of maximum 10mm/m2.
Support feet
Manual
Machine
Figure 2.6: Location of the support feet of a manual machine (all values in mm)
Support feet
Single
Cassette
Machine
Figure 2.7: Location of the support feet of a single cassette machine (all values in mm)
Support feet
Multiple
Cassette
Machine
Figure 2.8: Location of the support feet of a multiple cassette machine (all values in mm)
Environmental Specifications
Temperature To Ensure a reliable operation of the UV-Setter, the relative humidity (RH) and the ambient
and Relative temperature (T) should full-fill to the following conditions.
Humidity • The temperature must be between 18°C (65°F) and 24°C (75°F), max fluctuation 2°.
• The relative humidity must be between 20% and 80%
Noise Emission - 2.9
RH(%)
100
80
60 Working Range
40
20
18 19 20 21 22 23 24 T(° C)
Figure 2.9: Diagram of humidity and temperature
WARNING
Variations of the environmental conditions should never result in
the formation of condensation!
Noise The maximum noise emission of the UV-Setter is 73dB(A)

Emission
Dust and Dust and vibrations can decrease the output quality.
Vibrations
Altitude The altitude during operation should be maximum 1000m above sea-level.
Cooler The cooler has it’s own specifications. These are mentioned in the cooler’s manual.
Room Requirements
Heat
Dissipation Mode Head(s) Heat Dissipation
Normal Operation Single Head 2100 BTU / hour
Standby Single Head 700 BTU / hour
Ventilation The ventilation of the room should have sufficient capacity for the following reasons:
• To avoid sudden change in operating conditions due to the system’s heat dissipation.
• To avoid O3 buildup in the room above a level of 0,05 ppm.
The air refreshment flow rating has to be at least 1500m³/h.
Connections
Power Supply
Be aware that the power supply cable for the UV-Setter is to be supplied by the
customer himself.
The power supply cable has to comply with the following specifications:
Property Requirement
Voltages The UV-Setter can be connected to the AC power supply line as shown below:
Single phase 200-240 VAC (±10%) (50/60Hz) + earth.
Earth Connection There must be a separated earth connection with a resistance less than 2 ohm.
Power See:
“Power Consumption” on page 2.10
Over Current Branch circuit protection is not provided, therefore an 20A over-current
Protection protection needs to be installed in the power supply line.
High Leakage The UV-Setter has a high leakage current.
Current
CAUTION
To avoid electrical hazard or overheating, verify if the local electrical
supply matches with the unit’s electrical ratings.
Power
Consumption Head(s) Requirement
Single Head 600 Watt
Compressed Only applicable for machines with unloader, trolley or cassettes.

Air The compressed air connected to the machine must be between 7 and 12 bar or between 102 and 174
PSI. The supply hose should have a minimum inside diameter of 13mm. The coupling to connect the
supply hose to the machine is delivered with the machine.
Figure 2.10: The coupling to connect the supply hose (all values in mm)
The press air quality should be in appliance with the ISO-8573-1 norm:
• Fix particles: Class 3 = 5μm
• Humidity: Class 4 = dew point 3°C (dew point should always be 15°C below the coldest possible
environment and/or press air temperature)
• Oil (compressor oil): Class 2 = 0.1mg/m³ (oil free air)
Press Air Only applicable for machines with unloader, trolley or cassettes.
Consumption The maximum air consumption is 800l/min or 212 gallon/min measured at 6 bar or 88 PSI.
Network Connections - 2.11
Network The customer has to foreseen 2 network connections. The connection to the UV-Setter has to be fixed.
Connections The 2nd to the customer LAN can be freely choosen.
TeamViewer
Connection
Figure 2.11: TeamViewer Setup
Toenable fast and smooth service support, our service personnel must be granted access to the UVSS
PC. This requires some setup at the client side. First of all the customer network should be accessible
from the internet.The UVSS PC has to possess a standard internet connection (Internet Explorer,
Firefox etc.). Firewall settings or modifications or safety settings in the corporate network must not be
done. The "TeamViewer" host module has to be installed on the UVSS PC. Please refer to the
Operator‘s Guide UVSS, that you can open in the UVSS software via the "help" menu. The Punch
Graphix contact person willalso provide you more info if desired.
Cooler
Connections
Figure 2.12: Cooling connections
The connectors for the cooler liquid connection are located at the service side in the lower right corner
(red and blue arrow). The electrical cooler connection is also located at the service near the main
electrical connection (grey arrow).
Locations
Manual
Machine
Figure 2.13: Top view of the manual machine

Locations Single Cassette Machine - 2.13
Locations
Single
Cassette
Machine
Figure 2.14: Top view of the single cassette machine
Locations
Multiple
Cassette
Machine
Figure 2.15: Top view of the multiple cassette machine

Introduction - 3.1
Chapter 3: Safety
Overview
Introduction In this chapter you can find important information about how to observe safety regulations.
In this \ Overview ..................................................................................................3.1

Z Introduction .....................................................................................3.1
Z In this chapter..................................................................................3.1
\ Version 1 .................................................................................................3.2
X General ...............................................................................................3.2
Z Reading the Safety precautions..........................................................3.2
X Specific Safety Information ...................................................................3.2
Z Plate Outlet .....................................................................................3.2
\
3.2 - Chapter 3: Safety
Version 1
General
Reading the Before installing, operating or servicing the UV-Setter, first read the chapter “Safety” in the user manual
Safety and service manual. If there is referred to another procedure, first read the safety instructions of this
precautions procedure before executing it. Always follow the instructions of the procedures in this manual. Use of
controls, adjustments or performance of procedures other than those specified here, may result in
hazardous radiation exposure.
Specific Safety Information
Plate Outlet Through the slit of the unloader system the unloader can be reached by the system operator. The
printing plate can injure the operator while feeding the plate to the processor. Since the UV-Setter is an
automated system to be linked up with the processor protecting this outlet will be subject to final
installation.
WARNING
Bruising / Cutting Hazard
The printing plate can injure the operator while feeding the plate to
the processor.
Install the processor against the UV-Setter in such way that the
operator can’t injure himself.
Introduction - 4.1
Chapter 4: Transport of the Crates

Overview
Introduction
In this \ Overview ..................................................................................................4.1

Z Introduction .....................................................................................4.1
Z In this chapter..................................................................................4.1
\ Version 1 .................................................................................................4.2
X Overview..............................................................................................4.2
Z Introduction .....................................................................................4.2
Z In this chapter..................................................................................4.2
X Handling the Crates..............................................................................4.2
Z Special Concerns..............................................................................4.2
Z Transport Notifications......................................................................4.3
Z Returning the Crates .........................................................................4.3
X The Crates ...........................................................................................4.3
Z About the Crates...............................................................................4.3
Z Overview ..........................................................................................4.3
Z Units on pallet .................................................................................4.4
X Breakdown...........................................................................................4.5
Z Dimensions ......................................................................................4.5
X Shipping and Storage of the Engine .......................................................4.5
Z Storage Location...............................................................................4.5
Z Environmental Specifications.............................................................4.5
\
4.2 - Chapter 4: Transport of the Crates
Version 1
Overview
Introduction
In this \ Overview ..................................................................................................4.1

Z Introduction .....................................................................................4.1
Z In this chapter..................................................................................4.1
\ Version 1 .................................................................................................4.2
X Overview..............................................................................................4.2
Z Introduction .....................................................................................4.2
Z In this chapter..................................................................................4.2
X Handling the Crates..............................................................................4.2
Z Special Concerns..............................................................................4.2
Z Transport Notifications......................................................................4.3
Z Returning the Crates .........................................................................4.3
X The Crates ...........................................................................................4.3
Z About the Crates...............................................................................4.3
Z Overview ..........................................................................................4.3
Z Units on pallet .................................................................................4.4
X Breakdown...........................................................................................4.5
Z Dimensions ......................................................................................4.5
X Shipping and Storage of the Engine .......................................................4.5
Z Storage Location...............................................................................4.5
Z Environmental Specifications.............................................................4.5
\
Handling the Crates
Special To transport the crates, material handling systems such as levers, forklift, pallet trucks, lift,... must be
Concerns used. When this is not practicable, specially trained persons or services must be used (for instance
riggers or movers). Also Punch Graphix Support can offer help.
Always keep the following things in mind:
• Handle the crates with special care.
• Always transport the crates upright. The crates should remain upright at all times.
• The crates contain delicate devices which could brake.
• All crates are very heavy.
• Protect yourself against heavy load - work safely.
CAUTION
Mechanical hazard
Risk of splinters or other injuries
Wear protective gloves during handling of the wooden crates
CAUTION
Mechanical hazard
Risk of injuries
Wear safety shoes during handling of the crates
• Some of the crates may only be accessed to lift from one side due to weight distribution inside (see
signs on crates).
Transport Notifications - 4.3
Transport The crates have to be transported always upright.

Notifications The crates can be opened with a cross-head screwdriver preferably an electrical screwdriver.
Leave the crates closed until they are at their final position. Uncrate only just before installing - you
prevent damages and parts getting lost.
If you need to uncrate the crates before they are entering the final destination, pay attention to handle
the devices with care.
• Not all frames have the same strength.
• Most devices are not designed to be lifted.
Use the engine lifting tool (jacks) only for repositioning of the engine on the spot.
Returning the The crates are disposable crates and must not be sent back to Punch Graphix.
Crates
The Crates
About the The complete system will be transported packed in crates and mounted on-site. These crates are large
Crates and therefore particular attention must be paid to ceiling height and door ways.
If a door way is too small, contact Punch Graphix Support for help.
Overview Only one single crate or palette is used for the different units (see the following figure).
Figure 4.1: Dimension of the pallet
The table below showsthe dimensions of the crate:

Height Length Width

mm inch mm inch mm inch
1830 72 3440 135,4 1910 75,2
The following table gives an overview about the packaging of the different units:
Unit Gross Weight*
kg lbs
Manual module 4UP 1700 3750
Manual module 8UP 1800 3970
Plate Loading Module 700 1550
Single cassette 280 620
Multiple cassette 930 2050
*If no automatic unloader is installed you can substract 20 kg.
Units on The following table shows the packaging situation of the different units:
pallet
Machine Type Illustration of packaging
4up/8up manual
4up/8up SCA
Dimensions - 4.5
Machine Type Illustration of packaging

4up/8up MCA
Breakdown
Dimensions With the information in the previous paragraphs, it is possible to determine whether or not the crates
can be transported to the location where the Engine has to be installed.
However, Punch Graphix also provides “breakdown” services which means that the Engine will be taken
apart to facilitate transportation.
A breakdown is custom.
Describe the specifications of your problem by means of picture and drawings, and e-mail the request
to your Punch Graphix representative.
Shipping and Storage of the Engine
Storage • Storage area for supplies and spare parts needs to be provided close to the installation.
Location • Intensive UV sources at the location are to be avoided.
• Fluorescent tube lighting is allowed at normal levels for room lighting. Hence avoid fluorescent
lighting when the engine is not closed.
• Direct sunlight falling on the engine is not allowed. It is advised to cover outer windows.
• A room ambient level for maintenance, service and troubleshooting near the print engine of
minimum 500Lux is recommended.
Environment • The environmental conditions for shipping and storage are:

al • -20°C < T < 35°C
Specifications • 15% < RH < 80%
• When the engine is transported from a cold to a warm environment, dew formation can occur.
Switching on the Engine may only occur after the engines environmental conditions are achieved.
Introduction - 5.1
Chapter 5: Installation of Manual Module

Version 1
Overview
Introduction Before starting with the uncrating, make a installation planning. Think about space for uncrating,
preferably as close as possible to the installation site. A good path free from inclinitions or thresholds for
moving the machines to the installation site. Whenever elavators are being used, they should be large
enough. On the entire route the floor should be able to support the machine + eventually crate,
transport tools + the installation crew.
Plate Outlet Through the slit of the unloader system the unloader can be reached by the system operator. The
printing plate can injure the operator while feeding the plate to the processor. Since the UV setter is an
automated system to be linked up with the processor protecting this outlet will be subject to final
installation.
WARNING
Bruising / Cutting Hazzard
The printing plate can injure the operator while feeding the plate to
the processor.
Install the processor against the TIGER so the operator can’t injure
himself.
In this Overview5.1
chapter Introduction5.1
In this chapter5.1
Uncrating and Positioning the Elements5.2
Introduction5.2
Shock and tilt indicators.5.2
Uncrating Procedure5.2
Unlocking the Elements5.7
Procedure5.7
Leveling the Elements5.9
Procedure5.9
Uncrating and Positioning the Elements
Shock and tilt Before starting with uncrating check the shock and tilt indicators. You can find these on the crate.
indicators. If any of these indicators are tripped, there is a risk that the UV-setter or some parts are damaged. In
such case notify the superior and gather evidence and information.
5.2 - Chapter 5: Installation of Manual Module
Left Front
Back Right
Tilt Watch
Schock Watch
Top
Figure 5.1: Position of the transport indicators
Uncrating For this procedure at least 2 persons are required to work in a safe way.
Procedure
Step Description Figure
1 Open the Crate
Remove all the cross - headded woodscrews.
Start with the Top Panel, followed by the 4
side pannels.
Uncrating Procedure - 5.3

2 Remove the Strech Foil.
Remove all the foil from the machine. Be
carefull when using sharp objects.
3 Open the Front Door.

Open the door by unlocking the 2 locks
with an allen key of 8mm.
4 Remove the Shielding Protections

Remove the shielding protection from the
front panel en the vacuum cabinet.
Removing the socket-head screws. Keep this
screws to fix the protections later on.
5 Take out the Accesoires box

In the machine you will find a small
cardboard box. This box contains accesoires
needed for the installation and service.

6 Remove the Service Door
Use the triangle key that you’ll find in the
cardboard accesoires box to open the 2
locks. Remove the door with 2 persons.
7 Remove the Bolts from the Wooden Balk

Remove the 4 bolts so the wooden beams
are not fixed to the pallet anymore.
8 Lift the Machine

Lift the machine with a forklift.
Don’t lift undeneath the service door
supports at the back.
9 Remove the Pallet from the machine

Now that the machine is lifted you can
remove the pallet.
WARNING
Crushing Hazzard
Don’t stand underneath the machine when dismounting the wooden
beams.

10 Remove the Leveling Bolts from the
Wooden Beam
While the machine is lifted, remove the 4
bolts who were used to fix the beam to the
machine. Don’t throw away these bolts,
they will be used later on.
11 Mount the Levelling Bolts in the

Machine
Now mount the 4 bolts in each corner of
the machine. Set the bolts to a height of
80mm.
12 Put the machine on the ground

Take the levelling plates from the accesoires
box. Lay a levelling plate underneath each
corner. Now lower the machine until it
stands on the levelling plates.
13 Transport the machine to the installation

site
Now transport the machine to the
installation site with a pallet lifter or other
suiteble transportation rollers.
14 Lower the machine on levelling plates

Once the machine is on the correct place,
lower the machine on the levelling plates.
15 Continue
Continue the installation by executing the
unlocking procedure
Unlocking the Elements
Procedure
1 Remove the Bolts on the Dampers
Remove the bolts from the orange table
chassis dampers.
2 Unlock the Head(s)

Remove the socket head screw from the
mechanical limit. Make sure that no objects
fall in the machine.
One the first bolt is removed, you can push
the head away to ease the removal of the
next screw.
Remove the screw who holding the red
plate.
3 Unlock the Table

Remove the socket-head screws from the
table lock and remove the table lock.
4 Remove the Screen Protection

Remove the transport protections from the
screen.
Procedure - 5.7

5 Unlock the unloader
Remove the strap and foam who is blocking
the unloader.
6 Continue
levelling procedure
Leveling the Elements
Procedure
1 Setting the height
Start by setting the height of the UV-Setter
at 90mm.
The front left side (output) is the reference.
2 Levelling
Put 2 levels underneath the machine and
level the machine by adjusting the 3
levelling screws. Don’t toucht the refrence
bolt in the front left corner.
The use of a magnetical level is very

praktical.
3 Fix the positions

Once the machine is levelled, secure the
levelling bolts by fix the nut against the
chassis.

4 Fix Vacuum Cabinet Panel
Fix the panel from the vacuum cabinet. Re-
use the same screws.
5 Continue
If you are installing an single or multiple
cassette, continue by executing the
installation of the loading module.
If you are installing a manual machine,
continue by performing the main electrical
connection.
Introduction - 6.1
Chapter 6: Installation of the Loading Module

Overview
Introduction
In this \ Overview ..................................................................................................6.1

Z Introduction .....................................................................................6.1
Z In this chapter..................................................................................6.1
\ Version 1 .................................................................................................6.2
X Uncrating and Positioning the Elements .................................................6.2
Z Introduction .....................................................................................6.2
Z Shock and tilt indicators. ..................................................................6.2
Z Uncrating Procedure .........................................................................6.3
X Unlocking the Elements ........................................................................6.6
Z Procedure ........................................................................................6.6
X Leveling the Elements ..........................................................................6.8
Z Procedure ........................................................................................6.8
X Electrical and Pneumatical Connection...................................................6.8
Z Procedure ........................................................................................6.8
6.2 - Chapter 6: Installation of the Loading Module
Version 1
transport tools + the installation crew.
Shock and tilt Before starting with uncrating check the shock and tilt indicators. You can find these on the crate.
indicators. If any of these indicators are tripped, there is a risk that the UV-setter or some parts are damaged. In
such case notify the superior and gather evidence and information. First remove the loader from the
pallet.
Figure 6.1: Crate Plate Loader with SCA
Figure 6.2: Crate Plate Loader with MCA

Procedure
1 Open the Crate
Remove all the cross - headded woodscrews.
Start with the Top Panel, followed by the 4
side pannels.
2 Remove the Foil.

3 Take Out the Boxes and Pieces.

Open the load door and remove all the
boxes and pieces.
4 Take away the Service Door

Use the triangle key that you’ll find the
small cardboard accesoires box.
5 Remove the Screws from the Wooden

Balk
Remove the screws that are used to fix the
special wooden-foam beams to the pallet.

6 Lift the Loader
Lift the loader with preferably the side with
the paper-gripper motor closest to the fork
lift.
WARNING
Crushing Hazzard
Don’t stand underneath the machine when removing the wooden
beams.
7 Remove the Leveling Bolts from the
Wooden Beam
While the machine is lifted, remove the 2
bolts who were used to fix the beam to the
machine. Don’t throw away these bolts,
they will be used later on.
8 Mount the Levelling Bolts in the Loader

and Lower Down
Mount the 2 levelling bolts in the loader
and gently lower down.
Put 2 wooden blocks underneath the
machine on the other side.
9 Transport the Machine to the Installation

Site
Transport the loading module to the
installation site with a pallet lifter.
Don’t forget to safely transport the service
cover jou did remove in the beginning.
Bring the loading module 20cm before the

imager module.
Be carefull to not dammage the elements

mounted on the punch bar !

10 Bring the Loader at the Same Height
Bring the loader at the same height as the
machine.
The front of the loader must be supported
by blocks.
On the back side put the levelling plates

under neath the levelling bolts. You can
find the plates (rubber +metal) inside the
acessories box
11 Route all the Cables and Pneumatic

Tubes
Route all the cables and pneumatic tubes at
the back trough the triangle cut-out to the
distribution board and vice versa.
12 Push the Loader Against the Imager

Push the loader against the imaging
moudule.
13 Fix the Modules Together
Bring the loading module to the correct
height and fix it to the imager module.
The bolts can be found in the accesoires
box.
The module must be alligned in a way that
the front and top of the electrical box is
equal with the loading module. If the
height is correct you will feel no difference
on the top edges of the electrical box and
the loader (fig2).
Tip: sometimes it is better to remove the

valve block support to reach the bolt behind
it.

14 Continue
unlocking procedure
Procedure
1 Unlock the Paper Bin
2 Unlock the Paper Gripper
Unlock the locking nut, then you can pull
away the paper gripper.
Procedure - 6.7

3 Unlock the Loader
Remove all red transport fixings.
Remove the bolts, then you can push away
the Loader.
4 Remove the Transport Holder

Remove the holder by removing the 4 bolts.
5 Remove the Red Straps

Be sure to cut and remove all the red straps.

6 Continue
levelling procedure.
Procedure
1 Take Out the Paper Bin
Pull on the paper bin until it hits the stop.
Now lift the front of the of the paperbin
out the slider. Pull again on the paperbin
until you can remover the bin from the
slider.
2 Level the loading module

Level the loading module by adjusting the
height of the 2 levelling screws in the
module.
If you are finished, lock the bolts with the
nut.
3 Slide the Paperbin Back In

Mount the paperbin back in.
4 Continue
electrical and pneumatical connection
procedure.
Electrical and Pneumatical Connection
Procedure
1 Connect the Valve Block
Connect cable W400 to J8 of the
distribution board.
More information in the electrical drawings

on page 162.2
Procedure - 6.9

2 Connect W401 and W422
Connect the loader signals W401 and the
stepper motor W422 to J36 of the
distribution board.

on page 162.6
3 Connect the Pos Finger Stepper Motor

Connect cable W419 to the stepper motor
X52.

on page 164.4
4 Connect the Position Finger Home

Connect the sensor cable W407 with the
extension cable W404 with connector X54.

on page 163.8
5 Connect the CAN Cables

Connect the purple CAN cables W406,
409 and in case of a cassette machine W452
to the distribution board plugs J22, J27 and
J32.

on page 162.4, 162.6 and 171.4

6 Connect the Connector XBK
Connect connector XBK (W451) to the
connector wich is located on the left side of
the distribution board.
7 Connect the Cassette Signals

In case of a cassette machine, connect
W453 to J9 of the distribution board.

on page 171.3 and 172.5
8 Connect W402
Connect W402 to J37 of the distribution
board.

on page 162.6
9 Connect the Signal Lamp

Connect W405 to J35 of the distribution
board.
1-1
2-2

on page 162.3
10 Connect the Emergency Stop Circuit

Connect W303 comming from the imaging
module to EXPB from the loader module.

on page 102.1
Procedure - 6.11

11 Route the Cassette Lift Drive Power
Cable
In case of cassette machine, route cable
W380 trough the loader cable-conduit at
the back, towards the cassette module.
12 Connect the Earth Strip

Connect the earth strip wich connects the
loader to the imaging module.
13 Connect the Press air Tube

Connect the press air tube to unloader valve
block group on the imaging module. This
group is located at the service side.
14 Connect the Door Interlock Cable

Connect the door interlock cable (W306).
• Route the cable upwards trough the
triangle shaped door hinge
• Follow the cable strap holders
• Connect to the sensor
• Strap the cable

15 Connect the Punch Bar
Connect the tubes to the punchers, pin
detectors and positioner finger.
Connect the edge sensor to the Distribution

PCB J13 with cable W408.

on page 162.4
16 Continue
Continue with the installation of the single
cassette or the mulpitple cassette module
depending on the machine type.
Introduction - 7.1
Chapter 7: Installation of the Single Cassette

Overview
Introduction
In this \ Overview ..................................................................................................7.1

Z Introduction .....................................................................................7.1
Z In this chapter..................................................................................7.1
\ Version 1 .................................................................................................7.2
Z Introduction .....................................................................................7.2
X Adjusting the Elements .........................................................................7.2
Z Procedure ........................................................................................7.3
7.2 - Chapter 7: Installation of the Single Cassette
Version 1
transport tools + the installation crew. The SCA unit is positioned on the crate of the loader. Remove
the SCA from the pallet.
Figure 7.1: SCA on pallet
Procedure
1 Remove the Wooden Beam.
Remove the wooden beam on the bottom
of the crate.
2 Lift the Single Cassette out of the

Platform
3 Remove the plastic foil
Adjusting the Elements

Procedure - 7.3
Procedure
1 Push the Trolley in the loading module
Gently push the trolley in the loading
module. Try to fix the trolley with the
handle bar at the back of the trolley.
If the trolley doesn’t fit in the loader, 770mm

sometimes the height needs to be re-
adjusted. (see step below)
The height needs to be 770mm between
the load surface of the trolley and the
ground chassis of the loader.
2 Adjust the Height (if necessary)
Tilt the cassette module on his side, so you
can easily work at the bottom of the trolley.
Now you can loosen the 4 bolts of each
wheel support and move them up or down.
3 Adjust the Lock and InterlockPlate

If the lock or the interlocks does not fit
well, you can adjust them.
Loosen the 4 bolts in each corner, but do
not loosen to far! Move the plate to the
desired position and fix the 4 bolts again.
4 Adjust the Sensors for the Trolley ID

If needed you can adjust the depth or
height from the sensors that detect the
trolley ID. When the trolley is “in”, the
sensors should be 1,5mm from the bolt(s).
5 Continue
Continue by performing the main electrical
connection. See:
“Performing the Main Electrical
Connection” on page 10.1
7.4 - Chapter 7: Installation of the Single Cassette
Introduction - 8.1
Chapter 8: Installation of the Multiple Cassette Module

Overview
Introduction
In this \ Overview ..................................................................................................8.1

Z Introduction .....................................................................................8.1
Z In this chapter..................................................................................8.1
\ Version 1 .................................................................................................8.2
Z Introduction .....................................................................................8.2
X Unlocking the Elements ........................................................................8.4
Z Procedure ........................................................................................8.4
X Leveling the Elements ..........................................................................8.5
Z Procedure ........................................................................................8.5
X Electrical and Pneumatical Connection...................................................8.6
Z Procedure ........................................................................................8.6
8.2 - Chapter 8: Installation of the Multiple Cassette Module
Version 1
transport tools + the installation crew. The MCA unit is positioned on the crate of the loader. Remove
the MCA from the pallet.
Figure 8.1: MCA on pallet
Procedure
1 Remove the Strech Foil.
2 Take away the Service Door

Use the triangle key that you’ll find in the
accessoires box from the imaging module.

3 Remove the Screws from the Wooden
Balk
Remove the screws that are used to fix the
special wooden-foam beams to the pallet.
4 Lift the Module from the Pallet

Lift the module with preferably the side
with the lift motor closest to the fork lift.
WARNING
Crushing Hazzard
Don’t stand underneath the machine when dismounting the wooden
beams.
5 Unscrew the Leveling Bolts from the
Wooden Beam
Unscrew the leveling bolts from the wooden
beam so you can remove it. Keep the
levelling bolts for later use.
6 Mount the Levelling Bolts in the Module

and Lower Down
Mount the levelling bolts in the Module
and gently lower down. Use the levelling
plates to protect the floor. You can find the
levelling plate in the accesoires box.
7 Transport the Machine to the Installation

Site
Transport the cassette module to the
installation site with a pallet lifter.
Don’t forget to safely transport the service
cover you did remove in the beginning.
Bring the cassette module 20cm before the

loading module.

8 Route all the Cables
Route all the cables at the back of the loader
trough the cut-out to cassette module.
9 Push the Module Against the Ioader

Push the cassette module against the loader
moudule.
10 Bring the Module at the Same Height
Put a levelling plate underneath each
levelling bolt. You will find these levelling
plates in the accessories box.
Bring the left side of the cassette module at
the same height as the rest of the machine.
when the height is correct you will feel that
there is no difference between the 2
modules .
11 Continue
unlocking procedure
Procedure
1 Open the Cassette Door
You can open the cassette door by lifting up
the cassette lock and push the door open at
the same time.
2 Remove the Cassette Lock Bar(s)

Remove the cassette lock(s) by removing all
the bolts.
Procedure - 8.5

3 Remove the Cassette Locks
At the back side, each cassette is fixed with
2 screws. Remove these screws, so that the
cassette can move freely.
4 Remove the Magnet Strap

Cut the straps from the magnet actuator.
Procedure
1 Levelling
Put 2 levels underneath the module and
level the module by adjusting the levelling
screws. The height of the module must be
the same as the rest of the machine. A good
rule of tumb: the edges of the 2 modules
must be at the same height, (see fig ->).
The use of a magnetical level is very

praktical.
2 Fix the positions

Once the machine is levelled, secure the
levelling bolts by fixing the nut against the
chassis.

3 Fix the Modules Together
Bring the loading module to the correct
height and fix it to the loading module.
The bolts can be found in the accesoires
box.
4 Continue
Continue by performing the electrical and
pnematical connection.
Electrical and Pneumatical Connection
Procedure
1 Connect the Lift Drive Power Cable
Open the lift drive with a flat screwdriver.
Connect cable W380 to the lift drive.

• W3801 - A61;L1
• W3802 - A61;L2
• W380PE - A61;PE2
Fix the cable with the strain relief below the

drive
More info in the schematic diagram page

172.1.
Procedure - 8.7

2 Connect the Lift Drive CAN Cable
Connect cable W452 to the lift drive.
• W452; white - A61;22
• W452; brown - A61;23
Close the lift drive with a flat screwdriver.

172.2.
3 Connect the Emergency Stop Connectors

Connect the 2 plugs of the emergency stop
circuit. The 2 plugs are XEPF and XEC.

102.1.
4 Connect the Cassette Signals Connector

Connect the 25 pins connector J16 (W453)
to the cassette PCB.

172.5.

5 Connect the Cassette PCB Power Supply
Connect plug J17 (W450) to the cassette
PCB.
172.4.
6 Connect the Cassette Front Sensor

Connect the plug from the cassette front
sensor W463 to plug J7 of the cassette
PCB.
7 Connect the Tubes for the Cassette Left/

Right Cylinder
Connect the 2 tubes for the cassette left/
right cylinder.
8 Connect the Tubes for the Cassette Front/

Back Cylinder
Connect the 2 tubes for the cassette front/
back cylinder.
Do not tighten the tubes too much, the

cylinder will move left and right.
9 Connect the Earth Strip

Fix the earth strip on the cassette module.
Procedure - 8.9

10 Continue
Continue by performing the main electrical
connection. See:
“Performing the Main Electrical
Connection” on page 10.1
Introduction - 9.1
Chapter 9: Installing the Cooler

Overview
Introduction During operation mode of the UV-Setter the DMD gets hot. To avoid any damage on the machine a
cooler is needed.
In this \ Overview ..................................................................................................9.1

Z Introduction .....................................................................................9.1
Z In this chapter..................................................................................9.1
\ Version 1 .................................................................................................9.2
X Uncrating and Positioning .....................................................................9.2
Z About ..............................................................................................9.2
Z Positioning.......................................................................................9.2
X Installation ..........................................................................................9.2
Z About ..............................................................................................9.2
Z Procedure ........................................................................................9.2
X Filling Up ............................................................................................9.3
Z Procedure ........................................................................................9.3
9.2 - Chapter 9: Installing the Cooler
Version 1
Uncrating and Positioning
About Always try to uncrate the cooler as close to his final position
Always transport the cooler horizontally. The cooler must be installed horizontally and at the same floor
level as the UV-setter
Positioning Position the elements as described in the Installation manual of the cooler.
Installation
About The installation procedure describes the standard installation of the cooler. The standard cooler can be
placed max 5m from the UV-Setter. However if needed the cooler can be placed up to 50m away from
the UV-Setter depending on the tubes that are used . Keep in mind that if you use longer tubes you
have to lenghten the signal cable as well. See:
“Cooler” on page 2.6
Procedure
WARNING
Before connecting the cooler always first read the manual from the
cooler.

1 Execute Installation Procedure
Execute the installation procedure as
described in the installation manual from
the cooler
2 Connect the Hoses to the Machine
Connect the red and blue hoses to the
machine.
3 Switch Off the Cooler

Ensure that the main power cord is
unplugged.
Procedure - 9.3

4 Connect the Signal Cable
Connect the signal cable to the machine.
5 Connect the Power Plug

If the power supply meets the specifications
for the cooler; connect the plug to the
socket.
Filling Up
Procedure
WARNING
Before executing this procedure the cooler always first read the
manual from the cooler.

1 Switch Off the Cooler
Ensure that the power cord is unplugged.
2 Fill the Tank
Slowly fill the tank with coolant trough the
filling tupe up to the -MAX- mark on the
liquid level indicator.
3 Switch the Cooler “on” and “off ”

Plug in the power cord.
After 1 min switch off the cooler by
unplugging the power cord.
4 Visually Inspect the Circuit
Visually inspect the complete circuit for
leakages.
9.4 - Chapter 9: Installing the Cooler

5 Top up the coolant level
Check the coolant level and if necesarry top
up the coolant level.
6 Switch on the Cooler
Plug in the power cord.
Introduction - 10.1
Chapter 10: Performing the Main Electrical Connection

Overview
Introduction
In this \ Overview ................................................................................................10.1

chapter X Overview............................................................................................10.1
Z Introduction ...................................................................................10.1
Z In this chapter................................................................................10.1
\ Version 1 ...............................................................................................10.2
X Electrical Connection of the UV-Setter Series 400&800.........................10.2
Z Electrical Safety .............................................................................10.2
Z Regulations....................................................................................10.2
Z Mains Supply Cable Specifications ...................................................10.2
Z Procedure ......................................................................................10.2
10.2 - Chapter 10: Performing the Main Electrical Connection
Version 1
Electrical Connection of the UV-Setter Series 400&800
Electrical
Safety
Regulations Electrical connections should be made to the applicable national electrical code for that country or area
(for example NEC in the USA).
Mains Supply
Cable Be aware that the power supply cable for the UV-Setter Series 400&800 is to be
Specifications supplied by the customer himself.
The power supply cable has to comply with the following specifications:
Voltages The UV-Setter Series 400&800 can be connected to the AC power supply line
as shown below:
Single phase 200-240 VAC (±10%) (50/60Hz) + earth.
Earth Connection There must be a separated earth connection with a resistance less than 2 ohm.
Power The UV-Setter Series 400&800 has a maximum power consumption of 600 W
or 0.8 HP.
Over Current Branch circuit portection is not provided, therefore an 20A over-current
Protection protection needs to be installed in the power supply line .
High Leakage The UV-Setter has a high Leakage Current
Current
CAUTION
To avoid electrical hazzard or overheating, verify if the local
electrical supply matches with the unit’s electrical ratings.
Procedure
1 Open the Service Cover
Open the service cover with the main
electrical switch on the back of the
machine.
Procedure - 10.3

2 Remove the safety plate
Remove the safety plate by unscrewing the
2 screws at the bottom of the plate.
3 Insert the Cable

Loosen the strain relief by turning counter-
clockwise.
insert the cable trough the strain relief.
WARNING
High Leakage Current
Earth connection essential before connecting supply
4 Connect the Conductors.
Start with connecting the earth conductor,
followed by the rest of conductors.
5 Fix the Strain Relief

Fix the strain by turning clockwise.
Ensure that the cable is fixed.
6 Fix the Security Plate

Fix the previously removed security plate.
10.4 - Chapter 10: Performing the Main Electrical Connection

7 Close the Cover
Close the cover.
8 Continue
• If an unloader is installed, continue by
performing the press air Connection
connection. See:
“Performing the Press Air Connection” on
page 11.1
• If no Unloader is installed, continue by
performing the commisioning
procedure.
Introduction - 11.1
Chapter 11: Performing the Press Air Connection

Overview
Introduction This chapter describes the details about the press air connection. There is a difference between the 2
major machine types. The procedure for a manual machine is not the same as for the automatic types.
In this \ Overview ................................................................................................11.1

Z Introduction ...................................................................................11.1
Z In this chapter................................................................................11.1
\ Version 1 ...............................................................................................11.2
X Pneumatic Connection ........................................................................11.2
Z Regulations....................................................................................11.2
Z Specifications ................................................................................11.2
Z Procedure For Automatic Machines ..................................................11.2
Z Procedure For Manual Machines ......................................................11.3
11.2 - Chapter 11: Performing the Press Air Connection
Version 1
Pneumatic Connection
Regulations The pnematic connection should be made according to the applicable national pneumatic code for that
country or area.
Specifications
Press Air The maximum air consumption of the Manual Machines is 800 l/min or 212
Consumption gallon/min.
Manual Machines
Press Air The maximum air consumption of the Automatic Machines is 800 l/min or
Consumption 212 gallon/min.
Automatic
Machines
Air Pressure The press air connected to the UV-Setter Series 400&800 must be between 6
and 12 bar or between 87 and 174 PSI.
Press Air To avoid dammage to the UV-Setter Series 400&800, it’s important that the air
Requirements is filtered, non-lubricated and condense free.
Hose Coupling The coupling MOUNTED in the UV-Setter Series 400&800 is manufatured
by Legris, le 9087 25 13, Male Probe, BSP parallel.
Procedure
For Step Description Figure
Automatic 1 Open the Service Cover
Machines
Open the service cover of the loader.
2 Insert the Hose

Insert the hose in the machine.
Procedure For Manual Machines - 11.3

3 Connect the Hose.
Connect the hose to the male probe.
4 Open Valve and Regulate Pressure.

Open the main Valve (1). Regulate the
pressure to 6 bar with valve 2.
5 Close the Cover
Procedure
For Manual Step Description Figure
Machines 1 Open the Service Cover
Open the service cover of the loader.
11.4 - Chapter 11: Performing the Press Air Connection

2 Insert the Hose
Insert the hose in the machine.
3 Connect the Hose.

Connect the hose to the male probe.
4 Open Valve and Regulate Pressure.

Open the main Valve (1). Regulate the
pressure to 6 bar with valve 2.
5 Close the Cover

Introduction - 12.1
Chapter 12: Connecting the Peripheral Devices

Overview
Introduction .
In this \ Overview ................................................................................................12.1

Z Introduction ...................................................................................12.1
Z In this chapter................................................................................12.1
\ Version 1 ...............................................................................................12.2
X Ethernet Connection ...........................................................................12.2
Z About ............................................................................................12.2
Z Procedure ......................................................................................12.2
X Processor...........................................................................................12.2
Z About ............................................................................................12.2
Z Plug Pinout....................................................................................12.2
Z Procedure ......................................................................................12.3
12.2 - Chapter 12: Connecting the Peripheral Devices
Version 1
Ethernet Connection
About The UV-Setter must be connected to the UVSS trough an ethernet connection. This can be
accomplished by making a direct connection or trough a network.
The IP adress can be freely choosen as long as the UV-Setter and the UVSS are in the same range.
The file transport happens via TCP/IP protocoll. More information can be found in the UVSS
Operator‘s Guide that can be opened via the „Help“ menu in the UVSS software. See also
“Network Connections” on page 2.11
Procedure
1 Open the Service Covers
If needed open the sercive covers
2 Connect the Ethernet Cable
Plug the ethernet cable into the sockect
from the machine.
Processor
About The UV-Setter can monitor the ready line of the processor. When the processor is ready to accept plates
from the UV-Setter, the processor needs to close a contact. If the contact is opened, the UV-Setter will
interpret this as “Processor not ready” and therefore will not unload the plate to the processor.
The UV-setter is also equipped to remote start-stop the processor. The UV-Setter will supply 24VDC
in order to start the processor.
Plug Pinout The plug from the processor must be subD9 Male. The ready line lies between pin 1 (24VDC) and pin
2 (GND).
The remote start stop line lies between pin 3 (24VDC) and pin 4 (GND).
Procedure - 12.3
Figure 12.1: Processor plug pinout
Please check the following parameter ("Menu" --> "Parameter"):

"Machine\processor ready\IsActive" should be on "1".
Procedure
1 Open the Service Covers
If needed open the service covers
2 Connect the Plug
Connect the plug from the processor to the
socket of the machine.
12.4 - Chapter 12: Connecting the Peripheral Devices
Introduction - 13.1
Chapter 13: Commisioning and Safety Check

Overview
Introduction
In this
chapter
13.2 - Chapter 13: Commisioning and Safety Check
Version 1
Commisioning
Safety Make sure that you have read and understand the safety chapter of the installation, service and user
manual.
Procedure
1 Switch Off all the Fuses
Make sure all fuses at the front panel are off.
2 Measure the Tension on the Input

Measure between clamp 1 and 2 of X0
You should have 220-230VAC.
3 Switch on the Main Switch Q1

Switch on the main switch, the switch sould
display “on”.
Procedure - 13.3

4 Switch on Fuse F1
Switch on F1. This will enable the 24VDC
from G1. This will supply the Pilz safety
relay. Check if the lights from the safety
relay (Pilz K4) are all green. A red light
indicate a fault situation.
5 Check the Pilz Circuit

If everything is ok no red lights should be shown on the Pilz PLC verify the following
things:
• Test every EM button. Input I0 and I14=”1” when nothing pressed, check if the state of
the input changes to “0” if you press an Emergency button. Test this for every EM
button.
• Front door closed=I15 and I16=”1” when OK. (hard to see if you have no extra
interlock keys)
• Back door closed=I17 and I18=”1” when OK.
• Optional: Loader back door closed=I2=”1” when OK.
• Test Load door, Door Closed=> I3=off and I4=on; Door Open=> I3=on and I4=off
6 Press Start
Press the Start button on the front door.
K1 should attract
7 Switch on Fuse 3
Switch on fuse 3, the fan “Air In” should
operate right now (located at the back).
13.4 - Chapter 13: Commisioning and Safety Check

8 Switch on the Fuses
Switch on the fuses one by one starting with
F2.
The fuses F5 and F7 need to kept switched
off !
If no cassette module is installed, the fuse
F9 needs to be switched off.

UV Setter 400-800 Installation en V03 Draft

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UV Setter 400-800 Installation en V03 Draft

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INSTALLATION MANUAL

UV-SETTER SERIES 400 & 800

Copyright © 2008 Punch Graphix International nv

UV Setter, UV Setter Server are trademarks of Punch Graphix International nv.

Chapter 1: Introduction 1.1

Chapter 2: Pre Installation 2.1

Flooring Requirements 2.6

Environmental Specifications 2.8

Room Requirements 2.9

Chapter 3: Safety 3.1

Specific Safety Information 3.2

Chapter 4: Transport of the Crates 4.1

Handling the Crates 4.2

The Crates 4.3

Shipping and Storage of the Engine 4.5

Chapter 5: Installation of Manual Module 5.1

Uncrating and Positioning the Elements 5.1

Unlocking the Elements 5.6

Leveling the Elements 5.7

Chapter 6: Installation of the Loading Module 6.1

Unlocking the Elements 6.6

Leveling the Elements 6.8

Electrical and Pneumatical Connection 6.8

Chapter 7: Installation of the Single Cassette 7.1

Adjusting the Elements 7.2

Chapter 8: Installation of the Multiple Cassette Module 8.1

Unlocking the Elements 8.4

Leveling the Elements 8.5

Electrical and Pneumatical Connection 8.6

Chapter 9: Installing the Cooler 9.1

Chapter 10: Performing the Main Electrical Connection 10.1

Chapter 11: Performing the Press Air Connection 11.1

Chapter 12: Connecting the Peripheral Devices 12.1

Chapter 13: Commisioning and Safety Check 13.1

Chapter 2: Pre Installation

In this \ Overview ..................................................................................................2.1

Figure 2.1: Plate Output (all values in mm)

Figure 2.4: footprint of a multiple cassette machine (all values in mm)

Figure 2.5: Position of the cooler

More information can be found in the operating manual of the cooler.

Floor Wooden floor or raised computer floors are forbidden.

Noise The maximum noise emission of the UV-Setter is 73dB(A)

Compressed Only applicable for machines with unloader, trolley or cassettes.

Figure 2.11: TeamViewer Setup

Figure 2.12: Cooling connections

Figure 2.13: Top view of the manual machine

Figure 2.14: Top view of the single cassette machine

Figure 2.15: Top view of the multiple cassette machine

In this \ Overview ..................................................................................................3.1

Specific Safety Information

Chapter 4: Transport of the Crates

In this \ Overview ..................................................................................................4.1

In this \ Overview ..................................................................................................4.1

Handling the Crates

Transport The crates have to be transported always upright.

Figure 4.1: Dimension of the pallet

The table below showsthe dimensions of the crate:

Height Length Width

*If no automatic unloader is installed you can substract 20 kg.

Machine Type Illustration of packaging

Shipping and Storage of the Engine

Environment • The environmental conditions for shipping and storage are:

Chapter 5: Installation of Manual Module