Scodix Ultra Foil Station - Operator Guide Ultra Foil Station - Operator Guide - Rev 02 Operator...

Scodix Ultra Foil Station Operator Guide

The Scodix Ultra Pro Press with the Scodix Ultra Foil Station (in- line)

Scodix Ultra Foil Station - Operator Guide - Rev 02

Important Notice Page 2 of 37

Important Notice Copyright © 2016 Scodix Ltd. All rights reserved.

All product names are trademarks of Scodix Ltd. Other names are the property of the respective owners. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system or translated into any language or computer language, in any form or by any means, electronic, mechanical or otherwise without prior written permission of Scodix Ltd.

Disclaimer of Warranty

Scodix Ltd. has made every effort to ensure the accuracy and relevancy of the material in this document. It is expected that all sections of this document will be read thoroughly and that all information and procedures should be fully understood. However, Scodix Ltd. assumes no responsibility for any errors that may have been included in this document, and reserves the right to make changes to the document without notice.

Scodix Ltd. makes no warranty of any kind in regard to this document including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.

Scodix Ltd. disclaims any responsibility for incidental or consequential damages in connection with the furnishing, performance or use of this document.

Parts of this document may be based on hardware or software developed by third-party vendors. Scodix Ltd. disclaims any responsibility for the accuracy of this document with respect to such hardware and software, and assumes no responsibility for incidental or consequential damages arising due to discrepancies between this document and such hardware or software.

When the system is operated properly, as specified by Scodix in this and other publications, there is no danger to operators or to equipment. High-voltage power supplies and UV sources are behind protective covers, which should not be removed. Warning labels are attached to each protective cover.

Environmental Policy

Service personnel are advised that when changing any part of the Scodix Ultra Foil Station, care should be taken to dispose of those parts in the correct manner and, where applicable, they should be recycled.

When the lifecycle of parts, such as filters is complete, the product should be disposed of according to the laws and regulations of the local authority.

For more detailed information regarding these recommended procedures, please refer to your local or regional Scodix Ltd.

Scodix is committed to continuously seek and implement the best possible manufacturing procedures and servicing routines.

Part Number: DBK-0026-02 Edition: March 2016

Revision: Rev 02

Compatible with software version: Scodix Ultra Press - V3.1.5 and higher


Important Notice Page 3 of 37

Table of Contents Important Notice ................................................................................................................................................ 2 About this operator guide ................................................................................................................................... 4 Overview ............................................................................................................................................................. 5

Scodix Ultra Foil Station - Rewind/Unwind Specifications ........................................................................ 5 Foiling process description ........................................................................................................................ 5 Component overview ................................................................................................................................ 6

Components inside the Scodix Ultra Foil Station ............................................................................... 6

Operator Safety Precautions ............................................................................................................................... 6 Scodix Ultra Foil Station Lockout Procedures ............................................................................................ 7

To lockout power to the Scodix Ultra Foil Station .............................................................................. 7 To lockout the drive system and energy sources ............................................................................... 8 To lockout the Pneumatic Air System ................................................................................................ 8

Safety Information .............................................................................................................................................. 8 Safety Notice ............................................................................................................................................. 9 Interlocks ................................................................................................................................................... 9 Flammable Liquids and Fumes .................................................................................................................. 9 Material Safety Data Sheets (MSDSs) ........................................................................................................ 9 Handling Polymer and Flushing Fluid ........................................................................................................ 9 Disposing of Consumables and Cleaning Materials ................................................................................... 9 Cleaning liquids........................................................................................................................................ 10 Handling Polymer .................................................................................................................................... 10 Environment ............................................................................................................................................ 10

Working Environment ...................................................................................................................... 10 Illumination Conditions .................................................................................................................... 10 Ventilation ........................................................................................................................................ 10 Noise Level ....................................................................................................................................... 10

Scodix Ultra Foil Station – Main Control Touch Screen .................................................................................... 11 Main Control Touch Screens ................................................................................................................... 11

Running Information Screens ........................................................................................................... 12 Alarm Screens ................................................................................................................................... 15

Working with the Scodix Ultra Foil Station ....................................................................................................... 16 Measuring the diameter of the roll of foil, and an “empty” core ........................................................... 16 Loading a roll of foil ................................................................................................................................. 17 Loading an “empty” core ......................................................................................................................... 18 Threading the foil .................................................................................................................................... 20 Setting roller type and diameter parameters .......................................................................................... 22

Setting the Rewind roll diameter parameters .................................................................................. 24 Setting the Unwind roll diameter parameters ................................................................................. 26 Checking that the new settings are now updated into the memory ............................................... 28 Passing control back to the Scodix Ultra Press ................................................................................. 29

Setting the tension of the Rewind and Unwind rolls ............................................................................... 30 Setting the Foil settings in the Job ticket on the Scodix Ultra Press ........................................................ 31

Selecting the “Selective Foil” area .................................................................................................... 32

Operating the Scodix Ultra Foil Station ............................................................................................................. 34 Operating in Local mode ......................................................................................................................... 34 Starting the Scodix Ultra Foil Station ....................................................................................................... 34 Stopping the Scodix Ultra Foil Station ..................................................................................................... 34


About this operator guide Page 4 of 37

Routine Maintenance ....................................................................................................................................... 35 Daily Maintenance ................................................................................................................................... 35 Weekly Maintenance ............................................................................................................................... 35

Appendix ........................................................................................................................................................... 36 Threading for Cast & Cure (not currently in use) .................................................................................... 36

Document History ............................................................................................................................................. 37

About this operator guide This Operator Guide should be considered as part of the Scodix Ultra Foil Station, should be referred to regularly. A copy of the Operator Guide must be kept with the Scodix Ultra Foil Station at all times. The instructions contained herein will be invalidated should any modification to the Scodix Ultra Foil Station or to the control system be carried out without the approval of the supplier. Scodix reserves the right to amend in any way the contents of this Operator Guide, at any time. All amendments to the contents of the Operator Guide supplied by Scodix must be incorporated in to the text by the end user. It is the end users responsibility to supply the Operator Guide to any subsequent user of the Scodix Ultra Foil Station. The Scodix Ultra Foil Station should only be operated and worked upon by personnel who have been trained and have read and understood the contents of the Operator Guide. The Scodix Ultra Foil Station should only be used within the limits that it was designed for which is contained within the Scodix Ultra Foil Station specification.


Overview Page 5 of 37

Overview The Scodix Ultra Foil Station is designed to apply cold foil, or “cast & cure” effects to sheets indexed through the Scodix Ultra Press. (Note, the “cast & cure” functionality is not currently in use.) Users should not operate or maintain this Scodix Ultra Foil Station until they have been instructed in the correct procedures by qualified personnel, and have read and understood all the safety precautions and operating procedures contained in this Operator Guide. A copy of this Operator Guide should be kept near the Scodix Ultra Foil Station at all times so that it may be referred to without delay.

Scodix Ultra Foil Station - Rewind/Unwind Specifications Maximum web width 545 mm

Maximum reel diameter 300 mm

Material Thickness 12-2000 Micron

Unwind core sizes 76 mm

Foiling process description The sheet foiling parameters are preloaded into the Scodix Ultra Foil Station prior to the sheet arriving at the foil station. An encoder is fitted to the preceding conveyor to measure the speed of the line. This encoder is used to set the speed of the conveyors in the foiling section. When the sheet transfers to the foiling section it passes under the infeed heater which warms the polymer slightly prior to foiling if required. The sheet travels on the infeed conveyor and is detected by the infeed paper sensors. Activation of these sensors will reset the foiling encoder to zero and increments the sheet counter by one. The foiling encoder is used to determine to position of the sheet at the index nip. Prior to entering the index nip the sheet passes under the infeed air jet which directs the sheet's leading edge towards the nip reducing the effect of sheet curl which can cause paper jams. The sheet then passes through the index nip where the sheet meets the foil. The nip will move up and down when the encoder count synchronizes with the preloaded sheet parameters. When the nip is down foil is attached to the polymer. As the leading edge of the sheet exits the nip it passes under the outfeed air jet, this ensures the foil peels away from the sheet. The sheet then passes under the UV lamp to cure the polymer under the foil. The sheet then passes under the outfeed paper sensor which counts the sheet out, a missing or slow to exit sheet will actuate a paper jam alarm stopping the Scodix Ultra Foil Station.


Operator Safety Precautions Page 6 of 37

Component overview Components inside the Scodix Ultra Foil Station Figure 1: Components inside the Scodix Ultra Foil Station

Operator Safety Precautions To ensure the safety of Scodix Ultra Foil Station operators and maintainers, the safe working practices and precautions (including hazard WARNING and CAUTION notices) in this Operator Guide must be observed at all times.

• The inclusion of a WARNING notice indicates that a danger exists which would result in injury to or death of a person.

• The inclusion of a CAUTION notice indicates that a risk exists that could result in the Scodix Ultra Foil Station being damaged.

WARNING! Before operating ensure that no unauthorized person is near the Scodix Ultra Foil Station, and that it is safe to proceed. Beware of possible trap points (places where loose clothing, hair, jewelry, etc. may become trapped), between moving parts and between moving parts and fixed parts; or between the web and rolls; or between rolls.

WARNING! The Scodix Ultra Foil Station drive and the energy sources lock-out procedure must be implemented before carrying out any set-up, adjustment or maintenance work not requiring the Scodix Ultra Foil Station to be run. See the “Scodix Ultra Foil Station Lockout Procedure” on page 7.

Safety precautions to be observed at all times by operators also include:

• Operators must ensure that the work area is free from any debris, oil spills or any item that could obstruct clear access to the Scodix Ultra Foil Station. Do not operate the Scodix Ultra Foil Station when the surrounding area is wet, slippery or fouled with web materials.

• Operators must be familiar with the location of all the Emergency Stop buttons and other

Manual alignment laser beam

Rewind roller Unwind roller

Index nip

Scodix UV lamp

Infeed sheet sensors

Web break sensor

Heater

Infeed airjet adjuster

Rewind twitch roller

Cast and cure roller

Unwind twitch roller


Operator Safety Precautions Page 7 of 37

• safety devices and must check the action of the emergency stop function before operating the Scodix Ultra Foil Station at the beginning of a new shift. At this time, operators must ensure that all Unwind/Rewind shaft support clamps are closed correctly before proceeding

• All non-essential personnel and unauthorized visitors must be kept at a safe distance (minimum of 1.6m) from the Scodix Ultra Foil Station when preparing to operate it and when it is operating.

• Do not wear bulky or torn clothing, long sleeves, neckties or jewelry while operating the Scodix Ultra Foil Station. Wear safety shoes and other items at all times. Long hair must be tied back.

• Ensure all safety guards, covers and doors are correctly in place and are in good condition before starting the Scodix Ultra Foil Station. Do not tamper with fixed guards or reach through, around or behind them.

• Do not touch any moving part when the Scodix Ultra Foil Station is operating. Do not clean glue, web particles or other material from the Scodix Ultra Foil Station during operation.

• Do not attempt to operate the Scodix Ultra Foil Station at a rate/capacity other than that for which it is designed.

• Any faulty, loose or misplaced electrical cables or pneumatic pipes must be reported immediately and only dealt with by authorized engineers.

• Never use damaged Rewind/Unwind shafts. • Safety precautions for maintenance engineers • Observe all the safety precautions stated above and. • Do not clean, oil or grease, adjust or service any part or assembly while the Scodix Ultra Foil Station is in

operation. Do not make adjustments to Scodix Ultra Foil Station parts or assemblies, which are on or near moving parts.

• Before proceeding with any cleaning, adjustment or service work, ensure that the Scodix Ultra Foil Station drive and the energy sources lock-out procedure has been applied (in which pneumatic and electrical supply main switches are padlocked [isolated] in their OFF positions. (See the “Scodix Ultra Foil Station Lockout Procedure” on page 7.).

• If it is essential to operate the Scodix Ultra Foil Station for inspection, servicing or repair purposes, exercise extreme care to avoid any injury caused by exposed, unguarded or moving parts.

• Never remove safety guards or covers, or open safety doors while the Scodix Ultra Foil Station is in operation.

Scodix Ultra Foil Station Lockout Procedures Health and safety regulations dictate that it is mandatory to perform a power lockout procedure, as described in this section, before performing maintenance on any subsystem in the Scodix Ultra Foil Station that has a mechanical or an electrical component.

Locking out the Scodix Ultra Foil Station protects the operator or maintenance person from being inadvertently electrocuted. It requires that you either:

• Install a lockable electrical power energy-isolating device (for example, a fuse box), to prevent activation of the Scodix Ultra Foil Station during service or maintenance procedures. Or,

• Unplug the Scodix Ultra Foil Station so that the plug is under the exclusive supervision and control of the person performing the service or maintenance.

To lockout power to the Scodix Ultra Foil Station The Scodix Ultra Foil Station Electrical supply is isolated from the Scodix Ultra Press. The isolator on the Scodix Ultra Foil Station can be locked off but power will still be present on the incoming terminals. The Main supply is fed from the Scodix Ultra Press. This Mains air supply should be isolated and locked off before any maintenance work is carried out.


Safety Information Page 8 of 37

Note: Every person who is working on the Scodix Ultra Foil Station should have his or her own individual pad-lock and key. Each person must apply their own pad-lock to lock off the supplies when carrying out maintenance work. These pad-locks should only be removed when it is safe to do so and when the maintenance work is complete.

1. Disconnect the Scodix Ultra Foil Station from all electrical power sources, and turn off the Main Power Supply.

2. Lock the isolator switch in the OFF position to prevent anyone from inadvertently turning on the electricity.

3. Switch off the external Uninterrupted Power Supply (UPS). 4. After the Scodix Ultra Foil Station is turned off, wait 20 seconds for residual stored electrical energy to

discharge.

To lockout the drive system and energy sources To ensure the safety of personnel and the Scodix Ultra Foil Station during set-up, adjustment or maintenance procedures in which the Scodix Ultra Foil Station is not to be operated, the installation must be isolated from all energy sources (i.e. electrical and pneumatic) before commencing any work.

To lockout the Pneumatic Air System The Scodix Ultra Foil Station pneumatic regulator set is mounted on the Pneumatic Panel. The Main air supply is fed from the Scodix Ultra Press. This Mains air supply should be isolated and locked off before any maintenance work is carried out.

Safety Information

IMPORTANT SAFETY NOTICE: The press uses Scodix PolySENSE™ Polymer:

• This polymer may cause eye irritation. • This polymer may cause skin irritation after prolonged or repeated contact.

Read and practice the safety guidelines as outlined in the Material Safety Data Sheet (MSDS). Print out the MSDS for the polymer, and post it in the work area as required by prevailing law. An excerpt of the MSDS is provided below:

• Personal Safety: The operator should wear rubber gloves, a protective apron and safety glasses with side shields when handling polymers.

• Handling Polymer Spills on Surfaces: Observe the following precautions:

• Ventilate the area. • Contain the spill. • Cover with absorbent material. • Collect spilled material. • Clean up residue with lint-free cloth soaked with Ethanol / IPA • Place in a closed container. • Do not release to waterways or sewer. • Incinerate in a permitted hazardous waste incinerator.

• Handling Spills on a Person: Observe the following precautions:

• Eye contact: Immediately flush eyes with large amounts of water. Get immediate medical attention. • Skin contact: Flush skin with large amounts of water and soap. If irritation persists, get medical attention. • Inhalation: Remove person to fresh air. If not breathing, give artificial respiration and get immediate

medical attention. If breathing is difficult, get immediate medical attention.



• If swallowed: Call a physician immediately. Do not induce vomiting, unless instructed to do so by a physician.

• Never give anything orally to an unconscious person.

Safety Notice The Scodix Ultra Foil Station contains a UV lamp and high-voltage power supplies. The system also has moving parts. There is no danger to persons or equipment when the system is operated in accordance with the directions provided by Scodix in this and other publications. All high-voltage power supplies are located behind protective covers with warning labels attached. Do not remove these protective covers.

Interlocks The main hood has an interlock switch. Opening the main hood during operation immediately stops all moving parts.

Flammable Liquids and Fumes If you have any questions regarding the safe operation of the Scodix Ultra Foil Station, do not hesitate to contact your local support representative.

Material Safety Data Sheets (MSDSs) The MSDS for Scodix PolySENSE™ can be found in the Scodix web site. The MSDS for other cleaning fluids used for cleaning e.g. Acetone, IPA, PM, alcohol are to be supplied by the chemical vendor. Keep the MSDS readily available in the work area. Read and consult it for your personal protection. Keep the MSDS in a protective plastic cover.

Handling Polymer and Flushing Fluid Use only Scodix PolySENSE™ Polymer and Flushing fluid supplied by Scodix with the Scodix Ultra Foil Station. When handling Scodix PolySENSE™ Polymer or Flushing fluid, follow these safety practices:

• Keep the room where the Scodix Ultra Foil Station is situated well ventilated. • Clean all spills immediately, and dispose of the used cleaning materials in accordance with local

regulations. • Do not smoke near the press. • Do not allow any ignition sources near the press, such as an open flames, halogen lights, heaters, pilot

lights, or stoves. • Do not allow sparks (static, electrical, or mechanical), or spark-producing equipment near the press.

Disposing of Consumables and Cleaning Materials All used consumables and cleaning materials must be disposed of in accordance with the relevant regulations. Consult your local authorities to determine the correct manner to dispose of the following wastes:

• Lint-free cleaning cloths • Contaminated chemical-resistant gloves • Empty coating-material containers

NOTE: For disposal of items other than those listed above, contact your local service provider.



Cleaning liquids Adhere to the local regulations regarding the usage of Acetone, Ethanol or IPA.

WARNING! Acetone, Ethanol and IPA are extremely flammable liquids. Do not use it near an open flame or sources of electrical sparks. Do not apply acetone to hot surfaces.

Handling Polymer The following precautions are mandatory when handling or storing coating materials. It is also mandatory to adhere to the MSDS specifications for each material:

• Store the Scodix PolySENSE™ Polymer in a dry and cool location without direct sunlight or heat. • Ensure that containers are tightly closed at all times. When a container is damaged, transfer its contents

to a dry, clean and suitable container that is sealed tightly. • Only trained personnel are permitted to handle Scodix PolySENSE™ Polymer. • Be especially careful while draining the air conditioner drain tank and avoid splashing. A suitable

receptacle must be used. • Wear safety glasses with side shields, long-sleeve overalls and protective gloves as indicated in MSDS

when handling Scodix PolySENSE™ or any other cleaning fluid. • Scodix PolySENSE™, Flushing fluid, acetone, IPA, Alcohol and all waste fluids must not be ingested. • Use the entire content of the PolySENSE Container into the press tanks.

Environment Make sure you have storage space for the Polymer (Ink) and the foil under the following conditions:

• Store the polymer in an environment below 35°C (95°F). • Avoid direct sunlight, UV radiation and strong oxidizers. • Keep containers tightly closed in a dry, cool and well-ventilated place. • Store in a place that is only accessible to authorized personnel. • Keep out of reach of children. • Only store polymer in the original HDPE container. • Never mix the polymer from one container with that from another container. • Do not store near inert gas, such as nitrogen. • Keep the container away from oxidizing materials, acids and bases.

Working Environment The production area should be reasonably free of dust and other airborne particles. Dust and particles can affect the printing quality. The temperature and humidity of the working environment should be kept within the limits listed in the Media Specifications.

Illumination Conditions Do not expose the Scodix Ultra Foil Station to direct sunlight.

Ventilation Make sure the production room is adequately ventilated.

Noise Level The operator should wear Ear Protection if required.


Scodix Ultra Foil Station – Main Control Touch Screen Page 11 of 37

Scodix Ultra Foil Station – Main Control Touch Screen The Scodix Ultra Foil Station is operated remotely by the Scodix Ultra Press. However it can be operated in Local mode through the Main Control Touch Screen, for example when threading the web.

Figure 2: Scodix Ultra Foil Station - Main Control Touch Screen

Emergency Stop Lock-Down Button

Pressing the Emergency Stop button brings the Scodix Ultra Foil Station drive and auxiliary functions to a rapid stop, and the button will automatically lock down. When the cause of the emergency condition is cleared, the button must be released by a turning and pull action.

NOTE: The Emergency Stop control must not be used for normal production stopping of the Scodix Ultra Foil Station.

E-Stop Reset

The E-Stop Reset is automatic once the Scodix Ultra Foil Station safety circuit and the Scodix Ultra Press safety circuit are true. The Main Control Touch Screen will indicate if the Emergency Stop is active, in the alarm screens.

Main Control Touch Screens The Scodix Ultra Foil Station has a Local and a Remote Main Control Touch Screen.

Figure 3: Home Screen - Local Control Home Screen - Remote Control

Emergency stop button

Main Control Touch Screen



The home screen provides information about the current mode of operation (top right text in blue). The modes of operation are:

Standby • Bypass • Foiling • Cast & Cure • Attention • Local •

The home screen allows the operator to access the following screens:

Running screens (described below) • Sheet info screens (these screen will not be described in this document.) • Alarm Screens (described on page 15) • Engineering Screen (these screen will not be described in this document.) • Local Control screens (described in “Working with the ” on page 16) • Tension Screen - allows the operator to quickly change the Unwind or Rewind tension values •

Running Information Screens Running Information Screen 1

Running screen 1 provides the operator with key information about the machine operating state.

MACHINE STATUS

This provides information about the Scodix Ultra Foil Station operating state:

Emergency stop • Safe to run • Running Stopping • Rewind at maximum diameter • Not safe to run • Web break • Unwind Diameter stop •



SCODIX STATE

This displays the Scodix Ultra Foil Station state, which was requested by the Scodix Ultra Press.

Off • Bypass • Foiling • Cast & Cure • Attention • Local •

This status request should match the machine status display in the top right of the screen.

REWIND DIAMETER

This shows the actual Rewind diameter. When this value reaches a pre-set maximum (set in the Engineering screen), the Scodix Ultra Foil Station will stop on a diameter stop.

UNWIND DIAMETER

This shows the actual Unwind diameter. When this value reaches a pre-set minimum (set in the Engineering screen), the Scodix Ultra Foil Station will stop on a diameter stop.

Navigation buttons

Pressing the NEXT button takes the operator to the RUNNING SCREEN 2. Pressing the HOME button returns the operator to the HOME screen.

Running Information Screen 2

TOTAL SHEETS ON

This displays the count of the number of sheets that have entered the Scodix Ultra Foil Station. The value is incremented each time a sheet passes the infeed sheet detection sensors. The blue reset button resets the SHEETS ON and SHEETS OFF count.

TOTAL SHEETS OFF

This displays the count of the number of sheets that have exited the Scodix Ultra Foil Station. The value is incremented each time a sheet passes the outfeed sheet detection sensors.

ULTRA-POINTER

This displays the sheet number which currently being processed by the Scodix Ultra Press. This sheet number will be loaded in the FIFO register.



FOILER POINTER

This displays the sheet number which currently being processed by the Scodix Ultra Foil Station.

Navigation buttons

Pressing the HOME button returns the operator to the HOME screen. Pressing the NEXT button takes the operator to RUNNING SCREEN 3. Pressing the BACK button returns the operator to RUNNING SCREEN 1.

Running Information Screen 3

LAMINATING DRIVE SPEED

This shows the speed of the Scodix Ultra Foil Station conveyor.

FOILER THREADED STATE

This shows the status of how the Scodix Ultra Foil Station has been threaded.

NO WEB: Scodix Ultra Foil Station thread state not selected. • FOIL STATE: Scodix Ultra Foil Station threaded for foiling operation. • CAST STATE: (not currently in use) Scodix Ultra Foil Station threaded for cast & cure operation. •

Navigation buttons

Pressing the BACK button returns the operator to RUNNING SCREEN 2. Pressing the HOME button returns the operator to the HOME screen.



Alarm Screens The alarm screen allows the operator to view all active alarms.

Alarms that can be displayed are:

• Machine not safe to run: Scodix Ultra Foil Station unable to run, because the running conditions do not meet the safety conditions.

• Emergency stop: Emergency stop circuit activated. • Ultra Comms Fault: Communication failure between Scodix Ultra Foil Station and the Scodix Ultra

Press. Drives Comms faults: Communication error between PLC and Drives. • Drives not safe to run: Faulty drives. • Encoder Direction: Mismatch between Unwind & Rewind Directions. • Web break: Common web break alarm indicating a web break has been detected. • Web break sensor 1: Web break 1 sensor activated. • Web Break Sensor 2: Web Break 2 sensor activated. • Web Break Sensor 3: Web Break 3 sensor activated. • Web Break Sensor 4: Web Break 4 senor activated. • FIFO Empty: FIFO register is empty. • Thread Error: Mismatch between Scodix Ultra Foil Station thread state and selected mode of

operation. • Machine Guard Open: Scodix Ultra Foil Station cover is open. • UV System Alarm: Faulty UV system. • PLC fault: Error within PLC. • Paper Jam: Indication of paper jam. • Foil low warning: Warning that the Unwind roll is low on foil. • Unwind Diameter Stop: Unwind roll at minimum diameter. • Rewind Diameter Stop: Rewind roll at maximum diameter.

Pressing the RESET ALL button resets all alarms, if the alarm is still active it will not reset. Pressing the HOME button returns the operator to the home screen.


Working with the Scodix Ultra Foil Station Page 16 of 37

Working with the Scodix Ultra Foil Station Measuring the diameter of the roll of foil, and an “empty” core

1. Measure the diameter of the core of a roll of foil.

Figure 4: Measuring the diameter of a roll of foil

2. Measure the diameter of an “empty” core.

Figure 5: Measuring an “empty” core



Loading a roll of foil Load a roll of foil as follows:

1. Turn the wing-screw to open the “Unwind” roller support.

Figure 6: Opening the roller support

2. Insert the roll of foil, and push it onto the “Unwind” roller.



3. Close the “Unwind” roller support, and turn the wing-screw to lock the roller support.

Loading an “empty” core Insert an “empty” core as follows:

1. Turn the wing-screw to open the “Rewind” roller support. 2. Insert an empty core, and push it onto the “Rewind” roller.



3. Close the “Rewind” roller support, and turn the wing-screw to lock the roller support.

4. Turn on the “Manual laser beam”, and use it to align the ends of the two cores. If they are not aligned, then push / pull the cores until they align with the laser beam.

Manual laser beam

Red stripe of light from the laser beam



Threading the foil Thread the foil as follows:

1. Thread the foil under the first roller, and then over the second roller.

2. Continue threading according the “blue” line in the diagram below:

Figure 7: Threading diagram



3. Pull the foil, and tape it to the empty core. Make sure that the foil is tight, and has no slack.

4. Tape the end of the foil to the empty core.



Setting roller type and diameter parameters 1. At the Scodix Ultra Foil Station control panel, press LOCAL.

WARNING! The Scodix Ultra Foil Station must not be left unattended when operating in local control mode, because the Scodix Ultra Foil Station does not be communicating with the Scodix Ultra Press, therefore some alarm signals are not monitored by neither the Scodix Ultra Press, nor by the Scodix Ultra Foil Station.

2. Press LOCAL CONTROL.



3. Press THREADING.

4. Press NEXT (1 of 4 times).

Figure: Pressing NEXT (1 of 4 times)









Setting the Rewind roll diameter parameters 1. Set the “Start Diameter” of the Rewind roll by pressing on the START DIA value box.



2. Enter the “empty” core diameter (mm). (This is the “empty” core diameter value that you measured, see “Measuring the diameter of the roll of foil, and an “empty” core” on page 16).

3. Press “ENTER”.

4. Set the “Stop Diameter” of the Rewind roll by pressing on the STOP DIA value box. (This is the maximum roll diameter that the Rewinder will allow onto the roll, before stopping.)



5. Enter the STOP DIA diameter. (The default is 180 mm).

Press “ENTER”.

6. The new parameters are displayed (for example 85 mm, and 180 mm). Press NEXT, to open the Unwind Parameters screen.

Setting the Unwind roll diameter parameters 1. At the “Unwind Parameters screen”, set the “Start Diameter” of the Unwind roll by pressing on the START DIA

value box.

Figure 8: Unwind Parameters screen



2. Enter the “empty” core diameter (mm). (This is the “empty” core diameter value that you measured, see “Measuring the diameter of the roll of foil, and an “empty” core” on page 16).

Press “ENTER”.

3. Set the “Stop Diameter” of the Unwind roll by pressing on the STOP DIA value box. (This is the diameter of the core when it is empty.)

4. Enter the STOP DIA diameter (mm).

Press “ENTER”.



5. Set the “Foil Gauge” by pressing on the FOIL GAUGE value box. (This is the thickness of the foil – see the specifications from the supplier.)

6. Enter the FOIL GAUGE value.

Press “ENTER”. 7. Press NEXT.

Checking that the new settings are now updated into the memory The values that you entered in the step above should now be updated into the memory. If not, then do the following:

1. At the “Diameter Reset screen”, update the Rewind parameters into memory by pressing RESET (under the “RW DIA” box).

Figure 9: Diameter Reset screen



2. Update the Unwind parameters into memory by pressing RESET (under the “UW DIA” box).

3. Press HOME.

Passing control back to the Scodix Ultra Press On the Home screen, press REMOTE, to give control of the Scodix Ultra Foil Station back to the Scodix Ultra Press.

The Scodix Ultra Foil Station control panel now shows that it is in the “Remote control” status:



Setting the tension of the Rewind and Unwind rolls Setting the roll tension correctly prevents the foil from breaking or buckling, and can reduce unnecessary foil wastage. Consider the following when setting the tension:

• Always set the Unwind tension higher than the Rewind tension, to prevent foil buckling. • Higher Unwind tension reduces unnecessary foil wastage. Tension that is too low allows too much “blank

foil” is lost in-between the images. • However, higher tension causes more friction, which can cause the web to break, as well as increases

resistance to the motor.

Set the tension of the Rewind and Unwind rolls as follows:

1. On the Remote Control screen, press TENSION.

2. Set the Rewind and Unwind tension as required, and adjust as necessary.

You can set the following basic initial values, and adjust as necessary:

Rewind Tension = 2 • Unwind Tension = 8 •

3. Press HOME to exit the screen.



Setting the Foil settings in the Job ticket on the Scodix Ultra Press Foil settings are located in the highlighted areas of the Job Properties window, as shown below.

1. Click on a “ripped” job in the Job Queue, to open the Job Properties window. Figure 10: Job Properties window – showing areas that are relevant to the Scodix Ultra Foil Station settings

NOTE: Old jobs that were not ripped with foil options, must be reimported and ripped with foil options.

2. In the Print Quality section, do the following: a. Set the Polymer Type to Polysense 500.

NOTE: Only Polysense 500 can be used for foiling. If necessary, switch the Press to Polysense 500, using the Ink Switching procedure. - See the Scodix Ultra Press Operator Guide - Ink Switching section.

b. Select the required Print Mode. (This will affect the height of the polymer and amount of polymer used.)



3. In the Pin (LED UV) section, do the following: a. Set the Pin (LED UV) to Auto.

(Pinning changes the polymer into a semi-cured state, which stops it from spreading out too much.) b. Set the Pin (LED UV) Power %, the recommended value is between 10 % and 30 %.

NOTE: In general, the higher the power, the less the foil adheres to the substrate. However, different foil types have different optimal power settings.

4. In the Scodix Foil section, do the following: a. Click Use Foil. b. Set the Activate (UV power) %, the recommended value is between 40 % and 80 %.

Selecting the “Selective Foil” area 1. Click Selective Foil to select the areas of the image that will receive foil.

The Selective Foil window shows one or more potential foiling areas, of 50 mm or more, that were automatically marked with a green line on the right of the preview image.

Figure 11: Selective Foil window – showing green areas for foiling

First foil area - roll engage point

Second foil area - roll engage point

First foil area - roll disengage point

Second foil area - roll disengage point



2. To remove gaps between foil areas, click Mark All Image for the foil area to be continuous. 3. To move the “First foil area - roll engage point”, enter an Offset distance (mm).

4. To unselect / select a foiling area, click on the green line.

Figure 12: Two Foil Areas selected One Foil Area selected


Operating the Scodix Ultra Foil Station Page 34 of 37

Operating the Scodix Ultra Foil Station The Scodix Ultra Foil Station can be operated in 'foiling' Mode. (Note, there is another mode that is not being used called the 'Cast & Cure Mode'.) Each mode requires the web to be threaded slightly differently, the control of the index nip also changes between each mode. The Scodix Ultra Foil Station has a 'Bypass' mode where all nips are in their disengaged positions and only the Conveyor is running, this mode is used to clear the Ultra & Scodix Ultra Foil Station of any sheets. This mode is selected by the Scodix Ultra Press when required.

Operating in Local mode The Scodix Ultra Foil Station has the ability to be operated locally from the Control Touch Screen, this function is tests that the Scodix Ultra Foil Station is functioning correctly and not intended for continuous Scodix Ultra Foil Station operation.

Starting the Scodix Ultra Foil Station The Scodix Ultra Foil Station is controlled from the Scodix Ultra Press, when the Scodix Ultra Press is ready to print, a Foiling state signal is sent to the Scodix Ultra Foil Station. The signal will put the Scodix Ultra Foil Station into a foil state. The nip will lower closing the nip to 3mm and start the Laminating drive and Rewind drive. The Laminating drive will be held at zero speed until the Ultra outfeed conveyor starts moving. The laminating drive will then follow the speed of the Ultra Conveyor. The Rewind shaft will rotate with a 10% over speed. When the Scodix Ultra Foil Station Conveyor speed is above 10m/min the UV shutter signal will be activated, when the speed drops below 10m/min the UV open shutter signal is removed. The Scodix Ultra Foil Station will index the index nip as determined by the sheet parameters loaded into the Scodix Ultra Foil Station.

Stopping the Scodix Ultra Foil Station Under normal circumstances the Scodix Ultra Press will initiate the off signal to stop the Scodix Ultra Foil Station, when the signal is received the nip roll will raise to the disengaged position and the drives will ramp to zero speed and switch off. As the speed drops below 10m/min the UV shutter signal will be removed ensuring the UV shutter is closed by the time the conveyor speed reaches zero. The foil web only moves through the Scodix Ultra Foil Station when the index nip is down. The foil nip is quickly stopped by a brake when moving to the up position to achieve maximum foil saving. The foil is monitored by web break sensors, so in the event of the foil web breaking the Scodix Ultra Foil Station is stopped quickly. The Scodix Ultra Foil Station can initiate a stop cycle if a problem has occurred within the Scodix Ultra Foil Station via an attention signal to the Scodix Ultra Press these are:

a. Unwind diameter stop, (Scodix Ultra Foil Station has run out of foil) b. Paper Jam c. Drive fault d. Not safe to run e. PLC fault. f. Encoder direction mismatch


Routine Maintenance Page 35 of 37

Routine Maintenance Daily Maintenance • Scodix Ultra Foil Station:

• At the start and finish of each shift, check the Emergency Stop condition and reset if necessary. • Check that equipment condition overall is satisfactory and safe for operation. • Check the Emergency stop buttons and the Scodix Ultra Foil Station guard.

• Air system: Check air pressure at Air Set gauge is set to supply 6 bar. • Air pressure settings: Check for correct settings at Scodix Ultra Foil Station pressure regulator gauges. • At start and finish of each shift: The equipment should be dusted down with a clean soft cloth to remove

any dust and dirt, which may have accumulated.

Weekly Maintenance • Repeat Daily maintenance. • Pneumatic system: Check throughout for loose connections and air leaks. Take any necessary action to

correct. • Rewind airshafts: Check for correct expanding operation and absence of any air leakage. • Unwind airshafts: Check for correct expanding operation and absence of any air leakage.


Appendix Page 36 of 37

Appendix Threading for Cast & Cure (not currently in use)

Cast & Cure is not currently operational. This section has been included for future use. The foil web is threaded through the Scodix Ultra Foil Station as per the figure below. The foil web only moves through the Scodix Ultra Foil Station when the index nip is down. The foil is monitored by web break sensors, so in the event of the foil web breaking the Scodix Ultra Foil Station is stopped quickly. The Scodix Ultra Foil Station also monitors the direction of two idler rolls. If these two rolls are not rotating in the same direction the Scodix Ultra Foil Station will initiate a stop as there is a problem with the foil web.

Figure 13: Cast & Cure Web Path

1. Select Local control of the Scodix Ultra Foil Station by pressing LOCAL on the Control Touch Screen. 2. Select the THREADING button. 3. Turn the Unwind and Rewind shaft air supply OFF, this will remove the tension from the shafts. Remove the

differential shaft supports. 4. Rotate all the Unwind Differential shaft elements in a clock wise direction and slide the new Unwind reel(s) of

foil onto the shaft. Move the foil reel(s) to the desired position on the shaft. Refit the differential shaft support.

5. Rotate all the Rewind Differential shaft elements in an anti-clock wise direction and slide the new Rewind reel(s) onto the shaft. Move the reels to the desired position on the shaft, using the laser alignment position the Rewind reels with its corresponding Unwind reel of foil. Refit the differential shaft support.

6. Press the NEXT button on the Control Touch Screen.

WARNING: Before operating the manual control of any nip ensure that no unauthorized person is near the Scodix Ultra Foil Station, and that it is safe to proceed. Beware of trap points between fixed and moving parts.

7. Operate the index nip roll manual control button to the ON position. 8. Thread the foil web as per the figure above. 9. Operate the nip roll manual control button to the ON position. 10. Press the NEXT button on the Control Touch Screen. 11. Turn the Unwind and Rewind Air to the ON position. 12. Press and hold the jog button, the Scodix Ultra Foil Station will jog the foil web through the Scodix Ultra Foil

Station. If the Jog button is released the Scodix Ultra Foil Station will stop.


Document History Page 37 of 37

13. Press the NEXT button on the Control Touch Screen. 14. Operate the nip roll manual control button to the AUTO position. 15. Operate the index nip roll manual control button to the AUTO position. 16. Press the NEXT button on the Control Touch Screen. 17. Enter the START DIAMETER and STOP DIAMETER of the Rewind reel (pressing the Value will open up a text box

to enter new value). 18. Press NEXT on the Control Touch Screen. 19. Enter the START DIAMETER, STOP DIAMETER and FOIL GAUGE of the Unwind roll. 20. Press NEXT on the Control Touch Screen. 21. Press the RESET button to reset the diameters of the Unwind and Rewind Reels, the value will change to the

start diameter entered on previous screens. 22. Press NEXT on the Control Touch Screen. 23. Select how the Scodix Ultra Foil Station has been threaded, for cast & Cure web path select Cast & Cure, the

text will change to Machine threaded for Cast N Cure. 24. Press the LOCAL button on the Control Touch Screen. 25. Ensure all nip roll control buttons are in the AUTO position. 26. Press NEXT on the Control Touch Screen. 27. Select the UV SYSTEM shutter control to AUTO. 28. Select the HOT AIR BLOWER to AUTO if required. (Temperature and Fan speed adjusted manually.) 29. Select the FANS to AUTO. 30. Press NEXT on the Control Touch Screen. 31. Select the INFEED AIR JET to AUTO if Required (Pressure set manually). 32. Select OUTFEED AIR JET to OFF. 33. Press NEXT on the Control Touch Screen. 34. Select WEB BREAK sensor 1 to 3 to the ON if positioned over the threaded foil. 35. Press NEXT on the Control Touch Screen. 36. Select WEB BREAK sensor 4 to the ON position if positioned over the threaded foil. 37. Press the LOCAL button to return to the local control screen. 38. Ensure Scodix Ultra Foil Station guard is down and no alarms on ALARMS screen. 39. Press the HOME button and select remote control to give control back to the Scodix Ultra Press. 40. The Scodix Ultra Foil Station is now ready to run in Cast N Cure state.

Document History Rev Written /

updated by Date Approved by Remarks

01 Yossi Bahar 25-01-2016 Yossi Bahar New Document

02 Yossi Bahar 01-03-016 Yossi Bahar Added “Setting the tension of the Rewind and Unwind rolls” section.

Head Office:

Scodix Ltd., 13 Amal Street, Park Afek, Rosh Ha’ayin 480925, Israel. Tel: (+972) 3 9033371 Fax: (972) 3 9033375 www.scodix.com

Date post:	01-May-2018
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