Operating manual UCT - Universal cutting tool Version Menu 002 1.20
UCT G3 Series Contents 1 Product description...........................................3 1.1 Introduction................................................. 3 1.2 UCT....................................................... 3 1.3 Technical information......................................... 4 2 Safety regulations............................................5 2.1 General.................................................... 5 2.2 Intended use................................................ 5 2.3 Examples of improper use..................................... 5 2.4 Dangers caused by improper use................................ 6 2.5 Protective clothing and equipment............................... 6 3 Operation...................................................7 3.1 Selecting the blade size....................................... 7 3.2 Using/replacing the blade with the slipper spring.................... 8 3.3 Using/replacing the blade with the rigid slipper...................... 9 3.4 Inserting tool............................................... 10 3.5 Adjusting the height......................................... 11 3.6 Description of menu......................................... 12 3.7 Setting UCT as the tool for the module........................... 13 3.8 Setting Pos / Pressure mode.................................. 13 3.9 Initialisation in the position mode (slipper spring)................... 14 3.9.1 Introduction................................................ 14 3.9.2 Defining the zero point....................................... 15 3.9.3 Setting the upper position..................................... 16 3.9.4 Setting the lower position..................................... 17 3.9.5 Setting the Z-offset.......................................... 17 3.10 Initialising in the pressure mode (rigid slipper)..................... 18 3.11 Tool positions.............................................. 19 3.12 Making material-specific settings............................... 20 3.13 Carrying out a test cut........................................ 20 4 Cleaning and maintenance....................................21 4.1 Steps for maintenance....................................... 21 4.2 Lubricant.................................................. 21 4.3 Lubricate slipper O ring....................................... 22 2
G3 Series UCT Introduction 1 Product description 1.1 Introduction The UCT (universal cutting tool) is designed for the use of Zünd blade holders and can be used for processing popular packaging materials. A spring-mounted slipper serves to hold down and smooth out the material being used during cutting. A rigid slipper is optionally available which defines a fixed cutting depth. Important! Keep a spare tool ready in order to avoid cutter downtime. 1.2 UCT Fig. 1 UCT 1 Slipper spring 2 Blade holder 3 Insert sleeve 4 Adjustment wheel 3
UCT Technical information G3 Series 1.3 Technical information Description Measurements Units Weight 0.3 kg L x Ø 190 x 40 mm Max. cutting depth with slipper spring 0-4 (8) mm 4
G3 Series UCT General 2 Safety regulations 2.1 General Important! These safety regulations and notes are only tool-specific supplements to the "Safety regulations" section in the Operating manual This section defines the proper use of the tool contains tool-specific safety precautions and instructions provides information on the protective equipment required for work and maintenance Special operational and situation-specific safety requirements are listed in the relevant processing steps in subsequent sections of this manual. 2.2 Intended use Safe operation is guaranteed when the equipment is used solely for its intended purpose. The equipment provided determines the possible uses of the tool. The UCT is intended for cutting packaging materials and foils with Zünd blades and blade holders in combination with Zünd modules. Any other use which does not meet this description shall be classed as improper use. The user bears sole liability for any damage arising as a result of improper use. The tool is deemed to be used as intended under the following conditions: All nationally imposed safety regulations are complied with The safety instructions listed in this operating manual are complied with The operating conditions are adhered to and the prescribed materials are used 2.3 Examples of improper use Use of unsuitable blades Incorrect clamping of the blade/blade holder Use outside of the intended module Improper or non-intended use Incorrect mounting of the tool in the module Incompatible sizes of blade and blade holder Failure to clean the tool at regular intervals Non-observance of maintenance instructions Non-adherence to safety requirements Failure to react to signs of wear and damage 5
UCT Dangers caused by improper use G3 Series 2.4 Dangers caused by improper use Risk of damage to tool and cutter system Cutting injuries Blade breakages Blade may unintentionally slip out of blade shaft 2.5 Protective clothing and equipment When operating, cleaning or maintaining the equipment, wear close-fitting clothing and personal protective equipment suited to the task at hand. The following protective equipment is required: Work clothes Safety goggles Protective gloves if there is a danger of being burned or injured by pointed or sharp-edged objects Ear protection if the continuous sound pressure level is over 85 db(a). Important! You are personally responsible for: Using the required personal protective equipment Cleaning and maintaining the equipment on a regular basis Replacing damaged and unusable elements of protective equipment in a timely fashion 6
G3 Series UCT Selecting the blade size 3 Operation Attention! Danger of injury The blades are extremely sharp and can cause severe cuts. 3.1 Selecting the blade size Attention! Risk of injury from blade. If the wrong size of blade is selected there is a risk of the blade breaking off and the broken off parts may injure people. Use blade sizes appropriate to the type and thickness of material. Fig. 2 Determining the blade size (with slipper spring) 1 Clamped tool 4 Example: Blade for material thickness 5 mm 2 Slipper spring 5 Incorrect choice of blade or slipper 3 Example: Material thickness 5 mm Ensure that the slipper spring is always on the material. Use the appropriate blade for the material thickness. 7
UCT Using/replacing the blade with the slipper spring G3 Series 3.2 Using/replacing the blade with the slipper spring Fig. 3 Inserting/replacing blades A B C D E F Insert the blade up to the cutting edge in the blade holder and fix the holder with the two hexagon socket screws. Insert the blade holder up to the stop in the insert sleeve. Turn the blade holder until it engages in the guide of the insert sleeve and press into the sleeve at the same time. Screw the blade holder using the height adjustment wheel in a clockwise direction. Tighten the screws on the blade holder through the holes on the sleeve. Carefully place the slipper spring on the insert sleeve. Using the height adjustment wheel set the height so that the blade and slipper are flush. 8
G3 Series UCT Using/replacing the blade with the rigid slipper 3.3 Using/replacing the blade with the rigid slipper Fig. 4 Inserting/replacing blades G H I J K L Insert the blade up to the cutting edge in the blade holder and fix the holder with the two hexagon socket screws. Insert the blade holder up to the stop in the insert sleeve. Turn the blade holder until it engages in the guide of the insert sleeve and press into the sleeve at the same time. Screw the blade holder using the height adjustment wheel in a clockwise direction. Tighten the screws on the blade holder through the holes on the sleeve. Carefully place the slipper on the insert sleeve. Use the adjustment wheel to adjust the blade height until the blade protrudes from the slipper by distance s (cutting depth) 9
UCT Inserting tool G3 Series 3.4 Inserting tool Fig. 5 Inserting tool 1 Bayonet catch 2 Module lock Move the module to the lower right-hand corner Use to switch to the operating status STOPPED Insert the selected tool into the module holder. Ensure that the red point on the module is located above the module lock. Important! The tool holder and a holding fixture are each marked with a red dot. The tool is in the correct position when the dots are aligned. Lower the shaft of the tool into the module opening until it stops Press the module lock and latch the bayonet catch 10
G3 Series UCT Adjusting the height 3.5 Adjusting the height The height is generally adjusted using the universal module. If necessary, the height can, however, be set using the height adjustment wheel on the insert sleeve. 1 turn = 1 mm Fig. 6 Adjusting the height 1 Adjustment wheel 11
UCT Description of menu G3 Series 3.6 Description of menu The examples in the following guide assume that the tool is being used in module 1. Description Menu Setting/function Initialisation Pos / Pressure mode 1-1-1-3-4-7-1 Activate position/pressure X&Y pressure 1-1-1-3-4-7-2 Setting contact pressure for X/Y axis X pressure 1-1-1-3-4-7-3 Setting contact pressure for X axis Y pressure 1-1-1-3-4-7-4 Setting contact pressure for Y axis Define Z init pos 1-1-1-2-1 Defining the zero point Up Z pos 1-1-1-2-3 Setting the position when the tool is raised Down Z pos 1-1-1-3-4-5 Set cutting depth Z Offset 1-1-1-2-5 Value for the correction of the cutting depth Speed and acceleration Up X&Y 1-1-1-3-2-1 Moving speed with raised tool Down X&Y 1-1-1-3-2-2 Moving speed with lowered tool Lift Z 1-1-1-3-2-3 Lifting speed Lower Z 1-1-1-3-2-4 Lowering speed Up tool 1-1-1-3-3-1 Tool acceleration in upper position Down tool 1-1-1-3-3-2 Tool acceleration in lower position 12
G3 Series UCT Setting UCT as the tool for the module 3.7 Setting UCT as the tool for the module Refer to the "Tool handling" section of the operating manual 3.8 Setting Pos / Pressure mode Select the position function (position mode) or pressure function (pressure mode) in the submenu Pos / Pressure mode. In the position mode, the cutting depth is defined using the zero point of the Z axis. The module moves to the set zero point irrespective of the pressure/the cutting depth. In the pressure mode, the cutting depth is the result of a set pressure which is exerted on the tool by the module. The module moves into the material until the preset pressure is reached. Position mode In the menu Pos / Pressure mode1-1-1-3-4-7-1, select Position to activate the position mode Pressure mode In the menu Pos / Pressure mode1-1-1-3-4-7-1, select Pressure to activate the pressure mode Make the pressure settings for the X and Y axes, either separately or together - Select X&Y pressure1-1-1-3-4-7-2 and enter a value. - Select X pressure1-1-1-3-4-7-3 and enter a value for the X axis; select Y pressure1-1-1-3-4-7-4 and enter a value for the Y axis 13
UCT Initialisation in the position mode (slipper spring) G3 Series 3.9 Initialisation in the position mode (slipper spring) Warning! Danger of injury when initialising the tool! The light barriers are not active during manual initialisation! Do not touch the operating area of the tool during initialisation. Define the zero point with automatic initialisation. 3.9.1 Introduction The following activities are required for successful initialisation: Define zero point (manual/automatic*) Setting the upper position Carrying out a test cut Correct the operating depth using the 'Adjust tool init pos' function if necessary Ensure, that following preconditions are fulfilled: The machine is in the 'STOPPED' operating state The tool has been mounted and assigned to the module Position mode is active Fig. 7 Initialisation 1 Zero point 2 Down Z pos 3 Z Offset a Material b Base 4 Up Z pos 5 Max. Z down 1 6 Max. Z up 1 1 these values may only be changed at the 'Service' user level. 14
G3 Series UCT Initialisation in the position mode (slipper spring) Calculation of cutting depth Cutting depth = zero point + Down Z pos ± Tool init pos 3.9.2 Defining the zero point Fig. 8 Defining the zero point Select Manual initialisation1-1-1-2-1 Use the travel keys to move to the zero point (cutting base) Choose OK to confirm 15
UCT Initialisation in the position mode (slipper spring) G3 Series 3.9.3 Setting the upper position Important! If the cutting base is defined as the zero point, the value for the setting Up Z pos must be greater than the material thickness. The Up Z pos setting defines the position of the tool when raised. Definition: Upper position = zero point + Up Z pos To increase cutter efficiency, this position should only be set as high as is necessary. Fig. 9 Setting the upper position a Material thickness 1 Zero point 4 Up Z pos Select Up Z pos1-1-1-2-3 Enter a value Choose OK to confirm 16
G3 Series UCT Initialisation in the position mode (slipper spring) 3.9.4 Setting the lower position Important! If the cutting base is defined as the zero point, the value used for the Down Z pos setting must be set to zero. Entering a positive value will damage the cutting base. The Down Z pos setting defines the position of the tool when lowered. When a zero point is defined, the value for the lower position is automatically set to zero. Definition: Lower position = zero point + Down Z pos Fig. 10 Setting the lower position 1 Zero point 2 Down Z pos Select Down Z pos Enter 0 Choose OK to confirm 3.9.5 Setting the Z-offset Value for correcting the cutting depth (Down Z pos) by ±1.5 mm. When a zero point is defined, the value for the Z-offset is automatically set to zero. Select Adjust tool init pos Enter a value Choose OK to confirm 17
UCT Initialising in the pressure mode (rigid slipper) G3 Series 3.10 Initialising in the pressure mode (rigid slipper) Description to follow 18
G3 Series UCT Tool positions 3.11 Tool positions Example: EOT/POT/UCT Three tool positions are possible following initialisation Fig. 11 Tool positions Item Position Description Key Signal A Park position Moves to the highest position on the Z axis B Up Z pos Zero point + Upper position C Down Z pos Zero point + Lower position + Z offset 19
UCT Making material-specific settings G3 Series 3.12 Making material-specific settings The speed and acceleration settings must be set for each material. You can find recommended settings for specific materials on the Zünd homepage or by contacting your Zünd partner. 3.13 Carrying out a test cut Ensure, that following preconditions are fulfilled: The pos/pressure mode or the pressure mode has been set The tool has been initialised When using a rigid slipper: The lower position has been set The machine is in the 'OFFLINE' operating state Material-specific settings (speed, acceleration) have been made The tool is active Procedure Place the material to be processed on the working surface Use the travel keys to position the tool over the material to be grooved. Choose OK to continue must be pressed until the tool is in the lower position. The LED on the key turns green. Carry out a test cut using the travel keys Check the test. If necessary, correct or redefine the zero point on the Z axis using the Z offset function. 20
G3 Series UCT Steps for maintenance 4 Cleaning and maintenance Attention! Danger of injury The blades are extremely sharp and can cause severe cuts. Attention! Risk of damage to the tool Never clean the tool using ultrasound, a steam jet, compressed air etc. Never use cleaning products (cleaning spray, grease solvents etc.) for cleaning. 4.1 Steps for maintenance The maintenance intervals provided are only guidelines. The intervals must be shortened as required, depending on the material worked on. Interval Every 25 operating hours monthly Activity Oil the blade holder shaft Clean the blade holder shaft Lubricate the slipper spring O ring 4.2 Lubricant Attention! Risk of damage if incorrect lubricant is used. Only use the lubricant recommended by Zünd to maintain your equipment. Lubricant Guideway oil Vaseline Lubricating points General maintenance Slipper O ring 21
UCT Lubricate slipper O ring G3 Series 4.3 Lubricate slipper O ring Attention! Risk of injury from blades Take care when placing the slipper on the tool. The blade will protrude several millimetres out of the slipper when this is fully retracted. Fig. 12 Lubricate slipper O ring Remove slipper Clean slipper Rub some Vaseline on the inner side of the O-ring ("Fig. 12, Lubricate slipper O ring", item 1) Carefully place the slipper on the tool 22