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Dover markem imaje CSAT ITS6 210, Operating Instructions Manual

The Dover Markem Imaje CSAT ITS6 210 is a versatile printing system that delivers high-quality results. To ensure smooth operation, it is crucial to have the Operating Instructions Manual handy. You can conveniently download this comprehensive manual for free from manualshive.com, providing step-by-step guidance for optimal usage of this exceptional product.

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Operating Instructions 

Transport 

 

 

© Copyright by Markem-Imaje CSAT GmbH 

 

ITS6_135_Manual_EN.doc 

Subject to Technical Modifications 

Page 221 / 370 

 

5.6 

External transport or storage for any length of time 

External  transports  include  all  transports  that  are  not  internal  transports. 
These are transports: 

 

… from one building to another building within a company, 

 

… from one company to another company, 

 

… on public streets by truck or trailer, 

 

… with long and/or uneven transport routes. 

 

Notice 

  Transports by forklifts or other vehicles without suspension should 

be kept to an absolute minimum. 

 

The ITS6 printer should be packed in the special wooden crate in which it 
was  delivered.  Similarly,  due  to  the  unavoidable  jarring  during  transport, 
more  extensive  measures  for  securing  the  printer  have  to  be  taken  than 
during a transport within the company.  

These instructions also apply to situations where the printer has to be taken 
out of commission and stored for any length of time. 

5.6.1 

Transport preparations 

> 

In addition to the tasks listed in Chapters 5.4.1 and 5.4.2, the following 
tasks also have to be completed: 

> 

Rinse all print heads thoroughly with cleaning fluid (tab 

Job > Clean-

ing

). This process has to be repeated several times until the contents 

of each print head and the connecting lines have been completely re-
placed. 

> 

Remove the substrate web roll from the unwinding unit!    
This  is necessary  since otherwise,  each time  the  printer  is jarred,  the 
strain on the unwinder shaft would be too great.  

> 

Remove the substrate web roll from the rewinding unit!  

 

This  is necessary  since otherwise,  each time  the  printer  is jarred,  the 
strain on the rewinder shaft would be too high.  

> 

Remove all of the unwound printing substrate from  the machine. This 
prevents the material no longer under tension from rubbing against the 
sensitive surfaces of the printing unit.  

> 

Drain the cooling circuit and seal the inlet and outlet with the appropri-
ate plugs. 

> 

The following components have to be removed/replaced: 

  Remove the cartridge with the cleaning fluid (in case of longer stor-

age), 

Summary of Contents for markem imaje CSAT ITS6 210

Page 1: ... the Original Instructions Operating Instructions Digital Continuous Printer CSAT ITS6 210 Serial No EG LAA0 00135 Save for use at a later date Markem Imaje CSAT GmbH Daimlerstraße 32 D 76344 Eggenstein Leopoldshafen ...

Page 2: ...ing instructions were drawn up to the best of our knowledge Nevertheless if they should contain errors or ambiguities please let us know Furthermore we are grateful for any helpful hints or suggestions Please contact us Markem Imaje CSAT GmbH Daimlerstr 32 D 76344 Eggenstein Leopoldshafen Telefon 49 721 97315 88 Fax 49 721 97315 99 E Mail csat support markem imaje com Unauthorized reproduction eve...

Page 3: ...ions 16 2 Safety 17 2 1 Intended use 17 2 2 Foreseeable misuse 17 2 3 Safety symbols 20 2 3 1 Safety symbols and their meaning 21 2 3 2 Safety symbols in the operating instructions 21 2 3 3 Safety symbols on the machine 24 2 3 4 Safety symbols on the cartridges for ink and cleaning fluid 25 2 4 Safety instructions 26 2 5 Safety concept 29 2 5 1 Safety zones 29 2 5 2 Safety measures 30 2 5 3 Safety...

Page 4: ...ions 51 3 9 1 Paper like roll fed material 53 3 9 2 Plastic roll fed material 54 3 9 3 Aluminum foil roll fed material 55 3 9 4 Textile roll fed material 56 3 9 5 Label material made out of paper 57 3 9 6 Label material made out of aluminum foil 58 3 9 7 Label material made out of plastic 59 3 9 8 Suitable printing substrates 60 3 9 9 Unsuitable printing substrates 61 3 10 Adhesive tape 64 3 11 No...

Page 5: ... curing 118 4 6 18 Main curing 122 4 6 19 Air circulation system 124 4 6 20 Air cooling 125 4 6 21 CAPS server 126 4 6 22 Camera system 127 4 6 23 Function of the camera system components 128 4 6 24 Friction drive 129 4 7 Indicators and control elements 133 4 7 1 Main switch and ON OFF switch 133 4 7 2 Control panel 134 4 7 3 Access restriction 136 4 7 4 The printer s display 136 4 7 5 Using touch...

Page 6: ...b System Machine info 178 4 11 5 Tab System User management 180 4 12 Menu Consumables 184 4 12 1 Tab Consumables Fill levels 185 4 12 2 Tab Consumables Reels 186 4 12 3 Tab Consumables Print heads 187 4 12 4 Tab Consumables UV modules 189 4 12 5 Tab Consumables Wipers 191 4 12 6 Tab Consumables Drive rollers 192 4 12 7 Tab Consumables Air filters 193 4 12 8 Tab Consumables Ink filters 194 4 13 Men...

Page 7: ...Transport preparations 221 5 6 2 Preparation of the transport route 223 5 6 3 Carrying out external transports 223 5 6 4 Packing the printer in the transport crate 224 5 6 5 Shipping the transport crate 225 5 6 6 Unpacking the printer from the transport crate 226 6 Assembly 227 6 1 Safety instructions for the assembly 227 6 1 1 Set up at final destination 228 6 2 Installation of the printer s supp...

Page 8: ...nting substrate 245 8 6 1 Inserting printing substrate 246 8 6 2 Feeding in the printing substrate 247 8 7 Login and logout at the touchscreen 250 8 7 1 Touchscreen login 251 8 7 2 Touchscreen logout 252 8 8 Preparing and executing print jobs 254 8 8 1 Image files and format files 254 8 8 2 Preparing data for 4C digital printing 254 8 9 Working with format files 255 8 9 1 Loading format files 255 ...

Page 9: ...e residual ink bottle 296 10 6 6 Changing the rubber rollers of the friction drive and the web tension control 298 10 6 7 Maintenance of the printing substrate cleaning module 302 10 6 8 Changing the filters of the air circulation system 304 10 6 9 Replacing the guide rollers of the printing table and adjusting the infeed height control unit 307 10 6 10 Replacing the lighting unit on the camera sy...

Page 10: ...uid 353 11 1 2 Storage of cleaning agents 353 11 1 3 Storage of replacement parts and consumables 354 12 Disassembly and Disposal 355 12 1 Safety instructions for disassembly of the machine 355 12 2 Disassembly of the machine 357 12 3 Safety information for the disposal of the machine 358 12 4 Disposal of the machine 358 12 5 Safety instructions for the disposal of production waste 359 12 6 Dispos...

Page 11: ...wing conditions should be achieved constant availability of the machine optimum performance and therefore perfect print quality timely detection and rectification of defects thereby reducing mainte nance and repair costs the assurance of operational safety extended service life of the machine The personnel responsible for the machine must always have access to and be familiar with the operating in...

Page 12: ... the responsibility of Markem Imaje CSAT GmbH The initial commissioning will be performed by Markem Imaje CSAT GmbH The owner is responsible for the proper function and the safe operation of the machine The operating instructions are a constituent part of the product and should be kept throughout the service life of the machine and then passed on to the next owner or user A copy of the operating i...

Page 13: ...s if the relevant safety regulations are not observed see related chapter in these operating instructions if the machine including any associated equipment is maintained im properly in terms of time intervals as well as execution this also in cludes the use of original replacement parts and checks and inspec tions are not complied with if changes additions or conversions which could compromise saf...

Page 14: ... print heads Markem Imaje CSAT GmbH guar antees that the guaranteed lifetime can be achieved if used properly Notice Unfortunately Markem Imaje CSAT GmbH finds itself forced to pass on to all users of the ITS6 and treat as binding the print head manu facturer s extremely strict guarantee conditions in their current form These are worded as follows the manufacturer of the print heads guarantees tro...

Page 15: ... Understanding and handling these operating instructions All commissioning operation maintenance and repairs of the machine must be carried out strictly on the basis of the procedural instructions speci fied in these operating instructions Before operating the machine please read through these operating instruc tions carefully The specially marked safety instructions must be observed Follow all in...

Page 16: ...d in the appen dix of the operating instructions and on the documentation CD 1 8 Notations in the text and abbreviations Notations Function Item Representation Instructions start with an arrow Lists start with a bullet Keys switches touchscreen functions are placed in quotation marks Text of messages and pop up windows are placed in quotation marks File and folder names touchscreen menus and assoc...

Page 17: ...to be observed Proper use also includes reading knowledge and compliance with the op erating instructions and adherence to the maintenance and repair instruc tions Any other use of the machine or parts of this machine requires the written approval of Markem Imaje CSAT GmbH 2 2 Foreseeable misuse Improper use is considered any use beyond the purpose for which the ma chine is intended It is not perm...

Page 18: ...chanical and chemical properties as a re sult of using cleaning fluids and inks the processing of printing substrates which deviate strongly from the materials usually processed by the printer in terms of the substance material thickness composition or method of manufacture the use of textile material with fibers protruding from the fabric the use of damaged printing substrates that are torn or ha...

Page 19: ...s Page 19 370 Notice If you aren t sure whether a printing substrate is suitable please send a roll of the material along with the associated data sheet to Markem Imaje CSAT GmbH and let it be checked for its suitability The printer owner still bears sole responsibility nevertheless for the use of material tested this way ...

Page 20: ...ent potential danger Danger Symbol Panel Death serious injury or substantial material damage will occur if the corresponding precautions are not taken Warning Symbol Panel Death serious injury or substantial material damage can occur if the corresponding precautions are not taken Caution Symbol Panel Minor injuries can occur if the corresponding precautions are not taken Notice Material damage can...

Page 21: ...s The meaning of the safety symbol is indicated by the shape and color ISO 3864 2 Shape Color Meaning Safety red Contrasting white Prohibition Safety yellow Contrasting black Warning Safety blue Contrasting white Mandatory action 2 3 2 Safety symbols in the operating instructions The following safety symbols are used in the operating instructions Prohibition symbols Safety symbol Meaning Safety sy...

Page 22: ...ral warning Entanglement hazard Dangerous voltage Tripping hazard Hazardous substances Slippery surface Danger of whipping hoses Danger machinery starts automatically Hot surface Danger of hand injuries Suspended load warning Danger of tipping Beware of industrial vehicles Danger of entanglement at printing substrate conveyance area Corrosive substances Warning electromagnet ic field Cutting hazar...

Page 23: ...bject to Technical Modifications Page 23 370 Mandatory action symbols Safety symbol Meaning Safety symbol Meaning Disconnect before work Unplug power supply before opening Wear safety gloves Wear respiratory protec tion Wear eye protection Wear safety shoes Read manual Disposal of substances ...

Page 24: ...of the printer in the installation area 400 on the pivoting plate with the automatic circuit breaker On the gas springs of the hinged hood Warning symbol Position on the printer Main switch Corona station Within the printer on different devices On all housing panels behind which could be live compo nents exceeding 24 V Print head unit Below the cover and at the rear side Gear motor with friction d...

Page 25: ...l ink bottle flap inside Notice Always keep the safety symbols clean Comply with the warnings and mandatory actions Do not expose yourself needlessly to danger 2 3 4 Safety symbols on the cartridges for ink and cleaning fluid The following safety symbols are used on the cartridges filled with ink and cleaning fluid Safety symbol Meaning Origin Hazardous to health CLP Directive EG Nr 1272 2008 Caut...

Page 26: ...ets Do not work on live parts Replace loose connections and damaged cable immediately Turn off and lock main switch before performing work Cables should not be jammed or crushed Cables must be laid so that they cannot be damaged or pose a tripping hazard Warning The machine may not be operated without locked and functioning safety equipment Risk of injury due to sudden movements of the handling sy...

Page 27: ...n switch and has been protected with a padlock against being switched back on Install a warning sign Attention Work on the machine in progress Do not start the machine Warning Risk of injury due to improper handling of compressed air Never aim the discharge end of pneumatic hoses at people oth erwise serious injury can result Never aim the discharge end of pneumatic hoses at loose objects Work on ...

Page 28: ...us start resuscita tion Also call a doctor or paramedic Persons staying in the direct vicinity of the electromagnetic field may be charged Caution Risk of injury due to incorrect programming Do not make any changes to the software of programmable sys tems Caution Risk of burning and or scalding Use caution when handling hot production supplies Do not touch the housing of the corona station Caution...

Page 29: ...d by the owner are entitled to access the individual zones 2 5 1 1 Traffic zone The traffic zone is the area specified by the owner which is accessible to or can be reached by anyone without opening hard guards triggering sensors on safety equipment or using any other means to gain access 2 5 1 2 Work zone The work zone is the area specified by the owner in which persons work on or operate the pri...

Page 30: ...s All of the aforementioned measures will be explained in detail below 2 5 3 Safety equipment All dangerous areas are protected by moveable mechanical hard guards Passive safety equipment is for the protection of the environment The hard guards include The complete housing of the machine Cover and safety doors with interlocking guard and monitoring The passive safety guards include Collection cont...

Page 31: ...oncept contains several measures Personal safety Machine safety Data safety User administration and access control In order to avoid damage to the ITS6 printer only authorized persons and groups of persons have access to the operating functions and modes which require the appropriate qualification All safety related functions of the printer e g changing the settings start ing the printing process ...

Page 32: ...are very aggressive and may cause serious injuries even after brief skin contact Therefore always use protective gloves that comply with the following specifications Material Minimum thickness of material Max period of use Butyl rubber 0 36 mm 480 min Nitrile rubber 0 38 mm 480 min Neoprene 0 65 mm 240 min Warning Risk of injuries when working on the printer Wear the required personal protection e...

Page 33: ... door unwinding unit Moveable hard guard access to unwinding unit 4 Safety door rewinding unit Moveable hard guard access to rewinding unit The safety doors installed on the machine are equipped with door monitor ing sensors and interlocks The interlocks ensure that the safety doors cannot be opened until the ma chine has come to a complete stop or potentially dangerous movements have been exclude...

Page 34: ...gh voltage All doors must be closed in order to start the printer Whenever the door interlock is not properly engaged this will be indicated on the printer s display Fig 2 Do not misuse the gas springs on the hinged hood as handles Warning Crushing hazard Risk due to falling hinged hood when the gas spring on the hinged hood is damaged Do not misuse the gas springs on both sides of the hinged hood...

Page 35: ...ge 1 Monitoring of the safety door at the rear access to the print head unit and the collection pan 66 Rear door open 2 Monitoring of the hinged hood access to web guider 63 Print head unit hinged hood open 3 Monitoring of the safety door access to unwinding unit 5 Bottom left door open 4 Monitoring of the safety door Access to U loop storage un winding unit and web outfeed 12 Bottom right door op...

Page 36: ...unction of the Emergency Stop button Never manipulate the Emergency Stop button The Emergency Stop button must always be accessible Never cover over the Emergency Stop button with objects hang something over it or use it as a coat hook After completing repair work make sure that the Emergency Stop button is working properly Notice When the Emergency Stop button is used sometimes it can cause the p...

Page 37: ...ressed it switches off all drives live com ponents and the pneumatic system and effectu ates a controlled shutdown of all mechanical parts of the printer The touchscreen displays and door interlocks remain switched on and active With the Emergency Stop button you can stop the entire machine in critical situations thereby reducing the chance of potential injuries The button ef fectuates a controlle...

Page 38: ...make sure that the Emergency Stop button is working properly When the Emergency Stop button is used sometimes it can cause the printer to switch off for an indefinite period Before the machine can finally be restarted the Emergency Stop must be reset Before the machine is restarted all moving parts must be checked and re turned to their normal position if necessary Information By twisting the red ...

Page 39: ...witch Pos Control element Effects of the main switch 1 Main switch Cuts off power to the entire printer 2 On Off switch Stops all moving parts incl pneumatic system Red button is pressed all moving parts incl pneumatic system are stopped The touchscreen and all lights remain switched on White button illuminates if an Emergency Stop hasn t been trig gered and the auto switching mode is ac tive Gree...

Page 40: ...he printer Whenever a parameter deviates from the set points the printer tries to restore the nominal condition on its own If that isn t possible then an alarm and an error message are triggered The error message is shown on the display see Chapter 9 1 4 Messages in the Current Alarm and Stopreason lines Depending on the gravity of the error the printing process will either be stopped in a control...

Page 41: ...d personnel qualified in electronics Warning Danger of entanglement at printing substrate conveyance area Do not reach into the individual guide rollers of the printing sub strate Caution Permanent damage to skin can be caused by contact with machine operating materials of all types long term injuries Wear solvent resistant safety gloves and protective eyewear when handling media see section 2 5 5...

Page 42: ... up a standard operating proce dure on the basis of the operating instructions and the operating conditions In addition to instructions for normal operation it should also include in structions for the following special situations Transport Assembly set up Test run Troubleshooting Repair Decommissioning Standard operating procedures can be compiled according to the following structure Area of appl...

Page 43: ... Only assigned personnel should work on the machine Never allow the machine to be operated by persons under the influence of substances which diminish their ability to react alcohol medicines drugs or who are not fit to operate the machine due to health reasons Personnel which is being schooled trained instructed or is learning on the job must be supervised at all times by a qualified and trained ...

Page 44: ...te several times a day and remove it immediately from the machine when the material begins to deform and thus may touch the print heads perform a standard or intensive cleaning of all print heads after switching on the printer and at least every two hours thereafter Fur thermore all print heads must undergo a final standard and manual cleaning at the end of each shift inspect the essential compone...

Page 45: ...mpetent individual An instructed individual is considered someone who has been instruct ed and if appropriate trained how to perform the assigned tasks who has been told about the potential danger arising from improper actions and who has been informed about the required safety equipment and safety measures A skilled worker is considered someone who based on his profession al training knowledge an...

Page 46: ...top button in case of machine related emer gencies The location of the First Aid stations must be known The location and operation of fire extinguishers must be known The personnel must have been instructed about fire alarms and firefighting measures The personnel must be aware of the escape routes displayed in the production hall The correct handling of emergencies must be checked and document ed...

Page 47: ... trol panel 2 614 mm Total length with doors closed including monitor in swiveled out position control panel on the right side Ltot opened 3 600 mm Total length with lower doors opened to the stoppers Wtot closed 1 065 mm Total width doors closed without control panel Wtot opened 2 577 mm Total width doors opened Hhou 1 640 mm Height of housing measured from the floor to the surface of the closed ...

Page 48: ...aximum concentrated load depends to a large extent on the distribu tion of the load onto the four adjustable feet of the printer If necessary the load can be balanced using a torque wrench 3 3 Ambient conditions Ambient conditions Ambient temperature 17 C to 28 C Relative humidity 20 60 Use indoors only Height above sea level max 2000 m Light Do not expose the printer to direct intense light Prote...

Page 49: ...1 part propylene glycol and 2 parts de mineralized water as well as corrosion in hibitor Diameter of hose intake 19 mm Diameter of hose discharge 19 mm Max length of inlet and re turn all in all 20 m Flow rate min 23 l min Cooling power min 8 kW Remaining rejected heat from the printing system to the ambience max 4 8 kW Notice 1 Mixtures of pure glycol and de mineralized water have corrosive prope...

Page 50: ... min depending on layout printing substrate and configuration Printing length No fixed limitation of printing length The maximum possible printing length depends on the kind of layout and the preparation by prepress Printing width max 210 mm Passage width 230 mm Max permitted width of the printing substrate 220 mm max diameter of printing substrate roll 550 mm Max weight of printing sub strate rol...

Page 51: ...ce and material properties The printing substrate should have a homoge nous structure a smooth blister free surface and straight edges The surfaces of the material to be printed this includes the end faces of the roll of printing material must be free of any loose particles dust or sticky substances e g gelatin since these could damage the print heads directly or greatly impair the effectiveness o...

Page 52: ... during the printing pro cess Heat resistance The temperatures beneath the print head units can reach levels of up to 50 C In the main cur ing unit the printing substrate is subjected to even higher temperatures which can reach 100 C under particularly unfavorable condi tions Besides the printing speed the greatest determining factor with regard to heat genera tion is the appearance of the print i...

Page 53: ... for printing table using suitable exchangeable deflection rollers max 600 µm Material properties Homogenous structure in all directions or fiber orientation in direction of travel No creases or blisters Edges become bowed by no more than 0 2 mm Straight edges without fringes Properties of the supplied material roll Roll fed material preferably without taped seams Any taped seams must be highly vi...

Page 54: ...for printing table using suitable exchangeable deflection rollers max 600 µm Material properties Homogenous structure in all directions or fiber orientation in direction of travel No creases or blisters Edges become bowed by no more than 0 2 mm Straight edges without fringes Properties of the supplied material roll Roll fed material preferably without taped seams Any taped seams must be highly vis...

Page 55: ...al for printing table using suitable exchangeable deflection rollers max 600 µm Material properties Homogenous structure in all directions or fiber orientation in direction of travel No creases or blisters Edges become bowed by no more than 0 2 mm Straight edges without fringes Properties of the supplied material roll Roll fed material preferably without taped seams Any taped seams must be highly ...

Page 56: ...us ma terial for printing table using suitable exchangeable deflection rollers max 600 µm Material Natural fibers or synthetics Fiber orientation Thick fibers should lie in the direction of travel of the print ing substrate whenever possi ble Fibers should not protrude from the fabric Edges become bowed by no more than 0 2 mm No creases or blisters Straight edges without fringes Properties of the ...

Page 57: ... mm in direction of travel Label spacing 2 mm in direction of travel Leading and trailing edges not at an angle but preferably perpendicular to the edge of the backing material Material properties of backing materi al and label Homogenous structure in all directions or fiber orientation in direction of travel No creases or blisters Edges become bowed by no more than 0 2 mm Straight edges without f...

Page 58: ...th 5 mm in direction of travel Label spacing 2 mm in direction of travel Leading and trailing edges not at an angle but preferably perpendicular to the edge of the backing material Material properties of backing materi al and label Homogenous structure in all directions or fiber orientation in direction of travel No creases or blisters Edges become bowed by no more than 0 2 mm Straight edges witho...

Page 59: ...5 mm in direction of travel Label spacing 2 mm in direction of travel Leading and trailing edges not at an angle but preferably perpendicular to the edge of the backing material Material properties of backing materi al and label Homogenous structure in all directions or fiber orientation in direction of travel No creases or blisters Edges become bowed by no more than 0 2 mm Straight edges without ...

Page 60: ...35 HD 70 white Mactac PP Maccrystal yes MP318UV Clear PET 36 Mactac PE PP Mix Coex top wh yes MP128UV Cent 6 Mactac PET Macmilmar Clear TC 25 yes MP312 Cent 6 Mactac PE Macthene 1029 TC yes MP128N Cent 6 Mactac PP Macpropy TC yes MP128N Cent 6 Mactac PVC 90 µm MacCal 8129 yes MP128N Cent 6 Mactac PVC 90 µm MacCal 8199 yes MP128N Cent 6 Mactac PVC 80 µm MacCal 9899 yes MP128N Cent 6 3M PET 92913 PE...

Page 61: ...tings which partially dissolve or become chemically altered through the use of inks and cleaning fluids Materials which under the influence of pressure and or high tempera tures emit gases liquids or even solid particles Labels which when deformed or subjected to heat come loose on their own from the backing material Label material in which the backing is deeply incised or heavily em bossed Printi...

Page 62: ...arm printing material Check the printing material for flatness This is done best on an electrostatic plate A printing material that can not completely be flattened after a forward feed is unsuitable for printing Notice Unsuitable printing substrates can cause serious damage irrepara ble in the case of print heads as a result of tearing and the emission of vapors Check each and every roll of printi...

Page 63: ...tions Page 63 370 Information If you aren t sure whether a printing substrate is suitable please send a roll of the material along with the associated data sheet to Markem Imaje CSAT GmbH and have it checked for its suitability The printer owner still bears sole responsiblity neverthess for the use of material tested this way ...

Page 64: ...e materials it s better to feed the seams slowly through the printer manually and not during the printing process Determining factor parameter Required property Adhesive power The adhesive tape should be suitable for the materials to be joined If in doubt test the holding power Temperature resistance 120 C The following materials have been approved by CSAT Manufacturer Description Order number CSA...

Page 65: ...t ends of adhesive tape next or above each other Never allow open adhesive surfaces to protrude from the sides of the web Solely the system user is responsible for any damage that results from improper application of the adhesive tapes and or using unsuitable material 3 11 Noise level Measured in accordance with DIN 45635 1 Kl 3 Emission Sound power level generated by the printer Lw 67 dB A Immiss...

Page 66: ......

Page 67: ...ctions Machine Description Copyright by Markem Imaje CSAT GmbH ITS6_135_Manual_EN doc Subject to Technical Modifications Page 67 370 4 Machine Description 4 1 Functional diagram Fig 7 Functional diagram of ITS6 part 1 ...

Page 68: ...Machine Description Operating Instructions Copyright by Markem Imaje CSAT GmbH Page 68 370 Subject to Technical Modifications ITS6_135_Manual_EN doc Fig 8 Functional diagram of ITS6 part 2 ...

Page 69: ...assemblies in the printer as shown by the numbered position in the fol lowing illustration Fig 9 Components ITS6 210 with Camera Pos Component Pos Component 1 Unwinder shaft 10 Web retraction system 2 Printing substrate cleaning unit 11 Printing table 3 Dancer roller 12 Infeed height control 4 Web tension control 13 Print head unit 5 Cut and splice device with blade and printing substrate clamp 14...

Page 70: ...itions relates to the sequence with which the printing substrate passes through the machine Fig 10 Sensors CSAT ITS6 210 with camera Pos Sensor 1 Material sensor for monitoring the diameter of the unwinding roll 2 Web guider 3 Web retraction system end stop left 4 Web retraction system working position left 5 Web retraction system working position right 6 Web retraction system end stop right 7 Pri...

Page 71: ...e or deactivate indi vidual components retrieving and editing actual values and setpoints The upper monitor is used for controlling the camera system In addition the upper part of the control panel contains an emergency stop button four command buttons and a USB interface that permits image files and format files to be read and written rapidly via a commercially available USB stick The operator is...

Page 72: ... travel The printing sub strate is then led over more guide rollers to the web guider and the web re traction system In the print head unit the printing substrate is passed by four consecutive print heads each of which transfers a primary color to the desired image During the subsequent curing process with UV light the ink is chemically cross linked The cross linked ink bonds securely with the par...

Page 73: ...h of the printing substrate The following illustration depicts the schematic diagram of the path of the printing substrate when the outside of the printing substrate is to be printed The printing substrate passes successively through the stations shown in the functional diagram see Chapter 4 2 Schematic representation Fig 12 Path of the printing substrate ...

Page 74: ...rocess Fig 13 Detailed view of the unwinding unit Pos Element Meaning 1 Unwinder shaft Supports and centers roll of printing substrate 2 clamping bar Secures the printing substrate roll to the shaft 3 Rotary switch Tightens or releases the roll of printing sub strate Unwinder shaft The unwinder shaft has a diameter of 69 mm With the help of three radial adjustable clamping bars it can accommodate ...

Page 75: ...ble to the outer surface Fig 14 The material sensor in the unwinding unit Material sensor unwinding unit The outer diameter of the roll of printing substrate inserted is monitored constantly by a sensor The distance to the outer surface is measured The actual diameter can be read in millimeters off the touchscreen in the tab Consumable Reels Once the roll of printing substrate reaches a preset dia...

Page 76: ...s and transferred to rollers with adhesive foil Fig 15 Printing substrate cleaning module Pos Element Meaning 1 Cleaning roller Removes loose dirt particles e g fibres or film scraps of the printing substrate 2 Roller with adhe sive foil Removes the gathered dirt particles from the cleaning roller and stores the dirt 3 Pneumatic cylin der Moves the cleaning roller and the glue rolls against the pr...

Page 77: ...ls where the dirt particles are retained by pa per coated with glue When the printer is standing still or even switched off the white rolls are re tracted from the printing substrate by means of springs the grey cleaning rollers glide a few millimetres away from the printing substrate The outer paper layer of the white glue rolls should be removed every eight hours by tearing it off at the embosse...

Page 78: ...unwinding unit and web tension control unit Technical realization A so called dancer roller is attached to a pivoting lever arm which is con nected to the swivel module The angle of the dancer roller is registered by an angle transmitter and used to the control the speed of the unwinding unit drive The printing substrate is pre tensioned in accordance with the dancer force set in the touchscreen F...

Page 79: ...ntered in the touchscreen The speed is controlled by means of the angle transmitter in the printing substrate storage assembly When too much printing substrate is unrolled the dancer roller is moved down by the pre set dancer force The speed of the unwinding unit is de creased so that the roller can return to its nominal position When not enough printing substrate is unrolled the dancer roller is ...

Page 80: ... control Purpose Generates a pre tension of the printing substrate entered in the touchscreen Technical realization Static friction on a rubber roller Fig 18 Cut and splice device with web tension control Fig 19 Structure of the ITS6 web tension control Pos Element Meaning 1 Swivel axis Releases the printing substrate by pivoting the pressure roller away 5 4 5 3 2 1 ...

Page 81: ...sion control In order to ensure that the printed material is fed through the printer without wrinkling the printer is equipped with a so called web tension control The web tension control achieves a constant tension of the printing sub strate in the area between the web tension control and the friction drive The web tension control setting can be read off the touchscreen and changed if necessary s...

Page 82: ...ric tion roller 2 Set screws with knurled lock nuts For setting the distance pressure between the pressure roller and friction roller 3 Latch Fixes the rack with the pressure roller either in the operating or in the service position Adjusting the pressure roller The pressure roller 1 is meant to increase the friction force between the supplied material and the light colored rubber roller of the we...

Page 83: ...2 at both ends of the pressure roller By turning the lower and or inner knurled screws counterclockwise the two black bearing heads are pushed down Make sure that the pres sure roller is lowered evenly and is aligned parallel to the rubber coated drive roller but without caving in its surface Afterwards the upper lock nuts should be tightened carefully so that the pressure roller is secured in the...

Page 84: ...h the printing substrate in the cut and splice device 4 Clamping drum Presses the web down onto the cutting table in order to secure it 5 Guide roller Exit area of the cut and splice device This component is used during roll replacement to cut off the printing sub strate Afterwards the end of the new web is joined to the material left in the printer by means of tape Afterwards the new web can be p...

Page 85: ... cutting table plate When the safety doors are opened the clamping drum is in the clamping position The printing substrate cannot be moved This ensures that this position is kept after the web is cut through The printing substrate clamp is released by means of a button located on the rear wall above the clamping drum When the button is pushed the rubber axis swings up and releases the web If the b...

Page 86: ...tem 4 Corona station The corona station improves the wettability of the particular printing substrate 5 Bar electrode Generates a corona through high voltage dis charge which alters the surface of the sub strate being passed through The corona treatment is needed especially when printing glossy plastic materials in order to improve the adhesion of the applied ink Without the corona treatment the a...

Page 87: ... off as needed using the tab Job Job settings on the touchscreen Likewise the setpoint for power can be entered here These settings are stored in the associated format file Caution The corona treatment produces ozone which can harm the respiratory tract and the components of the printer The ozone that is released is usually neutralized and rendered harmless in the activated charcoal filter of the ...

Page 88: ... the control 4 Clamping screw Positioning of the sensor The web guider The web guider is a self sufficient auxiliary system which functions inde pendently of the printer and is not affected by its controls The flow of the printing substrate to be fed to the printing unit is monitored by a sensor After the printing substrate has been inserted it is moved by hand along a rail until it is just above ...

Page 89: ...ease refer to the associated manufacturer s documentation in the appendix of this manual 4 6 9 1 The control panel of the web guider Fig 25 The control panel of the web guider The majority of the displays and buttons are not relevant for normal opera tion and therefore are mentioned only for the sake of completeness For more information please refer to the web guider manual The buttons and display...

Page 90: ...ensor display illuminates 5 Direction of travel of web Indicates which direction of travel of the web was programmed for the device In this case only the right down arrow should be illuminated 6 Manual shift ing of the web position Shifts the web in the direction of the arrow selected The buttons are active only in automatic or manual mode The display changes only in automatic mode however Further...

Page 91: ...to avoid any damage Whenever the printer is moved somewhere else the pivoting frame of the web guider must be secured in its center position by means of the two screws marked by red flags These lock screws must be removed before the printer is switched on for the first time since otherwise the drive of the web guider could become damaged due to overload 4 6 9 3 Web guider safety features The web g...

Page 92: ...it Technical realization Correction of the lateral position of the printing substrate at the exit by means of electromotive adjustment of the entire pivoting frame Fig 26 ITS6 sensor of web guider Pos Element Meaning 1 Sensor Sensor for the control Sensor of the web guider This fork shaped ultrasonic sensor is attached to a rail on which it can be moved from side to side During the set up of the p...

Page 93: ...inted 2 Electrode 100 E2 Eliminates electrostatic charges on the opposite side of the substrate Pure plastic foils or printing materials which also contain plastic for exam ple so called peel push foils or textiles made of synthetic fibers take on an electrostatic charge during the unwinding and diverting processes Since such charges dissipate only very slowly into the air and the substrate as wel...

Page 94: ...og the individual nozzles there In order to preclude the negative effects listed here the electrodes of the substrate discharger are automatically activated switched on whenever the substrate is in motion inside the printer that is during the normal print ing process and also during the mechanical feed process Caution Risk of injury upon contact with the electrodes of the printing substrate discha...

Page 95: ...te charge and adheres them The machine operator suffers harmless but annoying slight electric shocks when he she approaches the substrate Deterioration of the image quality In zones with a high charge or where discharges took place the applied ink droplets can be deflected or run on the material in a way that is different from the desired structure Winding up the printing substrate is worse if the...

Page 96: ...em Purpose Completion of the printed image curing of the printed areas and retraction of the last printed image This way the starting position is reached for seamless printing after a re start Technical realization The movement is achieved on a minimum length of printing substrate by means of a double roller pair on a linear carriage Fig 29 ITS6 web retraction system 1 2 4 3 ...

Page 97: ...rage whenever the printing process has to be stopped After a regular stop all images that have been started are completed and cured Afterwards the carriage with the guide rollers moves to the right taking the last image to be printed to the left of the print module where it remains until the printing process is restarted Once the printing process restarts the first image is printed precisely be hi...

Page 98: ...on Ultrasonic sensor with linear guide and clamping function Fig 30 Label sensor Pos Element Meaning 1 Label sensor Sends a signal to the printer s controls which initiates the transfer of the corresponding im age 2 Slide The label sensor is applied at a slide that can be moved in transversal direction of the print ing substrate s movement 3 Teach button Button for calibration 4 Warn Red LED Statu...

Page 99: ...nsor can register a difference in thickness A label printing substrate is unsuitable if it touches adjacent labels residual material is left between the labels the printing substrate is not supposed to be stamped until after printing The label sensor can only be shifted on one axis perpendicular to running direction of the substrate web to the front or to the back The label sensor must be position...

Page 100: ...en the substrate web is transported so that they can be captured by the sensor Press the Teach key T on the label sensor for at least 2 sec until the green and the yellow LED of the sensor start to blink Release the T key Close the open protective device Hold down the Feed forward of the printer until only the yellow LED on the sensor blinks while the green LED glows continuously If the red LED co...

Page 101: ...Positions of the ITS6 print mark sensors Pos Element Meaning 1 Print mark sensor on the side to be printed Detects print marks located on the side of the printing substrate to be printed by the ITS6 When it detects a print mark it emits a sepa rate signal which initiates the printing of the associated image 2 Print mark sensor on the side not to be printed Detects print marks located on the side o...

Page 102: ...ly be moved perpendicular to the direction of travel of the printing substrate and should be positioned so that the print marks pass directly through the sensor s light beam as seen from the di rection of travel When the sensor detects the leading edge of a print mark it sends a signal to the printer s controls which initiate the transfer of the next image as soon as the printing substrate has cov...

Page 103: ...op Position the carriage with the sensor so that when the printing sub strate is conveyed the print marks bars pass directly through the beam of light generated by the sensor and can be detected by it First position the printing material so that the print marks to be detect ed are centered exactly in the spot of white light Now press the sensor button for at least one second until the yellow indic...

Page 104: ...rpose Infeed control at the beginning of the printing process This is intended to prevent printing substrate that is too thick or labels that are sticking up from being able to reach the sensitive print heads Criterion is the height of the material entering the printing unit Technical realization Height adjustable lever which is read by a sensor Fig 32 Infeed height control 1 2 3 ...

Page 105: ...e printing width of the printing substrate Whenever thicker material comes along then the scanning bar will rise which in turn lifts a lever from a corresponding sensor inside the printer If the distance is too great the sensor will trigger an alarm and cause the transport of material to be stopped abruptly The scanning bar sits on an eccentric and can be rotated This permits the scanning bar to b...

Page 106: ... 0 2 0 5 0 2 to 0 3 mm 0 2 0 3 mm 0 2 0 3 0 7 0 3 to 0 4 mm 0 3 0 4 mm 0 3 0 4 0 9 0 4 to 0 6 mm 0 4 0 6 mm 0 4 0 6 1 1 Information Continuing the scanning bar rotation does not always lead automat ically to the next higher or next lower value Sometimes values are skipped that are marked at a different location The reason is that the space for inscriptions on the scanning bar is limited The limite...

Page 107: ...th running bearing mounted guide rollers Fig 33 ITS6 printing table Pos Element Meaning 1 Chassis Bracing ensures the accurate height and lat eral position 2 Exchangeable deflection rollers Support of the printing substrate The printing table has five deflection rollers This reduces the contact be tween the printing substrate and the surface below to such an extent that even electrically charged p...

Page 108: ... material thicknesses Always use the following table as a reference for selecting substrates and deflection rollers Thickness of the printing substrate Inscription on the exchangeable deflec tion rollers Scanning bar ad justment value 0 0 to 0 2 mm 0 0 0 2 mm 0 0 0 2 0 5 0 2 to 0 3 mm 0 2 0 3 mm 0 2 0 3 0 7 0 3 to 0 4 mm 0 3 0 4 mm 0 3 0 4 0 9 0 4 to 0 6 mm 0 4 0 6 mm 0 4 0 6 1 1 When the rollers ...

Page 109: ...nting material This also applies if the particular substrate tends to have bowed or wavy edges 4 6 15 2 Infeed roller of the printing table with angular encoder Task Wrinkle free infeed of the printing substrate into the printing table and ex act determination of the fed printing substrate quantity Technical implementation Roughened roller surface in conjunction with angular encoder Fig 34 Infeed ...

Page 110: ... that is fed to the printing table A gauge ring is secured to the front end of the infeed roller In a contactless process the optical angular en coder scans the fine pattern of horizontal stripes on this gauge ring As soon as the infeed roller and its gauge ring start rotating the angular encoder sends signal pulses to the print head controller The print head controller uses these signals to synch...

Page 111: ...nting sub strate Technical realization Four print heads in a row which apply the primary colors to the printing substrate one after another The print head unit has an automatic cleaning system Fig 35 ITS6 print head unit Pos Element Meaning 1 Print head Y Transfers the primary color yellow 2 Print head C Transfers the primary color cyan 3 Print head M Transfers the primary color magenta 4 Print he...

Page 112: ...hat they would apply the ink to the wrong place This could result in light or dark stripes and discoloration in the printed image when the ink drops are applied over each other instead of next to each other Misaligned print heads can only be readjusted by a qualified service technician from Markem Imaje CSAT GmbH Notice If the printing substrate should tear between the area of the cut and splice d...

Page 113: ...sage 83 Print head unit not in required position will be displayed In this event the print head unit should be pulled manually to the parking position before the printer is turned back on 4 6 16 3 Care of the print heads The underside of the print heads always have a thin film of ink which is at the risk of hardening when exposed to the rays of the pre curing unit or light from outside The only wa...

Page 114: ...nd can only be installed by one of the manufacturer s service technicians Therefore please emphasize to all your employees that the print heads al ways have to be handled with care and that the aforementioned cleaning procedures and intervals must be strictly adhered to Notice If the print heads are cleaned improperly or not often enough this can result in the loss of all warranty rights 4 6 16 4 ...

Page 115: ... se lected previously are rinsed out with ink for a few seconds While the print head unit is being moved back into its working position each wiper will stay flipped up as long as it is beneath a print head that has just been rinsed The ink that is wiped off the print heads flows down the wipers into the col lection pan Each wiper unit consists of three main parts each of which occurs in a pair rub...

Page 116: ...forming the cleaning pro cess often enough 4 6 16 6 Wiper shower Task Automatically cleaning adhering ink and other contamination off the wiper Technical implementation Cleaning fluid is sprayed automatically on each wiper Fig 39 Cleaning the left wiper unit with the wiper shower Item Element Meaning 1 Spray nozzles of the wiper shower Removing adhering ink and other contamina tion from the indivi...

Page 117: ...g fluid reservoir Efficient cleaning of more than one wiper unit could thus not be ensured The settings of the wiper shower can be changed in the Job Cleaning tab Fig 40 Wiper shower Item Element 1 Spray nozzles of the wiper shower 2 Wiper 3 Swivel type wiper holder Information Despite the wiper shower function manually cleaning the wipers and their supports after each shift and checking their fun...

Page 118: ...d on the surface by UV light on the way between the adjoining print heads to the point that it cannot mix with the next ink to be applied Conversion of short ink molecules into long chain chemically and mechan ically resistant macro molecules when subjected to UV light Fig 41 Pre curing inside the print head unit Pos Element Meaning 1 Pre curing Y Pre cures the yellow ink applied by the first prin...

Page 119: ...place since no more ink is applied but rather the printing substrate is conveyed to the main curing module where all of the applied ink is completely hardened Fig 42 Close up of a dismantled LED strip of the pre curing unit All three of the UV pre curing modules have the same design The lamps consist of UV LEDs which compared to UV fluorescent tubes do not have to be pre heated and therefore requi...

Page 120: ...the pre curing unit is operated at the lowest possi ble power level Make sure that all print heads undergo a standard or intensive cleaning at least every two hours Notice If thin white lines appear lengthwise in the prints then Stop the printing process immediately and have all print heads un dergo a standard or intensive cleaning Keep repeating these procedures until all of the print heads are c...

Page 121: ...or cross linked ink spots should be removed using only the special cleaning pads no ZE1010 75 All other cleansers are prohibited Notice Never clean the LED strips and the adjacent areas with aggressive solvents e g acetone or wipe off with dripping wet low viscosity liquids e g water glass cleaner isopropyl alcohol Solvents and low viscosity cleansers are prohibited since they can penetrate the la...

Page 122: ...of the printed image by means of chemical cross linking This pro duces an abrasion resistant print Technical realization Conversion of short ink molecules into long chain chemically and mechan ically resistant macro molecules when subjected to UV light Fig 43 main curing Pos Element Meaning 1 Lamp module 1 Complete curing of the ink 2 Lamp module 2 Complete curing of the ink 1 3 2 4 5 ...

Page 123: ... even heat sensitive materials won t be damaged The UV main curing lamp modules are water cooled The UV main curing modules are switched on automatically before the un cured image reaches the first lamp module While the printing process is going on all of the UV pre curing modules remain switched on continuous ly They are not switched off until the printing process is stopped and the printing subs...

Page 124: ...rom the interior of the printer 2 Activated charcoal filter Eliminates odors and intercepts particles 3 Exhaust duct Inflow of cleaned air into the interior of the printer Circulation system The air circulation filter system is used to eliminate unwanted substances from the air circulating inside the printer and to prevent odors Since the printer is almost entirely enclosed the exchange of air wit...

Page 125: ...ning via activated char coal filters Fig 45 Air cooling rear view with open safety door rear Pos Element Meaning 1 Intake grille Extraction of hot air from the interior of the printer 2 Activated charcoal filters behind the ventilation grille Eliminates odors and separates particles 3 Ventilation grille Discharge of the cleaned air into the environ ment By the extraction of hot air the interior of...

Page 126: ...nd inserting variable components Technical implementation Standard PC with installed CAPS software CSAT Advanced Print Server Fig 46 CAPS server rear view The CAPS server performs color separation and enters variable data into the rendered images All cables of the CAPS server are installed and secured The CAPS PC does not need to be switched on off separately It is connected to the power supply of...

Page 127: ...ubstrate to the camera Access to the camera to the mirror and to the plug in connection of the lighting 4 Lighting unit Illuminates the printing substrate with white LEDs 5 Guide roller Guides the printing substrate The camera system consists of the camera module that is installed in the printing system a control computer that is installed on the printing system and a camera control panel that is ...

Page 128: ...tion Controller is installed in the finishing system 4 6 23 Function of the camera system components Camera module Each printed image is fully scanned by a camera Two LEDs illuminate the image section in front of the camera lenses Most of the camera module is encapsulated so that almost no light can get to the outside dazzling the operators Incremental encoder The incremental encoder provides the ...

Page 129: ...rate for wrinkle free infeed 2 Drive shaft with rubber roller Ø 80 mm Transport of the printing substrate 3 Pressure roller Ø 50 mm Ensures static friction where the printing sub strate contacts the rubber roller The parallelism is adjusted by means of the knurled screws 4 Swivel axis Releases the printing substrate by pivoting the pressure roller away 5 Service access Replacement of rubber sleeve...

Page 130: ...friction unit conveys the printing substrate coming from the unwinding unit past the print head unit and UV curing systems at a constant specified speed The printed material is then conveyed to the rewinding unit The friction drive interacts with the web tension control to create a constant tension of the printing substrate between these two components The set tings of the friction drive can be re...

Page 131: ... screws Fig 49 Pressure roller Pos Element Meaning 1 Pressure roller Presses the printing substrate against the drive roller of the friction drive 2 Set screws with knurled lock nuts For adjusting the distance pressure between the pressure roller and the rubber coated fric tion roller 3 Locking mecha nism Secures the pressure roller either in the oper ating or the higher service position Adjusting...

Page 132: ...left so that the friction drive won t slip during printing operation First loosen all of the knurled lock nuts 2 at both ends of the pressure roller By turning the left inside knurled lock nuts clockwise the two black bearing heads will be pushed to the left Make sure that the pressure roller is aligned parallel to the rubber coated drive roller Furthermore never press the pressure roller into the...

Page 133: ...1 Main switch and ON OFF switch The round main switch and the red green ON OFF switch are located on one of the two narrow ends of the printer Fig 50 Main switch and ON OFF switch on the printer Pos Elements Meaning 1 Main switch Disconnects the printer from the power supply In the 0 position the entire printer is dead 2 ON OFF switch In the 0 position it disconnects the power supply to all drives...

Page 134: ...back out and a green ring becomes visible 2 Start printer Pushbutton that is active only in roll to roll mode After this button is pressed the printer will start working This button will blink until the material starts to be conveyed This button is constantly illuminated during the print ing process This button remains dark when the printer is stopped Whenever the printer has been stopped it can b...

Page 135: ...riction unit will start up In addition the curing systems will be switched on This key is activated illuminated yellow only as long as the print head unit is in its parking position 6 USB port Interface for data exchange The USB port interface supplements the printer s network connection for the printer and is used primarily for the rapid import and export of image and format files by means of a U...

Page 136: ... it is possi ble to install an automatic block This is currently not available If neces sary the automatic block can be implemented by the CSAT The Emergency Stop button of the printer is not included in the access re striction it can therefore always be used 4 7 4 The printer s display The touchscreen of the control panel enables convenient operation of the ITS6 The operating status of the ITS6 a...

Page 137: ...tting your finger on the touch element you can intervene in the process events directly Notice Prevent any damage to the touchscreen The touchscreen should only be touched gently and with minimum pressure Do not punch around on the screen frantically Risk of breaking Never touch several touch elements simultaneously Otherwise you could trig ger actions unintentionally The touchscreen is suitable o...

Page 138: ...igura tion Inline or roll to roll mode ability to switch on the components or system parts required for the particular print job Automatic access to manufacturer provided parameter tables for vari ous materials and printing speeds This way the best printing quality is achieved faster and more easily Ability to compile and store detailed log files in which details of all of the events switching pro...

Page 139: ... other door lock switches of the printer Therefore even if one of the front doors of the print er is open the drives and high voltage will remain switched off even if the operator pushes the enabling switch 4 7 7 2 How the enabling switch works The enabling switch works overrides the rear door only as long as the spring loaded button is held down halfway or deeper but without reaching its switchin...

Page 140: ...creen Open the tab ManufacturerService Service and hit the On key in the Enabling mode box Open the rear door panel of the printer and remove the enabling switch from its compartment Function check It the enabling switch is held down at its switching point then the mes sage 66 Rear door open must disappear from the Current Alarm line of the control panel within a few seconds Then if the button is ...

Page 141: ...als No matter what the operating status is at a given moment each of the four different colored lights could burn continuously blink or remain dark It s also possible for several lights at once to give off signals If the signal light is equipped with a buzzer acoustic signals are emitted as well The stack light is divided into the following segments from top to bottom Fig 53 Stack light Pos Elemen...

Page 142: ...een the unwinder shaft of the print er and the web tension control of the unwinding device By consequence the lever with the dancer roller has fallen into its lower stopper The printing process will be stopped Notice Faulty signals after incorrect assembly The order of the light elements and the optional buzzer from top to bottom Buzzer red yellow green blue must not be changed since otherwise the...

Page 143: ... interfaces pose a hazard Avoid the penetration of dirt and moisture Whenever the interfaces are not in use cover the sockets with the matching plastic caps Information The printer is delivered without connection cables The machine owner must supply them and have them made to comply with the conditions on site Fig 54 Interfaces rear view Pos Bedeutung 1 Electrical power supply 2 Process interface ...

Page 144: ...of the printer via a network The connection cables must be suitable for industrial use on the basis of its shield Cat 5 Please make sure that the cables are always inserted se curely in the sockets of the printer 4 8 5 Compressed air connection A permanently installed FESTO KS4 1 4 A type compressed air coupler serves as the connection for compressed air The supplied air must be dry and oil free a...

Page 145: ...ption Copyright by Markem Imaje CSAT GmbH ITS6_135_Manual_EN doc Subject to Technical Modifications Page 145 370 4 8 9 Coolant connection Intake and discharge are standard hose fittings Required inner diameter of the connecting hoses 19 mm ...

Page 146: ... Enter to confirm After a successful login your user name appears in the bottom right corner of all screens The login button is colored and no longer black and white When you log in for the first time you must enter the standard password that is associated with your user account Next the system prompts you to replace the standard password with your personal password Use this new personal password ...

Page 147: ...ted if necessary An expired password must be replaced with a new one 4 9 1 Logging off at the touchscreen To log off press the login button in the bottom right corner of the touchscreen Most buttons and displays are now locked This shows with a dimmed gray display The system logs off the user automatically when the touchscreen is not used for a specified time after login The user is logged off aut...

Page 148: ...ng Main curing Web settings Print head alignment Cleaning System Settings Network File manager Machine info User management Consumables Fill levels Reels Print heads UV modules Wipers Drive rollers Air filters Ink filters Documents Audit trail Printing costs Alarms Alarms Manufacturer service Service 1 PV monitor PV monitor 2 Synchronization settings Other settings Cleaning settings Process settin...

Page 149: ...us messages 3 Tabs for selecting the various masks 4 Navigation keys Access to sub menus The key associated with the menu currently being shown will be color coded that is darker than the other keys 5 Indicates the printing speed for offline mode After hitting the key bearing the tachometer symbol this setpoint can be changed 6 Indicates the position of the print head unit The print head unit can ...

Page 150: ...ning 9 Hitting this key will shut down the curing systems automatically so that the printer can then be switched off 10 Key for unlocking or locking the touchscreen In order to obtain access to the touchscreen each user must log in with his personal user name and password 11 Footer Indicates the current date time 12 Footer Status name of the user logged in ...

Page 151: ...der Working position Dancer roll er in target position Hitting this key will move the dancer roller of the unwinding or rewinding unit automatically into its target position Shut down system Hitting this key will shut down the curing sys tems automatically so that the printer can then be switched off Clean Hitting this key will call the tab Job Clean ing where the most important parameters of the ...

Page 152: ...ct mark in succession several of the files listed The names of the files selected for data transmission are highlighted in blue As long as the color of this symbol remains dark all of the files marked by the cursor in one direction will be included in the selection list If you change the direction of the cursor the selection will be cancelled file by file Scroll bar The scroll bar appears when lon...

Page 153: ... in the box if activated Load file Loads the marked file or opens a menu in which you can select a file and then load it Export These keys are used in the tab System File Manager for exporting and importing files protocols or certain software Import Save as Hitting this key opens a dialog box with which the format file can be saved either under its current name or under a new name Delete Opens a m...

Page 154: ...presented as a thumbnail Unlock Unlocks a job container Cancel print job This button allows the currently selected print job to be cancelled but not until con firmed by a prompt Continue Starts enables user to start a print job Set up mode This button is similar to a Pause button As long as this button is depressed the current print job will be temporarily stopped for in stance in order to make pr...

Page 155: ... indicator Black color indicator Active If the black dot can be seen this function has been activated This indicator appears frequent ly when there is an optional choice i e only one function or option can be selected Inactive If the black dot is not visible this function has been deactivated Active Checks box for activation In this case multiple selections can always be made Cf User management In...

Page 156: ... the components in question are in their operative target positions Caution Either the components in question are not in the normal state for operation or else there is a malfunction Image cannot be displayed General error message that a graphic cannot be displayed by the HMI This refers to thumbnails of the image file but also to symbols or control elements of the HMI ...

Page 157: ...he printing system should stop the printing process automati cally Fig 57 Job Job settings tab Item Object Meaning 1 Image align ment The selection list shows what principle should be applied to print the individual images one after the other Only one of these options can ever be activated Additional gaps can occur on the printout when the printing process is inter rupted Print mark sensor Activat...

Page 158: ...ess stops automatically when this is reached 8 Lay outs Single images Job counter for the layouts and individual images printed Given in number of layouts or images The counters can be reset to 0 with the blue Reset button 9 Material Job counter for printed material measured in linear me ters The counter can be reset to 0 with the blue Reset button 10 Length per printout Total length of a printed ...

Page 159: ...Change order Move the selected job container upwards in the order 5 Delete Delete the selected job container 6 New Generate a new job container 7 Copy Copy the jobs of the selected job container to the clip board 8 Insert Insert the jobs currently located on the clipboard into the job container currently selected 9 Print Send the selected job container to the printer 10 Unlock Unlock a job contain...

Page 160: ...ob container that contains the desired job s Press the Copy button In the Job container list box select the job container into which the jobs should be inserted Press the Insert button The copied jobs are inserted into the selected job container Deleting jobs from a job container Select the desired job container in the Job container list box Display showing the jobs contained in the Jobs list box ...

Page 161: ...he padlock Confirm the safety inquiry The user can then edit the job container again If the job container should be printed it must be sent to the printer again 4 10 3 Tab Job Job manager This tab displays status information The operator can abort jobs or pro ceed with a job when the system required an intervention Fig 59 Tab Job manager Pos Item Meaning 1 Print job processing Display of status in...

Page 162: ...on Selection of which color pre curing should be activated for The pre curing can be activated simultaneously for one or more colors 2 All None Activate deactivate pre curing for the entire printing area 3 Selection Selection of the area for which pre curing should be activat ed 12 sections each 18 mm wide can be selected A contig uous region must be selected Multiple areas that are sepa rated fro...

Page 163: ...e main curing power P should behave with respect to the printing speed The higher the printing speed the higher the power 3 UV1 UV3 Actual temperature of the respective UV lamp module 4 UV power supply unit Status indicator and ON OFF switch to of the power supply unit of the UV curing unit The button serves especially to turn the main curing unit back on after the displayed temperatures UV1 UV3 h...

Page 164: ...e field remains empty 2 Web guider Status indicator and ON OFF switch to activate the web guider If the Locked option is selected the web guider switches to so called middle mode in which it has no influ ence of any kind on the position of the web There is a status indicator to the right of this A yellow tri angle with an exclamation point appears in the event of a fault otherwise the field remain...

Page 165: ...r and ON OFF switch for locking or releas ing all linear guides of the label and print mark sensors installed A black check mark should always be displayed here dur ing printing operation 6 Feeding speed Displays the target speed set for feeding The value can be modified with the adjacent button 7 Web cleaning turn on Status indicator and ON OFF switch to activate the printing substrate cleaning m...

Page 166: ...y 1 pixel 2 Indicator Current correction value for the respective color with respect to the left edge of the printing substrate viewed in the direc tion of travel 3 Increase distance Moving the respective color in the direction of the arrow or away from the left edge of the printing substrate Each press of the arrow button increases the respective correction value by 1 pixel 4 Input prompt Enter v...

Page 167: ...nt differs significantly from the value stored in the re spective format file 12 Input prompt Enter value manually Permissible values are 1000 to 1000 4 10 7 1 Print head alignment in feed direction The position of the yellow color cannot be changed All other colors are aligned to yellow Perform a short test print Use a scale magnifier to measure how far the target position of the im age elements ...

Page 168: ... printed image is OK 4 10 7 3 Web specific correction The printing substrate thickness has an effect on the color registration in the printing direction To achieve optimal color registration you can use a printing substrate specific correction value You determine a printing substrate specific correction value as follows Under Job Print head alignment on the touchscreen set all values in the Print ...

Page 169: ... and the next line in millimeters Multiply this line distance measured in millimeters by the constant factor 770 You must increase or reduce the amount by this value Example The current value of the Web specific correction field is 1000 The lines appear in a test printout in the order yellow cyan magenta black from left to right Therefore the value must be reduced You measure a distance from one l...

Page 170: ...on Operating Instructions Copyright by Markem Imaje CSAT GmbH Page 170 370 Subject to Technical Modifications ITS6_135_Manual_EN doc Fig 65 The value in the Web specific correction field must be reduced Print direction ...

Page 171: ...stem Fill with cleaner Selection key The print heads in question are filled with a greater amount of cleaning fluid This process has to be re peated several times until the contents of the print head and the connecting lines have been completely replaced Fill with ink Selection key The print heads in question are filled with a greater amount of ink This process has to be repeated sever al times un...

Page 172: ...ect to Technical Modifications ITS6_135_Manual_EN doc Information During the printing process and whenever the residual ink bottle is full or missing an orange red hand symbol will be shown next to the button This is to advise the operator that the cleaning process cannot be start ed at this time ...

Page 173: ...lection of the desired display language After hitting the desired key the display language of the MHI will change with in a few seconds Only one language can be selected at a time 2 System date and time Setting of the current time for the touchscreen and printer After hitting the command prompt key an input box will ap pear in which the new system time setting can be entered 3 Password current use...

Page 174: ...he existing settings Possible scenarios Production Local service Remote service enables servicing from an external source for example by a Markem Imaje CSAT service computer Development 2 Host Name Display of the host name of the process computer the local network This information can be changed after hitting the blue com mand prompt key 3 Domain Name Display of the domain This information can be ...

Page 175: ... 69 Tab System Network bottom section Pos Item Meaning 11 Web server Activates or disconnects the connection between the PC of the printer and the local web server This option is available for all scenarios 12 Mail server Activates or disconnects the connection between the PC of the printer and the local mail server This option is available for all scenarios 13 Allow for remote login This option a...

Page 176: ...ote Service and Development only 16 Allow for access to broker This option allows or prevents access of external systems to the broker of the printer PCs via Intranet This option is displayed in the scenarios Local Service Remote Service and Development only 17 Allow for Linux up date via network This option allows the Linux software operating system of the printer to be updated via Intranet This ...

Page 177: ...e Variables log One or more variables log protocol files in which all of the changeable variables are kept Message log One or more message log protocol files in which the current statuses and actions of the printer are kept Printing costs Printing costs System log System log Import of 2 Format Format files with the settings of the printer Layout Layout file Visualization pro ject Software that cre...

Page 178: ...ntly installed 3 Engine Version of the engine software currently installed 4 CAPS Service Version of the CAPS Service 5 CAPS Renderer Version of the CAPS Renderer 6 Machine type Machine model 7 Serial number Serial number of the printer 8 Total counter printed meters Total quantity of the printed material measured in me ters A user logged in as CSATAdmin has the possibility to reset this value to ...

Page 179: ...al measured in me ters A user logged in as CSATAdmin has the possibility to reset this value to the value as set in Manufacturer ser vice Other settings Counter initial value Doing so can be necessary when the engine board has to be ex changed in order to transfer the values that already have been accumulated on the old engine board to the new engine board 10 Total counter hours Total running time...

Page 180: ...and qualifications The individual access rights are assigned by the user administrator The authorization and privileges of each employee are defined during the crea tion of the user account by clicking on the corresponding selection buttons These rights can always be changed later The number of defined user groups and the establishment of precise ac cess rights are to be determined by the system o...

Page 181: ...ntered whenever you want to log in This information is recorded in the so called audit trail and in the event log 9 Real full name First and last name of the particular employee This infor mation is recorded in the so called audit trail and in the event log 10 Password The secret password of the particular user A password must be at least six characters long and contain numbers as well as at least...

Page 182: ... thermore a saved password is automatically disabled after the period of validity expires and has to be replaced with a new password 4 11 5 2 User Administrator lower section scroll bar down In the lower section of the screen all access rights and privileges which can be assigned to the individual employees are listed Each of these ac cess rights should be considered separate from the other privil...

Page 183: ...on electronic components They are also authorized to exchange software change or replace format files parameters lists etc 16 Fitting the printer Those setting up the printer are allowed to import and ex port image and format files change network settings and make basic settings on the curing unit 17 Operating the printer Operators are authorized to supervise the ongoing print job add replace subs...

Page 184: ...listed under the tab Consumables has been used up or a component has reached the end of its guaranteed lifetime the system will make the operator aware of this condition in the following way The Consumable navigation key will be marked conspicuously with a yellow warning sign The color of the letters on the tab in question will change from black to red The background of the particular elapsed time...

Page 185: ...s reached a critical fill level If the fill level of each is OK a green check mark will be shown If the fill level of a container should be critical then the tank in question will be marked by a yellow triangle with a black exclamation mark In this case a full cartridge should be inserted or respectively an empty residual ink bot tle should be installed Fig 74 Tab Consumables Fill levels Pos Item ...

Page 186: ... in the unwinding unit detected by the sensor 2 Warning Indicates the warning threshold diameter below which the message no 4 Unwinding unit web almost used up will be shown on the Alarms page The printing process will contin ue The blue signal light will start to blink This setpoint can be changed after hitting the blue command prompt key 3 Alert Indicates the alarm threshold diameter below which...

Page 187: ... larger solid colored areas The print head row 1 is located on the side next to the inside wall of the printer The print head row 2 is located on the side of the web of substrate facing the operator Fig 76 Tab Consumables Print heads Pos Item Meaning 1 Print head counter row 1 Indicates the location The print head row 1 is located on the side next to the inside wall of the printer 2 Shots Indicate...

Page 188: ...S6_135_Manual_EN doc Pos Item Meaning 7 Warning threshold Setpoint at which when reached the operator should be notified in several ways cf Section 4 12 that a print head has nearly reached the end of its recommended running time useful life The command prompt key opens an input box with which the setpoint can be entered manually ...

Page 189: ...e reading to 0 h Module 1 Uppermost module Module 2 Center module Module 3 Bottommost module 2 Usefule life main curing Setpoint at which when reached the operator should be notified in several ways cf Section 4 12 that the main curing has nearly reached the end of its useful life The command prompt key opens an input box with which the setpoint can be entered manually 3 Pre curing counters The la...

Page 190: ...tions ITS6_135_Manual_EN doc Pos Item Meaning 4 Usefule life pre curing Setpoint at which when reached the operator should be notified in several ways cf Section 4 12 that the pre curing has nearly reached the end of its useful life The command prompt key opens an input box with which the setpoint can be entered manually ...

Page 191: ... the wip ers of a certain color was used Fig 78 Tab Consumables Wipers Pos Function Meaning 1 Wiper counters Indicates the current number of hours in which the wipers installed beneath each line of print heads Hitting the blue Reset key will reset the reading to 0 2 Warning threshold Setpoint at which when reached the operator should be noti fied in several ways cf Section 4 12 that a pair of wipe...

Page 192: ...l reset the reading to 0 h 2 Counter of rewinder Current running time of the drive roller belonging to the web tension controller that leads the web to the finishing machine measured in meters Hitting the blue key will reset the reading to 0 h 3 Counter of friction drive Current running time of the drive roller belonging to the friction drive measured in meters Hitting the blue key will reset the ...

Page 193: ...nsumables Air filters Pos Item Meaning 1 Current Indicates the current running time of all installed air filters measured in hours Hitting the blue key will reset the reading to 0 h 2 Warning threshold Setpoint at which when reached the operator should be noti fied in several ways cf Section 4 12 that the air filters have nearly reached the end of their recommended running time The command prompt ...

Page 194: ... 81 Tab Consumables Ink filters Pos Objekt Bedeutung 1 Current Indicates the current running time of all installed ink filters measured in meters Hitting the blue Reset key will reset the reading to 0 h 2 Warning threshold Setpoint at which when reached the operator should be noti fied that the ink filters have nearly reached the end of their recommended running time The command prompt key opens a...

Page 195: ...g illustration The audit trail starts at the time of the initial commissioning of a printer or when the touchscreen software is newly installed and continues being writ ten thereafter In order to find the events of a certain time period faster therefore the audit trail is provided with a search by date function Fig 82 Tab Documents Audit trail Pos Item Meaning 1 Machine No Serial number of the par...

Page 196: ... events continues on unin terrupted regardless of whether the user makes use of this help function or not 7 Start date Starting date of the search by date function By hitting the blue command prompt key a calendar will open in which the desired starting date of the period to be shown can be en tered A more detailed entry of the starting time which in cludes hours and minutes is not possible End da...

Page 197: ...articular the messages which are less critical and which are usually overwritten by alarms with higher priority and therefore seldom appear in the line Current Alarm in the header The printing process cannot be started until all irregularities have been eliminated and the Alarms list is empty Fig 83 Menu Alarms Pos Item Meaning 1 Message list List of the error messages or irregularities registered...

Page 198: ...n switch to switch between test mode and normal operating mode The current state is marked with a black dot Furthermore the symbol is displayed in the header in test mode 2 Enabling mode Selection switch to switch between normal operating mode and the enabling mode necessary during setup or repair work using the enabling switch in order to be able to observe the cleaning of the print heads from th...

Page 199: ...6 Diagram Piping diagram representing the most important components and pipelines for cleaning fluid and inks If a problem is detected in a component a yellow triangle with a black exclamation point is displayed on the corresponding symbol Each print head unit is provided with its own piping diagram 7 Arrow but ton Selection button to switch between the piping diagrams ...

Page 200: ...test mode To improve the overview the PV process variables are combined into groups according to their functions or associations for example for web transport curing or cleaning Fig 85 PV monitor tab Item Object Meaning 1 Group Designation of the group or function to which the process var iables listed below should be assigned 2 Variable Short designation of the respective process variables 3 Setp...

Page 201: ...r service Synchronization settings Item Object Meaning 1 Image alignment The selection list shows what principle should be applied to print the individual images one after the other Only one of these options can ever be activated 2 Index length Setpoint for the distance between the beginnings of the imag es if Fixed distance mode is selected The value can be modified with the adjacent button The a...

Page 202: ...s The Top sensor is located on the side of the printing sub strate which is to be printed on and the Bot sensor is locat ed on the back of the printing substrate 6 Label sen sor Setpoint for the distance between the label sensors and the first print head The value can be modified with the adjacent button 7 Unlock Status indicator and ON OFF switch to unlock or clamp the linear guide of the label s...

Page 203: ...sibility to reset the values that are displayed in Machine info Printed meters and Machine Info Total meters to the value set here Doing so can be necessary when the engine board has to be exchanged in order to transfer the values that already have been accumulated on the old engine board to the new engine board 4 Printing cost fac tor Displays the cost factor used in the printing cost calculation...

Page 204: ...ch the Dancer force rewinder setting in the Job Web settings tab is reduced internally in 9 Web tension print head For entering a limit value The limit value represents the upper limit to which the Web tension print head setting in the Job Web settings tab is re duced internally in 10 Web tension rewinder For entering a limit value The limit value represents the upper limit to which the Web tensio...

Page 205: ...yed here during printing operation 2 Time span until next call for cleaning Interval in minutes after which the pop up window with the prompt to clean the print heads is displayed again The value can be modified with the adjacent button 3 Cleaning counter Number of automatic cleaning processes logged by the con troller The value displayed can be reset to 0 h by clicking the blue Reset button Clean...

Page 206: ... tion Setpoint for the power consumption of the pump during the process of rinsing with cleaning fluid as a percentage The value can be modified with the adjacent button 10 Pressure during cleaning process Actual value Displays the pressure measured in the pump during the rins ing process Unit bar Showering wipers 11 Pressure Setpoint for the pressure during intensive cleaning with ink Unit bar Th...

Page 207: ... be cooled without interruption In contrast the Off option should only be selected if the respective printer is not connected to a closed coolant system 4 Pre curing Selection switch to control whether or not the engine should monitor the pre curing unit 5 Parking position cleaning active Selection switch to control whether it should be possible to start cleaning when the print head unit is in its...

Page 208: ...370 Subject to Technical Modifications ITS6_135_Manual_EN doc Item Function Meaning 10 Disable web retraction system Selection switch to activate or deactivate web retraction 11 Corona Activate corona 12 F V network check Switch on or off checking of network connection to finishing machine ...

Page 209: ...ing turn on Selection switch to switch on the power supply of the printing substrate cleaning module 3 Web cleaning electrode active Selection switch to activate the printing substrate cleaning module If this option is switched on the rollers of the printing substrate cleaning module are pressed against the material to be printed on immediately Furthermore the electrodes of the printing substrate ...

Page 210: ...r service Ink pre heating You can control the ink pre heating in this tab Fig 91 Manufacturer service Ink pre heating tab Item Function Meaning 1 Activate pre heating Option for activating the ink pre heating for the respective color 2 Ref Displays the temperature setpoint The value can be modified with the adjacent button 3 Cur Displays the current ink temperature 1 2 3 ...

Page 211: ...pective correction value by 1 pixel 2 Indicator Current correction value for the respective color with respect to the left edge of the printing substrate viewed in the direc tion of travel 3 Increase distance Moving the respective color in the direction of the arrow or away from the left edge of the printing substrate Each press of the arrow button increases the respective correction value by 1 pi...

Page 212: ... Object Meaning 8 Move to the right Moves the respective color in the direction of the arrow or further away from the yellow print head Each press of the arrow button increases the respective correction value by 1 pixel 9 Input prompt Enter value manually 10 Input but ton Pressing this button saves the correction value determined previously through tests ...

Page 213: ...njury due to electrical shock Even when moving the machine only short distances Disconnect the machine from external power sources Before restarting the machine set it up properly and connect it to the power supply Warning Risk of crushing due to falling overturning loads Have the machine transported by trained personnel only Assign a knowledgeable person to give directions during lifting Make sur...

Page 214: ...ter must be placed on a sufficiently large transport pallet or else in its original transport crate so that the lifting gear makes no contact whatsoever with the housing Make sure the load has been secured and distributed evenly Lo cate the center of gravity of the machine when transporting Never stand under a suspended load Carefully remove and save the parts attached for transport pur poses Noti...

Page 215: ...port 5 4 1 Transport preparations Turn the pivoting frames of both web guiders into their central posi tions Push the print head unit back and secure it in place with the transport lock cf Chapter 5 4 2 Switch off the printer and secure against unauthorized restarting At tach a padlock to the main switch of the printer Disconnect the connecting cables and supply lines from the printer Power supply...

Page 216: ...red Position of the transport secur ing device during printing Fig 93 Transport securing device of the print head unit Pos Elements Meaning 1 Transport securing device Securing of the print head unit 2 Knurled screws Fastening of the securing device plate 5 4 2 1 Mounting the transport securing device to the print head unit Remove the top cover panel of the print head unit Move the print head unit...

Page 217: ...uider attach at least one cylinder head screw 2 M4X70 The tip of the screw 2 has to be screwed into console 3 by at least 15 mm Make sure that the tip of the screw penetrates the support roller 4 by some millimeters Please note the instructions on the red label of the pivoting frame 1 Fig 94 Transport securing of the web edge control unit by means of cylinder head screws M4x70 with red flag Fig 95...

Page 218: ... wires on the floor wire conduits with uneven covers light grids safety tread floor plate that lie higher or lower than the surrounding surface In case of doubt make a test run with a four wheeled trolley Clear the transport route of all obstacles Also check whether the floor has sufficient load bearing capacity 5 5 Executing the transport 5 5 1 Transport by crane Right way to transport Transport ...

Page 219: ...ight by Markem Imaje CSAT GmbH ITS6_135_Manual_EN doc Subject to Technical Modifications Page 219 370 The lifting gear touches the upper edg es of the printer The lifting gear is attached to the printer Fig 97 Prohibited transport by crane ...

Page 220: ...in this order Position the forklift under the printer s center of gravity Make sure that the machine is sitting solidly on the forklift and cannot tip over Secure the printer to the forklift Lift the printer off the ground Move the printer to the new location Slowly lower printer to the ground Remove transport restraints Pull out forklift Notice Avoid all jarring of the printer ...

Page 221: ...ission and stored for any length of time 5 6 1 Transport preparations In addition to the tasks listed in Chapters 5 4 1 and 5 4 2 the following tasks also have to be completed Rinse all print heads thoroughly with cleaning fluid tab Job Clean ing This process has to be repeated several times until the contents of each print head and the connecting lines have been completely re placed Remove the su...

Page 222: ...term storage or re move ink cartridges in case of longer storage Replace the residual ink bottle with an empty bottle Empty the collection pan and the small collection pans Dirty absorbent mats should be replaced with new ones All of the articles removed should be stored in their custom packaging outside of the printer and shipped in a separate crate If necessary shove the printer to an area with ...

Page 223: ...eck whether the floor has sufficient load bearing capacity 5 6 3 Carrying out external transports Proceed in the following order For longer transports it is imperative to pack the printer in its original transport crate cf Chapter 5 6 4 For shorter transports on the company premises the printer can be placed directly on a suitable transport vehicle Secure the load against slipping and tipping over...

Page 224: ...med by a company qualified for this purpose Lift the printer onto the floor panel of its original transport crate Place the machine with its floor panel either on squared timbers or screw down the feet of the printer as described in Chapter 6 1 1 3 Setting up the printer Tighten the lock nut of the adjustable feet This protects the threads against damage during transport Secure the machine against...

Page 225: ...een packed according to the requirements then it s ready to go However the following points must be observed throughout the shipping process The transport crate must be protected against heavy fluctuations in temperature as well as against moisture and wetness The transport crate must always be transported in an upright position The transport crate should be transported only by a suitable transpor...

Page 226: ...fore the print ing press is at room temperature Wait until the printing press is at room temperature This is particularly important when the printing press is delivered at a low outdoor tem perature Depending on the temperature difference acclimatization can take several hours or even days Remove the packaging film around the unit only after the printing press is at room temperature Check the cond...

Page 227: ...started Do not begin commissioning until all safety equipment has been installed in full and is functioning properly In case someone is forced to stand directly next to the machine or machine components during commissioning set up or conversion work e g alignment a second person must be present to press the Emergency Stop button if necessary Warning Danger of tripping due to improperly laid connec...

Page 228: ...face The printer should be set up only on even flat surfaces which have suffi cient load bearing capacity in terms of distributed load and concentrated load see Chapter 3 Technical Data 6 1 1 2 Ambient conditions The printer should not be operated unless all of the conditions defined in Chapter 3 Technical Data are met 6 1 1 3 Setting up the printer Lift the print system from the transport crate o...

Page 229: ...ne with the adjustable feet to a uniform height of around 80 to 100 mm The distance be tween the floor and the underside of the printer s base plate should not exceed 125 mm Set the spirit level down correctly Place the precision spirit level only on the surfaces shown in Fig 100 The lengthwise and crosswise measuring surfaces for the precision spirit level must be clean and free of burrs The prec...

Page 230: ...9 Adjustable foot Pos Element Meaning 1 Washer Load distribution 2 Lock nut To lock the levelling foot 3 Thread Guide for height adjustment 4 Lock nut To lock the adjusting nut 5 Adjusting nut To adjust the height 6 Levelling foot Positioning and vibration buffering Fig 100 Correct placement of the precision spirit level 4 2 3 2 5 2 6 2 1 3 2 2 ...

Page 231: ...umatic equipment on the ITS6 printer is pre installed The ITS6 printer requires dry oil free air Flow rate and pressure are maximum 10 dm min and 6 8 bar respective ly Connect the line coming from the on site compressed air supply to the coupling plug on the printer Check for leaks and the secure fit of all hose connections Notice Make sure to connect a pneumatic supply line with a 2 diameter and ...

Page 232: ...inder head screws must be labelled for later transports and kept with the print system Remove all cable ties tape and plastic wrap used to immobilize parts of the printer for the duration of the transport Unpack the indicator light and screw it back on top of the printer 6 2 5 Consumables Now install all of the printer components removed before transport Cartridge with cleaning fluid if missing In...

Page 233: ... damaged or burned cable immediate ly Make sure main switch is always turned off and locked before performing work Cables should not be jammed or crushed Cables must be laid so that they cannot be damaged or pose a tripping hazard Warning Danger of injuries due to non functioning safety equipment Do not remove safety equipment until the machine is shut down The machine may not be operated unless a...

Page 234: ... not reach into the areas where the safety doors and the hinged hood close Notice Potential damage to machine parts due to electrostatic charges Establish a potential equalization between the machine and the environment Do not operate the machine unless it is sufficiently grounded Notice Machine parts can be damaged by using the wrong substrate and consumable supplies Do not use any substrates tha...

Page 235: ... The printer should not be operated unless all of the conditions defined in Chapter 3 Technical Data are met 7 2 3 Reconnection and preparation of the printer Reconnect to the printer all of the lines that were disconnected before the transport power supply interface and network cables and pneu matic hose and exhaust line Remove any transport securing devices that were installed Replace all of the...

Page 236: ...ntil only one diode is illuminated on the control panel of the web guider Now you have manually ad justed it to the neutral position Retighten the knurled screw Press the Automatic Mode button on the control panel of the web guiders Let the print head unit move into its working position The printer is ready for operation again 7 3 Check the defaults of the printer Before the printer can be started...

Page 237: ...e touchscreen of the printer s control panel will display the home page The printer will not start running unchecked on its own Processes cannot be started until the operator has logged in with a password Is the required voltage being supplied Did a fuse blow Check cable connec tions 2 Test of the door monitors Open any one of the moni tored shrouds or doors Safety interlocks can only be released ...

Page 238: ...l not sound Is the required voltage being supplied 5 Start the print ing process and let it run for some time without inter ruption The printer will transfer the load ed image to the printing substrate and cure it thoroughly The im age can neither be scratched with a fingernail nor be dissolved with water The printing substrate will not drift to the side or weave back and forth perpendicular to th...

Page 239: ... remove safety equipment unless the main switch has been turned off and locked Caution Potential danger due to operational errors caused by operation by unauthorized and untrained personnel The machine should be operated by trained and authorized tech nical personnel only 8 2 Check the printer EACH TIME before switching it on Caution Check the machine each day before starting to work Make sure tha...

Page 240: ...n switch Disconnects the printer s electrical system from the power supply In the 0 position the entire machine is dead 2 On Off switch In the 0 position disconnects the voltage to all drives and high voltage parts The touchscreen displays and door interlocks all remain turned on and active Green button is pressed Drives and high voltage parts are activated and can be used White button is illumina...

Page 241: ...ect i e residue from web labels etc should be visible underneath nozzle plate Clean all ink residue off of all the guide rollers throughout the printer Clean the rollers of the friction drive thoroughly with isopropyl alcohol nothing whatsoever should be left sticking to the rollers Clean the rollers of the web tension control thoroughly with isopropyl alcohol nothing whatsoever should be left sti...

Page 242: ...ry insert a new roll and thread the printing substrate by hand through the entire printer until it reaches the rewinding unit Notice No matter what type of material you use make sure the print head unit is retracted before manually feeding the taped seam slowly through the printer to avoid tearing during the printing process First put the print head unit in the parking position Press the feed key ...

Page 243: ...irection of travel or was replaced by material with a different width the following sensors might have to be re positioned Sensor s of the web guider s Print mark sensor s Label sensor s If necessary load a new image and open the corresponding settings If it is a new layout which was never used before then test the settings first and don t save them until you are satisfied with the printing result...

Page 244: ...uide roll ers in the printer using isopropyl alcohol Guide rollers made of metal can also be cleaned with acetone if necessary In case of any soiling Clean the rollers of the friction drive thoroughly using isopropyl alcohol No residue whatsoever should be left sticking to the rollers In case of any soiling Clean the rollers of the web tension controllers thoroughly using isopropyl alcohol No resi...

Page 245: ...prone to bowing or becoming wavy when stretched in place The max amount of permissible bow ing or waviness is 0 2 mm to avoid rubbing against the nozzle plates of the print heads Do not open and remove the protective film of the substrate roll until ready to use the roll Store any leftover material rolls in a warm dry place or seal the roll airtight in plastic film until ready to use again If nece...

Page 246: ...d to do when the printing substrate roll is already in serted Fig 102 Print on the outside Unwind clockwise Interrupt the printing process and wait until the printer has come to a complete stop Open both lower door panels of the printer Release the clamp bars of the unwinding shaft 2 by turning the rotary switch 1 Remove roll of printing material If required tear off a layer of adhesive foil from ...

Page 247: ...top Procedure Open the safety doors Pull in the substrate to the left cut and splice device as shown in the winding diagram cf Section 4 5 Path of the printing substrate Clamp down the substrate in the cut and splice device Cut off the printing substrate cleanly with the integrated blade Stick the printing substrate together with the printing substrate left in the machine Close the safety doors an...

Page 248: ...d with a different material thickness and therefore the five rollers of the printing table must be replaced Requirements The printing substrate roll must be able to be wound by hand around the unwinder shaft release the clamping bars There is no printing substrate in upper part of the the machine The printing process has been interrupted and after the material re traction the machine has come to a...

Page 249: ...am attached to the print head unit as a guide feed the printing substrate through the web retraction system to the print head unit and then back to the web retraction system From there pull the printing substrate to the friction drive Briefly unlock the friction drive in order to push the print material be tween the two rollers through to the right From this point the yellow Infeed forward button ...

Page 250: ...me page will be shown first Information After each start up the touchscreen as well as the control buttons above will always be disabled Unless an operator has logged on with a valid user name and pass word the menus cannot be opened and settings cannot be changed In offline printers the printing process will not be able to be started The printing process can only be started in inline mode because...

Page 251: ...dard password associated with his user account Afterwards he will be asked to replace the standard password with a password of his own choosing Thereafter the user must log in with this new password The access levels are set up in such a way that the user with a certain ac cess level is also given access to all levels below that A user with Level 3 rights may do everything allowed by Levels 1 and ...

Page 252: ...color of the input line will change from red to white as soon as the minimum number of six characters has been entered After successful log in the name of the user will be displayed in the lower right hand corner of each window Furthermore the Login button will no longer be displayed in black and white but rather in color 8 7 2 Touchscreen logout If the touchscreen isn t touched for a specified ti...

Page 253: ...zed persons during their absence Manual logout To log out of the system all you have to do is tap briefly on the Login button in the lower right hand corner of the display This will disable most buttons and displays which is indicated by gray shading Information The touchscreen can also be disabled by individuals who have no access rights whatsoever Any ongoing process is not affected by the login...

Page 254: ...yellow and black key Work in CMYK color mode and with the grayscale for B W images The size of the motif must correspond with the size of the document The outer dimensions of the image data to be printed must be created properly with reference to the punch dimensions of the label Do not add any punch lines to the print files Punch lines can be entered in separate control files Do not create any of...

Page 255: ...in plastic foil could never be treated at the same curing power level as thicker metal foil By way of contrast format data is basically contingent upon the image files In other words a single format file can be used for printing several different images The greatest advantage of format data is that after it s imported it changes the printer s settings automatically and the operator only has to mak...

Page 256: ... and layout Formats and other pro cess files that have been changed are filed automatically in folders There is neither a search function nor the possibility of switching between multiple folders Therefore to exchange data it is essential to maintain this defined directo ry structure on the exchange media Consequently the required directory structure is created automatically on an empty USB flash ...

Page 257: ... the associated white green key In the dialogue window shown next select whether the data exchange should be carried out via a USB flash drive or via the Intranet using the special folder Exchange1 Fig 107 Dialogue window for selecting data medium If data transfer via USB flash drive is desired a pop up window will appear and the system will request that you insert the drive in the ap propriate po...

Page 258: ...lations should be observed Only original CSAT replacement parts may be used The machine must be stopped and cooled down before performing repair work Information When errors occur on the machine do not turn off the main switch or press the Emergency Stop button but rather read the error mes sages and remedy the error If a problem occurs with the printer during operation usually it will be stopped ...

Page 259: ...diate emergency stop of the printer then this message will also appear in the middle line Reason for stop The messages shown in the header of the touchscreen are numbered con secutively in all language versions so that if telephone contact is made with the manufacturer s customer service only the number at the beginning of each line has to be given Besides the error text in the two lines of the fo...

Page 260: ...cannot be repaired it must be shut down until it is returned to complete working order Lock the main switch into the 0 position with a padlock and close all covers Any attempts to get a defective printer going again by means of tricks or prohibited means will lead to the immediate forfeiture of all warranty rights Information In case of a malfunction it has to be determined which machine component...

Page 261: ... opened on the stopped printer Although this is not an error it is a condition that will prevent the printer from being started again and therefore has to be shown Each message shown in the Current Alarm line is displayed only until the irregularity has been eliminated or until another error signal with higher pri ority is received and simply writes over the previous text If an error message is sh...

Page 262: ...ding unit dancer roller at lower end stop A C The printing substrate has torn between the unwinder shaft of the printer and the friction drive Sensor 500 B29 is responding O T R Stick printing substrate together Feed in printing substrate manually S 30 Printer not ready to START C Defective sensor or interruption in line S C R Check sensor lines and contacts have de fective parts replaced by CSAT ...

Page 263: ...ove the clamping drum until they are no longer illuminated S 30 Printer not ready to START C Defective sensor or interruption in line S C R Check sensors lines and contacts have defective parts replaced by CSAT customer service 12 CA 12 Lower right door open A C Safety door is open Sensor 100 A2 is re sponding O T R Close safety door S 30 Printer not ready to START C Defective sensor or interrupti...

Page 264: ...perly The sensor 520 S16 is responding O T R Insert cartridge correctly S 30 Printer not ready to START C Sensor system out of order S C R Check sensor lines and contacts have de fective parts replaced by CSAT customer service 28 CA 28 Cleaning unit Fill level error A C The cartridge with the cleaning fluid is emp ty The lower sensor 520 B1 of the inter mediate reservoir responded O T S 30 Printer...

Page 265: ... displayed by frequency converter 300 FU4 against the product description cf appendix Check fuse 400 F607 and replace if nec essary Check fuse 400 F14 and replace if neces sary Has the sensitivity of the motor safety switch been set incorrectly S C 36 CA 36 Web retrac tion system posi tion error A C The carriage of the web retraction system is in the wrong position One of the sensors responded or ...

Page 266: ...CA 40 Pre curing 2 Temperature er ror A C The temperature of the second pre curing unit has reached the Alarm warning point entered on the HMI S C S 30 Printer not ready to START R Check the Alarm warning point Recom mended range of adjustment 35 C 39 C Is the cooling unit working Has it been set correctly and is enough coolant flowing Does the coolant line have a leak Has the nominal value for th...

Page 267: ... Curing turn off the UV power supply unit wait 10 sec onds and turn it back on If the alarm nos 42 44 should continue to appear frequently Call a service technician or the CSAT customer service 45 CA 45 Main curing power supply unit 1 Error A C Disturbance interruption in power supply to lamp 1 S C S 30 Printer not ready to START R Please check Was the motor circuit breaker 300 QM1 triggered Did a...

Page 268: ...49 CA 49 Coolant outlet Error A C Loss of water between inlet and outlet sen sors Sensor 300 B53 is responding S C S 30 Printer not ready to START R Check whether there is a leak inside the printer between the inlet and outlet Is water escaping anywhere or can any puddles in or under the printer be seen If water is leaking then the printer must be switched off IMMEDIATELY Call the cus tomer servic...

Page 269: ...g system A C Emergency Stop button of the finishing sys tem was actuated S 30 Printer not ready to START R Pull out the Emergency Stop button of the finishing system Switch the printer off and on again briefly with the ON OFF switch Not until then will the message disappear and can the system be restarted 56 CA 56 No com pressed air A C No compressed air available O T S C S 30 Printer not ready to...

Page 270: ...ck sensor 400 A147 lines and con tacts have defective parts replaced by CSAT customer service 71 CA 71 Waiting for image data from DSP M C Usually this is only a short status message The printer was started externally and is now waiting for the image data stored in the DSP O T S C S 11 Printing R None This message is shown only briefly and dis appears before the UV curing systems are switched on R...

Page 271: ...to its operating position 84 CA 84 Error by cleaning A C This alarm is emitted during the automatic cleaning of the print heads whenever a pro cess hasn t been started or is taking too long O T S C S 30 Printer not ready for START R Eliminate all of the errors indicated in the Alarm menu If this isn t possible please contact the CSAT customer service 85 CA 85 Cleaning mode hasn t been entered yet ...

Page 272: ... images to be printed O T S 30 Printer not ready to START R In order to ensure that incompletely cured printing substrate is not passed on to further production all of the printed material to the left of the friction unit should be marked clearly so that it can be easily found later and removed 90 CA 90 Ink man agement unit Cartridge emp ty M C The ink cartridge in question is empty O T S 0 Printe...

Page 273: ...tion is responding O T S 30 Printer not ready to START R At the rear of the printer push the collection pan all of the way into the machine C Sensor system out of order S C R Check sensor 400 B14 lines and contacts have defective parts replaced by CSAT customer service 93 CA 93 Residual ink intermediate res ervoir full A C The residual ink bottle is so full that the re sidual ink can no longer run...

Page 274: ...ensor system out of order S C R Check sensor 400 B35 lines and contacts have defective parts replaced by CSAT customer service 99 CA 99 Pre curing yellow error A C Defective module loose or broken cable The controls did not detect any current S C S 30 Printer not ready to START R If the power supply wiring and plug con tacts are OK then the module in question has to be replaced 100 CA 100 Pre curi...

Page 275: ... for START R On the touchscreen open the tab Consuma bles Print heads and read off the number of shots fired by each print head If a 0 is shown anywhere then the associated IJ image converter board is defective and has to be replaced S C 111 CA 111 Communi cation error IJ image converter C The communication between the IJ convert er boards and the IJ engine board is out of order S C S 30 Printer n...

Page 276: ...is not circulating enough coolant The hose lines could be at least partially clogged or interrupted S C S 30 Printer not ready for START R Switch on the cooling unit Check the hose lines and connections have defective parts replaced by CSAT customer service 116 CA 116 DSP mod ule not active C The DSP module has gotten hung up so that a print head can no longer transfer or print any images O T S 30...

Page 277: ...r cleaning the print heads is reached A C The time interval for cleaning the print heads has elapsed O T S 30 Printer not ready for START R Perform standard cleaning of all print heads 135 CA 135 Communicati on error on main bus A C Error in the internal communication of elec tronic components S C S 30 Printer not ready for START R Contact the Markem Imaje CSAT customer service 136 CA 136 Unwindin...

Page 278: ...eason The camera could not read the data matrix code but the DMC reader could read it S R No intervention necessary Invalid labels are rejected 183 CA LRC Error DMC reader did not react to a trigger M C Data matrix reader did not react to a trigger O T S R No intervention necessary Invalid labels are rejected C Data matrix reader is defective when the error keeps arising S C R Notify the customer ...

Page 279: ...an 1m no print mark detected A C More than 1m no print marks have been detected O T S R Cancel the current print job Start a new print job 190 CA LRC Error Empty label detected A C Empty label on roll O T S R Remove empty label from roll Continue printing 191 CA LRC Error Con secutive error A C A sequence of more than five bad labels occured O T S R Different reasons possible If reason was detecte...

Page 280: ......

Page 281: ...nstructions are to be given priority The specially trained personnel responsible for op eration and maintenance must have a complete and comprehensive under standing of the contents A copy of the maintenance and care instructions must be laid out directly next to the machine 10 2 Area of validity These maintenance and care instructions serve as a guideline for mainte nance and repair If different ...

Page 282: ...t has been installed Warning Risk of fatal injury from contact with live parts Work on electrical equipment must be performed only by author ized personnel qualified in electronics Always keep switch cabinets closed Only authorized personnel with key or tool are allowed access to the switch cabinets Do not work on live parts Replace loose connections or damaged cable immediately Cables should not ...

Page 283: ...t Avoid contact with operating materials and cleaning agents Wash exposed skin thoroughly See a doctor if skin irritation per sists Change contaminated or soaked clothing immediately Observe the safety instructions of the materials used Information Maintenance and repair work should be performed by specially trained personnel only who based on their professional training knowledge and experience a...

Page 284: ...be inspected tested regularly Defects such as loose connections or burnt wires should be fixed immedi ately Whenever work on live parts is necessary have another person standing by who in case of an emergency can press the Emergency Stop button or switch off the main power supply Cordon off the working area with a red and white chain and a warning sign Use only insulated tools Warning The supply l...

Page 285: ...ld be cleaned once a week Whenever there is a heavy accumulation of dust and dirt the deposits that could interfere with the functioning of the printer and the printing results should be removed daily Drops of ink should be removed immediately since they can no longer be removed after the ink has hardened Notice Clean the printer carefully Remove blotches of ink immediately Never touch the nozzle ...

Page 286: ...o the service position check the wipers used for cleaning the print heads for areas of dried on ink and clean by hand see chap 10 7 5 2 Manual cleaning of the print heads The edges of the wipers have to be straight and sharp and shouldn t have any cracks or especially any foreign objects on them Furthermore the cleaning edge of each wiper must be aligned parallel to the upper edge of the clamping ...

Page 287: ...heck of all screw connections for leaking ink Every 3 months Check connections in compressed air system for leaks Clean the cleaning rollers of the printing substrate cleaning module with the Roller Doctor System see chap 10 6 7 Maintenance of the printing substrate cleaning module Every 6 months Check drive belts of the web tension control and the unwinding mandrel of the unwinding and winding sh...

Page 288: ...e permanently lubricated For trouble free opera tion however please make sure that this assembly is kept as clean as possible and that the guide rollers do not suffer any damage Information The rubber roller of the web tension control is a consumable part The running time can be viewed on the touchscreen A message will be displayed when its useful life has expired Function check The guide rollers ...

Page 289: ...When a low level of ink is reported by the touchscreen the ink cartridge in question has to be replaced Information The cartridges cannot be replaced unless the printer has been switched on completely Notice Prevent soiling and environmental damage Do not squeeze the removed cartridge since otherwise ink could spray out of the penetrated membranes Dispose of the cartridges in compliance with the l...

Page 290: ... car tridge sits on the locking ele ment and the bar code 2 at the rear of the cartridge is at the level of the bar code reader 3 Wait a moment until the bar code reader has read the bar code When the signal sounds the cartridge was recognized as correct the locking element is released and the cartridge slips auto matically down to its end posi tion The lock remains if a signal does not sound The ...

Page 291: ...nual_EN doc Subject to Technical Modifications Page 291 370 Pull the slider back towards the front When you let go the sound of a pneumatic cylinder should be heard Proper order of the car tridges Pos Designation 1 Cleaning fluid 2 Yellow 3 Cyan 4 Magenta 5 Black Close the cover flap 1 2 3 4 5 ...

Page 292: ...te stop Press the button on the touchscreen The print head unit moves into the parking position On the rear of the printer Open the middle door Release the black knob located on the right hand side above the collection pan Pull the print head unit all of the way back until the wipers are exposed On the front of the printer Open the hinged hood Press down the bolt on the rubber wiper to be changed ...

Page 293: ...anged on the rear of the printer Push the print head for ward until the black knob locks into place again Move the print head unit into the working position Close the back door of the printer On the touchscreen Reset the corresponding counter reading to 0 in the tab Consumables Wipers Press the button on the touchscreen Close the hinged hood The machine is ready for opera tion ...

Page 294: ... separator Disconnect the printing system from the power line The printer must be switched off at the main switch 10 6 4 2 Performing visual inspection Open the right rear door of the printer by means of the supplied switch cab inet key Installation location of the separator 1 Separator 2 Clamping plate Fig 108 The separator of the degassing system Check Does the separator contain any liquid If no...

Page 295: ...e separator Drain the separator dispose of the content in the same way as re sidual ink Thoroughly clean separator It must be transparent and may not contain any dirt residue If the separator cannot be cleaned it must be replaced Screw cleaned separator back in Retighten clamping plate Information If the separator is filled with ink the error message 105 appears on the touchscreen In this case the...

Page 296: ...on Permanent damage to skin can be caused by contact with machine operating materials of all types long term injuries Wear solvent resistant safety gloves and protective eyewear when handling media see section 2 5 5 Personal protection equipment Avoid contact with operating materials and cleaning agents Wash exposed skin thoroughly See a doctor if skin irritation per sists Change contaminated or s...

Page 297: ...w residual ink bot tle and close the door The residual ink bottle is monitored by sensors Pos Designation Function 1 Fill level sensor Monitors fill level reports to touchscreen when full 2 Occupany control sensor Occupany control Reports to touchscreen whether collection container is present Close the door and turn locks to the right with a screwdriver The machine is ready for operation Informati...

Page 298: ...e defined useful life of 300 000 m has expired then the roller in question has to be replaced Information The rubber rollers can be replaced even if print material is still inserted in the printer Stop the printing process Wait until the printer has come to a complete stop Open the front safety doors and the hinged hood Remove all four screws 1 from the cover 2 and take off the bearing cover Pull ...

Page 299: ...ler Remove the centering sleeve 7 from the old rubber roller Never pry out the centering sleeve with a screwdriver If necessary insert a piece of wood or plastic at the other end of the rubber roller and drive the cen tering sleeve out by gently ham mering Use caution Avoid damaging any of the curved parts of the centering sleeve Place a new rubber roller upright on a clean table Twist the centeri...

Page 300: ... the rubber roller all of the way onto the drive shaft Make sure that the rubber roller contacts the rear end If there is still a gap then make sure that the hole 7 is seated over the dowel pin 8 First tighten the three inner M4 x 16 screws a few turns Tighten the outer M5 x 12 all the way Now finish tightening the inner screws Insert the bearing cover all the way into the bearing plate without ja...

Page 301: ...doc Subject to Technical Modifications Page 301 370 Pull out the two black knobs of the locking mechanisms 11 Lower the frame 12 with the pressure roller and let the locking mechanisms fall back into place Reclose the hinged hood and the safety doors The printer is now ready for op eration again 12 11 ...

Page 302: ...layer of the adhesive foil must be removed at regular intervals To remove the used adhesive foil of the printing substrate cleaning unit proceed as follows Stop the printing process The printer can remain turned on during the following steps Especially when printing on very wide printing substrate it can be help ful to remove the end plates from the unwinding and winding shafts Pull off one sheet ...

Page 303: ...ly Cleaning the cleaning rollers with Tekwipes MI6700 After cleaning the printing press should remain out of operation for 15 minutes This shall ensure that the alcohol in the Tekwipes evaporates completely from the cleaning rollers Every three months Cleaning the cleaning rollers with the Roller Doctor System After cleaning the printing press should remain out of operation for 15 minutes This sha...

Page 304: ...r no ZEOI 000 00 Z which eliminates ozone and other odors from the suctioned air All activated charcoal filters generally have to be replaced after 250 hours of use Replacement might have to be made even earlier if the printer is lo cated in a space where there is a proliferation of dust However if a printer is operated in a clean environment or especially in cleanrooms the filters can be used sig...

Page 305: ...age 305 370 Unscrew the cover 1 on the front of the printer Remove the three used filter elements These can be thrown away in the house hold garbage Insert the new filter ele ments order no ZEOI 000 00 Z carefully all of the way into the housing Replace the cover on the housing and screw down tight The ITS6 is now ready for operation again 1 ...

Page 306: ...cially in cleanrooms the filters can be used significantly longer than the recom mended 250 hours and can be replaced as needed Via the touchscreen menu Consumables Air filters you can determine how long the air filters have been in operation refer to Chapter 4 12 7 Tab Consumables Air filters Caution Risk of injury Switch off the printer prior to replacing the activated charcoal filter During ope...

Page 307: ...m 0 0 0 2 mm 0 0 0 2 0 5 0 2 bis 0 3 mm 0 2 0 3 mm 0 2 0 3 0 7 0 3 bis 0 4 mm 0 3 0 4 mm 0 3 0 4 0 9 0 4 bis 0 6 mm 0 4 0 6 mm 0 4 0 6 1 1 Using guide rollers that are too thin would show white lines on the printed image in the direction of paper travel Using guide roller that are too thick however could cause the printing sub strate to rub on the sensitive nozzle plates of the print head and obst...

Page 308: ... of the print head unit cover Pull off the print head unit cover from the front and deposit it at a clean place Remove the printing substrate from the printer Unscrew the small attachment blocks A of a guide roller Note down the installation position of the individual blocks Remove the guide roller B and put it down on a clean surface Take a guide roller that is compati ble with the new printing s...

Page 309: ... both ends of the scanning bar Rotate the scanning bar until mark 2 points to the correct value Tighten the screws of the scanning bar Load the new printing substrate into the printer If necessary load the new image and format files Close the hinged hood of the print er The printer is ready to run Information Continuing the rotation of the scanning bar of the infeed height control unit does not al...

Page 310: ...amera lens and any change of the camera ad justment Replacing the lighting unit Use the following procedure to replace the lighting unit Stop the printing process Wait until the printing system has stopped Shut down the printing system via the touchscreen Press the red button of the ON OFF switch Disconnect the printing system from the power supply system To do this set the main switch to 0 OFF Op...

Page 311: ...efully pull out the lighting unit Carefully insert the new lighting unit Ensure that the lighting unit is inserted into the guide pins 6 Establish the plug in connection 7 of the lighting Install and tighten the Allen screw 4 on the lighting unit Position the mirror carrier 8 and install it with the associated knurled screws 9 To do this insert and tighten the two knurled screws Close the hinged h...

Page 312: ...e by one Only the recommended cleaning agents and aids should be used For reasons of safety all of the cleaning work inside the printer that re quires the removal of cover panels should be performed by a qualified ser vice technician only 10 7 2 Safety instructions for cleaning Warning Risk of injuries due to short circuits or flashovers Always keep wet and especially dripping wet cleansers away f...

Page 313: ...aned if possible Whenev er moist cleaning is required make sure that moisture never penetrates the bearings Never use moisture to clean hot parts of the machine This will cause damage for example to the cover lenses and to the LED UV module Never clean the machine with high pressure cleaners or with degreasing agents The various components should be cleaned using only the substances and cleaning a...

Page 314: ... the curing system all rubber coated rollers e g from the friction drive web tension con troller rubber hoses Glass shields of the curing system Isopropyl alcohol pure an hydrous Moist cleaning of small parts and large sur faces All plastic and metal parts Labels could be dis solved when used in tensively Grey rollers of the print ing substrate cleaning module Glass shields of the curing system Ho...

Page 315: ...d removing dirt particles large surfaces dry Removal of dry dust and lint liquids wet powder or granules small parts screws nuts etc web residue Solvent resistant protective gloves Moist cleaning Cleaning the underside of the print head re moval of ink blotches touching objects that have ink or cleaning fluid on them Dry cleaning of the external housing han dling heavy or sharp edged objects Tekne...

Page 316: ...sopropyl alcohol Control panel screen As needed Machine operator cleaning personnel Soft cloths special cleaner for screens glass cleaner Cable pneumatic hose As needed Machine operator cleaning personnel Soft cloths isopropyl alcohol Exhaust air hose ex ternal As needed Machine operator cleaning personnel Hand brush soft cloths isopropyl alcohol 10 7 4 2 Print head unit Compo nent Cleaning in ter...

Page 317: ...isopropyl alco hol acetone 10 7 4 4 Cleaning the inside of the printer chassis Compo nent Cleaning in terval Should be cleaned by Approved cleaners and utensils Inside of chassis As needed Machine operator cleaning personnel Brush vacuum soft cloths isopropyl alcohol 10 7 4 5 Unwinding unit and rewinding unit Compo nent Cleaning in terval Should be cleaned by Approved cleaners and utensils Wall pa...

Page 318: ...ved cleaners and utensils Rubber coated roll ers of the web tension controller 1x per shift Machine operators cleaning personnel Soft cloths isopropyl alco hol NEVER use acetone or other solvents Electrodes of the sub strate dis charger 1x per shift Machine operators cleaning personnel Brush vacuum for re moving lint and sub strate residue With cloths moistened with acetone to wipe ink off the met...

Page 319: ... Special cleaning pads no ZE1010 75 for removing small spots Dry soft cloths no FF100252100 for pre cleaning Scraper for Ceran ceram ic stovetops only to remove thick encrustations 10 7 4 1 Printing substrate discharge Component Cleaning interval Cleaning by Approved cleansers and auxiliary equipment Electrodes 1x per shift Machine operator cleaning staff Remove adhering fluff and printing materia...

Page 320: ...To be cleaned by Allowed cleansers and aids Grey cleaning rollers Once per shift in case of dusty or fibrous printing material more often Machine operator cleaning personnel Tekwipes MI6700 Clean white cotton gloves Grey cleaning rollers Every three months Machine operator cleaning personnel Roller Doctor System 10 7 4 4 Rear of printer inside Part Cleaning inter val To be cleaned by Allowed clean...

Page 321: ...e to accept longitudinal white stripes in the prints from now on or else buy a new print head for thousands of Euros and install it But print heads can also be destroyed by incorrect cleaning methods namely whenever too much pressure is exerted against the nozzle plate when cleaning manually but also in particular when the wrong type of cleaning cloths are used either ones that are already dirty o...

Page 322: ...nozzles the print head unit will return automatically to its working position During this forward movement the wipers are flipped against the undersides of the print heads to wipe off any adhering drops Cleaning with cleaning fluid When cleaning with cleaning fluid first of all all of the ink is forced out of the print heads Afterwards the print heads in question are filled with clean ing fluid an...

Page 323: ...The nozzle plate on the underside of each print head must be kept very clean at all times If ever encrusted ink or anything else should collect here such as shreds of substrate or adhesive tape they should be removed im mediately bearing in mind the following instructions Required utensils Clean solvent resistant protective gloves cf Chapter 2 5 5 Clean cleaning cloth for print heads Order no FF10...

Page 324: ...he parking position Press the button on the touchscreen Open the middle door on the rear of the printer Unlock the black knob It s located on the right side above the collection pan Pull the print head unit all the way back Pull the collection pan out of the chassis and place it care fully on a level surface large enough to accommodate it Remove a cleaning cloth order no FF100252100 from its packa...

Page 325: ...ing cleaning Always use only clean sections of the cloth for cleaning Wrap the folded cloth around your index finger Moisten the cloth with a lit tle bit of cleaning fluid suitable for the type of UV ink used NEVER wipe from one end to the other First clean each wiper with a clean lint free cloth no FF100252100 and cleaning fluid suitable for the type of UV ink used After that the rubber wiper mus...

Page 326: ... contain foreign bodies must be replaced immediately See Chap 10 6 3 Changing the wipers on the print head First wipe from the back third of the print head towards your body and then wipe from the front third of the print head away from your body Rotate your fingers slightly during the wiping process so that only clean parts of the cloth come into contact with the nozzle plate To better explain th...

Page 327: ... exerting pres sure on the nozzle plate the cloth carefully to the other end of the nozzle plate while rotating your finger counterclockwise During the forward movement continue to rotate your finger counterclockwise without changing direction Sweep the cloth beyond the back end of the nozzle plate so that no dirt remains behind on the print head Now fold the cloth so that a clean area is on top o...

Page 328: ... to rotate your finger counterclockwise without changing direction Sweep the cloth beyond the back end of the nozzle plate so that no dirt remains behind on the print head Make sure that no dirt gets into the nozzles of the wiper showers and clogs them Repeat the previous 7 steps as often as necessary until the nozzle plate is shiny and spotless Check all of the LED strips of the pre fusing unit a...

Page 329: ...place Return the print head unit to its working position Press the button on the touchscreen Clean up any drops of fluid from the catch sheet under the print head unit If needed use cloths moistened with ace tone Carefully replace the collec tion pan in the chassis Push the collection pan all the way in until you hear it click in to place Close the rear door of the printer The machine is ready for...

Page 330: ...y be performed after the printer was switched off completely The lamp modules should be no more than warm to the touch during cleaning Only use the cleaning aids mentioned here Cleaning the main curing unit Unlock and remove lamp module Check the 3 glass covers for cleanliness First remove loose dirt or wet ink with a dry lint free cloth Order no FF100252100 If heavy deposits are pre sent first re...

Page 331: ... modules of the pre curing unit are very sensitive Therefore never touch their nozzle plates with your bare fingers do not exert pressure on the nozzle plates do not work with hard objects in the area beneath the print heads therefore remove bracelets and rings Non compliance will result in the loss of all warranty rights The lamp modules of the pre curing unit are not cleaned during the me chanic...

Page 332: ...ll the print head unit all the way back Pull the collection pan out of the chassis and place it care fully on a level surface large enough to accommodate it Remove a cleaning cloth order no FF100252100 from its pack age and immediately fold it in halves as shown here 2x crosswise 1x lengthwise IMPORTANT Never place the cloth being used aside either before or during clean ing Always use only clean ...

Page 333: ...ns of the cloth for cleaning Check all of the LED light strips of the pre curing unit between the print heads and clean them using a dry clean and lint free cloth CSAT order no FF100252100 The cloth may be slightly moistened with cleaning fluid suitable for the type of UV ink used as needed Make sure that the narrow light strips of all lamp modules are spotless and streak free see detail photo If ...

Page 334: ...ications ITS6_135_Manual_EN doc Carefully replace the collection pan in the chassis Push the collection pan all the way in until you hear it click in to place Close the rear door of the printer Return the print head unit to its working position Press the button on the touchscreen The machine is ready for op eration again ...

Page 335: ...sons who usually step into action whenever there is more ex tensive maintenance work or repairs to be done or during extraordinary events such as transports or conversions Notice Damage due to improper repair work Do not perform any repairs on your own Perform repair work only in coordination with Markem Imaje CSAT GmbH Use only original replacement parts Observe the supplier s documentation Pleas...

Page 336: ...of data it is necessary to make a back up of all of the data stored on the hard disk on a regular basis The backup is made on the bootable USB flash drive included with delivery How often backups are made is left to the discretion of the owner 10 9 1 Making a backup When a backup is made all of the data stored on the hard disk of the print er is copied in blocks which are then kept as a backup cop...

Page 337: ... completely Press the red 0 button of the ON OFF switch for this purpose Turn the round main switch to the 0 position Connect a standard computer keyboard to any of the two USB interfaces of the control panel Connect the USB flash drive to the other USB interface Information In order to avoid malfunctioning of the printer the smaller ON OFF switch must be left switched off during the backup Turn t...

Page 338: ...al configuration data The settings of the touchscreen which apply specifically to the printer e g specially adapted text or access rights F6 Operating system local configuration The complete operating system Linux F7 Visualization runtime programs The basis software of the control system This is required for instance to make the control elements see F3 visible ESC Back do not execute function Canc...

Page 339: ...se line Please hit return and blank screen is shown Tap on ESC As soon as only a black screen is shown after the green line of text Preparing for reboot is displayed pull out the USB flash drive immediately since otherwise the system would re boot from the USB flash drive again Store the USB flash drive in a safe place apart from the print er The operating system will boot Disconnect the standard ...

Page 340: ...ing of the hard disk installed in the printer If it is damaged then a new hard disk should be installed and the printer should be reconfigured before the restore process is carried out cf Section 10 9 2 Required equipment Bootable USB flash drive Standard computer keyboard with USB interface Please comply with the sequence of steps Stop any ongoing printing pro cess Shut down the printer and its U...

Page 341: ...F2 Your production data and settings All production related data e g layouts for mats log files F3 Visualization User Interface All information about the user interface pages control elements text etc F4 Visualization local configuration data The settings of the touchscreen which apply specifically to this printer e g specially adapted text or access rights F5 Operating system The complete operati...

Page 342: ...ata is transmitted This process can take several minutes When the data transmission has been concluded success fully the system will show the following screen Tap on the ESC key The following screen will be shown Please select ESC Wait until the turquoise line Please hit return and blank screen is shown Tap on ESC As soon as only a black screen is shown after the green line of text Preparing for r...

Page 343: ...bject to Technical Modifications Page 343 370 The operating system will boot Disconnect the standard com puter keyboard The backup is finished Now you can either switch off the printer completely turn the round main switch back to the 0 or OFF position or started back up by pressing the smaller ON OFF switch ...

Page 344: ...ction 10 9 2 of this manual The complete replacement of a damaged hard disk in the printer only takes a few minutes and must be performed only by qualified employees trained for this purpose Information Data sets and logs on the hard disk to be removed that were created after the last backup have to be backed up themselves cf Section 10 9 1 Required equipment Bootable USB flash drive Standard comp...

Page 345: ... panel Carefully remove the small screw next to the upper left hand corner of the hard disk Lift up the gray metal casing gently and pull it to the left Pull off the black connection plug at the same time Remove the hard disk and place it on a clean table Remove the four small attach ment screws shown here and lift the old hard disk out of the gray casing Insert the new hard disk in gray casing Re...

Page 346: ...g with the F10 key OR Cancel formatting with the ESC key If you re sure that formatting should be carried out then when prompted answer with Y Yes I m sure The data will be transferred This process can take several minutes When the data transfer has been successfully completed the system will show the follow ing screen Tap on the ESC key The following screen will ap pear Please select F3 and perfo...

Page 347: ... main curing unit Wipers Ink filter Degassing unit Activated charcoal filter Filter fleece liner of collection pan Suction inlet Suction outlet Adhesive rollers of the printing substrate cleaning module Information Whenever additional consumables are needed in addition to what was procured initially then these must be obtained as new parts It is not possible to purchase used and reconditioned comp...

Page 348: ...pylene glycol with corrosion inhibitor e g Pekasol Further information concerning the coolant is included in the manual for the cooling appliance which is attached in the appendix of these instructions as well as in chapter 3 6 of this manual 10 10 1 2 Lubricants All bearings of the ITS6 printer are permanently lubricated No central lubri cating system has been installed Likewise manual lubricatio...

Page 349: ...filter fleece rectangular air circulation system FF100312100 250 h Filter fleece for collection pan FF100313100 When required Filter fleece for intermediate reservoir 420 x 165 x 15 mm ZETB 078 00 M When required Foam rubber for printing table ZEFD 029 00 M When required Intake filter fleece round air circulation system ZECV 008 00 M 250 h Cleaning cloth for print heads 300 pcs FF100252100 For sin...

Page 350: ... term given by the manufacturer however By contrast if the service life of a component proves to less than 70 of the time period given in the table the cause is more than likely due to the soiling of the machine as a result of insufficient cleaning and care and or unfavorable environmental conditions If part of a consumable module has reached the end its guaranteed useful life shown in the followi...

Page 351: ... for the next interval of use If a part should exhibit a defect as a result of a production error before the scheduled time period expires the costs of materials for the subsequent repair will be calculated proportionate to the actual service life achieved The basis for assessment of the costs incurred are the replacement part and consumable part lists valid at the time of the repair 70 of the rec...

Page 352: ...alkali 11 1 Printer Whenever the ITS6 printer isn t going to be used for some period of time then the cartridges for ink and cleaning fluid should be removed and the printer and all of its accessories and consumables should be stored in a cool dry place with as little exposure to light as possible The following am bient conditions must be met Component Storage temperature Printer 15 C 59 F to 30 C...

Page 353: ...ct to warranty claims Notice The cartridges for ink and cleaning fluid should be stored in a cool and dry place Protect against all exposure to light especially sunlight Leave all supplied replacement parts and consumables in their original packages in order to avoid damage and environmental in fluences The cartridges and the original package carton should be kept closed Do not store near oxidizin...

Page 354: ...lectronic components should be left in their original packages to protect them against electrostatic charges and should be handled as little as pos sible All consumables should be kept in their customized packages in a cool and dry place and be protected against exposure to direct sunlight Please take account of the expiry date on the packagings especially in case of ink and cleaning fluid ...

Page 355: ...ine When the machine is taken out of commission certain hazards can be ex pected Warning Risk of fatal injury from contact with live parts Work on electrical equipment must be performed only by author ized personnel qualified in electronics Do not work on live parts Warning Deadly injuries due to improper transport Use only approved lifting gear with adequate lifting and load bearing capacity Make...

Page 356: ...f the substances used Caution Avoid environmental damage from exhausted consumables and cleansers Take precautions to collect spilled consumables and cleansers sealed floor collection pan small collection pans collecting tar paulins Pour binding agent on spilled substances and dispose of the soaked binding agent as hazardous waste Collect consumables in suitable containers and dispose of them thro...

Page 357: ...fe this work should be assigned to qualified personnel For the disassembly the printer must be disconnected properly and thoroughly from the power supply All connection cables to the drive units in the machine must be removed All other connections between the machine and supply systems or other machine components must be removed Use proper tools for disassembling machine parts Danger of injury on ...

Page 358: ...rinter and its accessories can be disposed of at any collec tion center for electronic and metal scrap The individual components of the machine are to be separated according to the following categories Steel Aluminum Oil contaminated parts e g motors lines etc Cleaning agents Ink and cleaning fluid Electronic parts Plastic parts Miscellaneous waste e g filters Notice The disposal is strictly gover...

Page 359: ...necessary precautions to catch spilled substances sealed floor catch pans drip sheets 12 6 Disposal of production waste The following waste is accumulated during operation Ink cleaning fluid Worn consumables Production auxiliary materials Cleaning agents Information For detailed information on disposal please observe the safe ty data sheets of the manufacturer see appendix of this man ual Disposal...

Page 360: ...CSAT ITS6 210 with camera 70 Fig 11 Workplace at the printing system 71 Fig 12 Path of the printing substrate 73 Fig 13 Detailed view of the unwinding unit 74 Fig 14 The material sensor in the unwinding unit 75 Fig 15 Printing substrate cleaning module 76 Fig 16 Printing substrate storage assembly unwinding unit 78 Fig 17 Diagram of the printing substrate storage assembly spatial representation 78...

Page 361: ...pment 114 Fig 38 Print head cleaning equipment 115 Fig 39 Cleaning the left wiper unit with the wiper shower 116 Fig 40 Wiper shower 117 Fig 41 Pre curing inside the print head unit 118 Fig 42 Close up of a dismantled LED strip of the pre curing unit 119 Fig 43 main curing 122 Fig 44 ITS6 air circulation system 124 Fig 45 Air cooling rear view with open safety door rear 125 Fig 46 CAPS server rear...

Page 362: ... Network top section 174 Fig 69 Tab System Network bottom section 175 Fig 70 Tab System File manager 177 Fig 71 Tab System Machine info 178 Fig 72 Tab System User management upper section 180 Fig 73 User management tab lower section 182 Fig 74 Tab Consumables Fill levels 185 Fig 75 Tab Consumables Reels 186 Fig 76 Tab Consumables Print heads 187 Fig 77 Tab Consumables UV modules 189 Fig 78 Tab Con...

Page 363: ... flag 217 Fig 95 Transport securing of the web edge control unit 217 Fig 96 Approved transport by crane 218 Fig 97 Prohibited transport by crane 219 Fig 98 Transport pictograms 225 Fig 99 Adjustable foot 230 Fig 100 Correct placement of the precision spirit level 230 Fig 101 Main switches of the printer 240 Fig 102 Print on the outside Unwind clockwise 246 Fig 103 Login button 251 Fig 104 Innput s...

Page 364: ... camera system 71 127 Replacing the lighting unit 310 camera system computer Interface 144 CAPS server 126 connection cables 144 clamping bar 74 clamping bar mandrel 74 cleaning fluid change cartridge 289 how to order 349 indicate fill levels 185 safety data sheets see appendix A of the operating instructions storage life 353 cleaning the printing system 312 area around the print head unit 317 cam...

Page 365: ...ensions of the printer 47 disassembly of the printing system 355 disposal of production waste 359 of the printing system 358 DNS 175 documents touchscreen menu 195 drive rollers touchscreen menu 192 due diligence 43 duties of the owner 42 E emergencies 46 emergency stop button 36 134 enabling switch 139 engine software 178 ethernet connector 50 F feed backward 135 feed forward 135 feeding speed ad...

Page 366: ...43 144 process interface cooler 143 144 process interface LVIS Server 143 intermediate reservoir order filter fleece 349 isopropyl alcohol 314 J job touchscreen menu 157 job containers 159 L label material made out of aluminum foil 58 made out of paper 57 made out of plastic 59 label sensor 98 calibration 99 lock unlock 165 layout see image file liability 12 load bearing capacity of the foundation...

Page 367: ... 321 set warning threshold for remaining useful life 188 standard cleaning 171 warranty 14 print heads touchscreen menu 187 print mark sensor 101 calibration 103 lock unlock 165 printing data see image file printing length 50 printing speed 50 adjust 165 printing substrate aluminum foil roll fed material 55 label material made out of aluminum foil 58 label material made out of paper 57 label mater...

Page 368: ...afety due diligence of the personnel 44 duties of the owner 42 foreseeable misuse 17 handling emergencies 46 intended use 17 requirements of the personnel 43 safety concept 29 safety symbols 20 training of the personnel 45 safety data sheets see appendix A of the operating instructions safety doors 33 safety instructions overview 26 safety symbols 21 in the operating instructions 21 on the cartrid...

Page 369: ...d for diameter of roll 186 set warning threshold for diameter of roll 186 Unwinding unit Determine direction of rotation of the roll 164 USB port 50 135 UV curing abrasive pad for cleaning 350 clean 319 clean the main curing 330 clean the pre curing 331 Display current power of the main curing unit 163 Display temperatures of the UV modules 163 main curing 122 monitoring running time 189 pre curin...

Page 370: ...web specific correction 168 weight of the printer 47 width of the printing substrate 50 wiper change 349 wiper holder 117 wiper shower 116 117 wipers 115 117 change 292 monitoring lifetime 191 set warning threshold 191 wipers touchscreen menu 191 wiring diagram see appendix A of the operating instructions work zone 29 working position 113 workplace at the printer 71 ...

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