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Dover markem imaje CSAT ITS6 210 Operating Instructions Manual

Digital continuous printer

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Translation of the Original Instructions

Operating Instructions

Digital Continuous Printer

CSAT ITS6 210

Serial No.: EG.LAA0-00135

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Markem-Imaje CSAT GmbH

Daimlerstraße 32

D-76344 Eggenstein-Leopoldshafen

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Page 1 Translation of 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 Operating Instructions Revision Date Version Chapter Reason Responsible Nov. 30, 2016 Matthias Lohrer These operating 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.
Page 3: Table Of Contents
Operating Instructions Table of Contents Chapter ..................Page General Remarks Introduction Notes to the customer Scope of delivery and responsibilities Liability, warranty, guarantee 1.4.1 General 1.4.2 Warranty in connection with print heads Identification Understanding and handling these operating instructions Other valid documentation Notations in the text and abbreviations Safety Intended use...
Page 4: Fig. 12. Path Of The Printing Substrate
Operating Instructions 2.8.2 Due diligence of the personnel 2.8.3 Training of the personnel 2.8.4 Minimum age Handling emergencies Technical Data Dimensions and weight Load-bearing capacity of the foundation Ambient conditions Electrical connections Pneumatic system Coolant connection Interfaces for signal and data transmission Performance range Substrate specifications 3.9.1...
Page 5 Operating Instructions 4.6.2 Material sensor on unwinding unit 4.6.3 Printing substrate cleaning module 4.6.4 Printing substrate storage assembly (unwinding unit) 4.6.5 Web tension control 4.6.6 Cut-and-splice device with integrated blade 4.6.7 Printing substrate clamp 4.6.8 Corona treatment 4.6.9 Web guider 4.6.10 Substrate discharge at the unwinding unit 4.6.11...
Page 6 Operating Instructions The user interface of the touchscreen 4.9.1 Logging off at the touchscreen 4.9.2 Menu structure of the touchscreen 4.9.3 Screen structure 4.9.4 Functions of the buttons 4.9.5 Symbols in the screen masks 4.10 Menu Job 4.10.1 Tab Job > Job settings 4.10.2 Tab Job >...
Page 7 Operating Instructions 4.15.9 Tab Manufacturer service > Print head alignment Transport General Methods of transport Safety instructions for the transport Internal transport 5.4.1 Transport preparations 5.4.2 Transport securing device 5.4.3 Preparation of the transport route Executing the transport 5.5.1 Transport by crane 5.5.2 Transporting by forklift External transport or storage for any length of time...
Page 8 Operating Instructions Check the defaults of the printer Function test Operation Safety instructions for operation Check the printer EACH TIME before switching it on Starting requirements 8.3.1 Preparations 8.3.2 Switching on the cooler 8.3.3 Switch on corona treatment Switch on printer Switch off printer Changing the roll of printing substrate 8.6.1...
Page 9 Operating Instructions Maintenance and Repair 10.1 Content and purpose 10.2 Area of validity 10.3 Safety through regular maintenance 10.4 Safety instructions for maintenance and repair 10.4.1 Instructions regarding hazards due to live parts 10.4.2 Instructions regarding hazards due to hot operating materials 10.5 Maintenance 10.5.1...
Page 10 Operating Instructions 10.11 Schedule for the replacement of consumable components Storage 11.1 Printer 11.1.1 Storage of ink and cleaning fluid 11.1.2 Storage of cleaning agents 11.1.3 Storage of replacement parts and consumables Disassembly and Disposal 12.1 Safety instructions for disassembly of the machine 12.2 Disassembly of the machine 12.3 Safety information for the disposal of the machine 12.4 Disposal of the machine...
Page 11: General Remarks
Operating Instructions General Remarks General Remarks Introduction These operating instructions are intended as an aid for the personnel re- sponsible for installing, operating and repairing the printer. Familiarity with these operating instructions is the only way to prevent problems with the printer and guarantee trouble-free operation.
Page 12: Scope Of Delivery And Responsibilities
General Remarks Operating Instructions Furthermore, Markem-Imaje CSAT GmbH is not liable for intent and gross negligence. All rights are reserved, including the right to reproduce these operating in- structions in full or in part in any manner. We reserve the right to modify the contents without prior announcement. We reserve the right to make technical modifications without prior an- nouncement.
Page 13 Operating Instructions General Remarks ther claims for damages, irrespective of the legal basis on which they arise, are excluded. Liability or warranty is excluded if:  the information and directions in these operating instructions are disre- garded,  if error messages or problems arise on the machine and are ignored and accepted without rectifying them, ...
Page 14: Warranty In Connection With Print Heads
General Remarks Operating Instructions Note In the event of a complaint:  Always use the original packaging to return the non-confirming compo- nent.  Fill out the form FRM-105-02 Return shipment dispatch note com- pletely and as precisely as possible. This form is enclosed with each component.
Page 15: Identification
Operating Instructions General Remarks Identification Designation Continuous Digital Printer CSAT ITS6 Serial No. EG.LAA0-00135 Manufacturer Markem-Imaje CSAT GmbH Daimlerstr. 32 D-76344 Eggenstein-Leopoldshafen The ITS6 printer is identified by its type plate beneath the main switch. 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.
Page 16: Other Valid Documentation
General Remarks Operating Instructions Other valid documentation In addition to the manual for the ITS6 printer, the information contained in the documents accompanying various purchased parts must also be ob- served. The corresponding files are stored on the documentation CD in- cluded with delivery.
Page 17: Safety
Operating Instructions Safety Safety Intended use The ITS6 printer was constructed in accordance with the state-of-the-art and the generally accepted safety regulations. It was designed and built to convert image data by means of the “inkjet” process into actual images, which can then be transferred to a multitude of materials, for instance metal foil, paper and plastic.
Page 18 Safety Operating Instructions face of the printing substrate so that damage to the print heads is quite likely,  … passing taped seams through the main curing unit or beneath print head units in their working positions,  … the use of labels which come loose from the backing material on their own when deformed or subjected to heat, ...
Page 19 Operating Instructions Safety 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: Safety Symbols
Safety Operating Instructions Safety symbols The following signal words are used in conjunction with safety symbols in this document to represent potential danger. Danger Symbol Death, serious injury or substantial material damage will occur if the Panel corresponding precautions are not taken. Warning Symbol Death, serious injury or substantial material damage can occur if the...
Page 21: Safety Symbols And Their Meaning
Operating Instructions Safety 2.3.1 Safety symbols and their meaning The purpose of safety symbols is to quickly draw attention to objects and situations that are potentially dangerous. Therefore, certain shapes and colors are used for the safety symbols. The meaning of the safety symbol is indicated by the shape and color (ISO 3864-2).
Page 22 Safety Operating Instructions Warning symbols: Safety Meaning Safety Meaning symbol symbol General warning Entanglement hazard Dangerous voltage Tripping hazard Hazardous substances Slippery surface Danger of whipping Danger machinery starts hoses automatically Hot surface Danger of hand injuries Suspended Danger of tipping load warning Danger of entanglement Beware of...
Page 23 Operating Instructions Safety Mandatory action symbols Safety Meaning Safety Meaning symbol symbol Disconnect before Unplug power supply work before opening Wear respiratory protec- Wear safety gloves tion Wear eye protection Wear safety shoes Read manual Disposal of substances © Copyright by Markem-Imaje CSAT GmbH ITS6_135_Manual_EN.doc Subject to Technical Modifications Page 23 / 370...
Page 24: Safety Symbols On The Machine
Safety Operating Instructions 2.3.3 Safety symbols on the machine The following safety symbols are attached to the machine: Prohibition Position on the printer symbol On the rear 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 Position on the printer...
Page 25: Safety Symbols On The Cartridges For Ink And Cleaning Fluid
Operating Instructions Safety Mandatory Position on the printer action symbol  Ink cartridge flap, inside  Collection pan  Residual ink bottle flap, inside Notice  Always keep the safety symbols clean.  Comply with the warnings and mandatory actions. ...
Page 26: Safety Instructions
Safety Operating Instructions Safety instructions The basic requirement for the safe handling and trouble-free operation of the ITS6 printer is awareness of the fundamental safety instructions and the work safety regulations. These operating instructions contain all of the important information needed for operating the printer safely.
Page 27 Operating Instructions Safety Warning The safety of the machine is ensured only when all safety equipment has been properly installed and is active.  Do not operate the machine without safety equipment.  Safety equipment must not be removed until the main switch has been disabled.
Page 28 Safety Operating Instructions Warning Warning of electromagnetic field.  Persons with pacemakers should stay away from the corona sta- tion during printing operation. A person who faints must be taken out of the danger area immedi- ately. If the person continues to be unconscious, start resuscita- tion.
Page 29: Safety Concept
Operating Instructions Safety Safety concept Warning Death, serious injury or substantial material damage can occur if the corresponding precautions are not taken.  Check the proper functioning of all safety measures on the ma- chine.  Do not bypass any safety measures. ...
Page 30: Safety Measures
Safety Operating Instructions 2.5.2 Safety measures The purpose is to protect…  … the personnel against injuries,  … the machine against damage and downtime,  … the environment against hazards. The following safety measures were taken based on a risk analysis of the ITS6 printer: ...
Page 31: Organizational Safety Concept
Operating Instructions Safety The instructions and safety signs attached to the printed must be observed:  They must not be altered or removed.  Damaged signs should be replaced immediately.  Labels must be legible. 2.5.4 Organizational safety concept In order to avoid accidents, the safety concept contains several measures: ...
Page 32: Personal Protection Equipment
Safety Operating Instructions 2.5.5 Personal protection equipment The personal protection equipment (PPE) that has to be worn depends on the particular activity that is being performed. Please refer to the following table: Symbol Activity Protective During all maintenance work eyewear Safety Work on the printer, e.g.
Page 33: Safety Doors With Position Monitor
Operating Instructions Safety 2.5.6 Safety doors with position monitor Fig. 1. Safety doors with position monitor (view from above) Pos. Components Function Moveable hard guard Safety door (access to the rear of the print head unit and the rear collection pan) Moveable hard guard Hinged hood (access to internal components)
Page 34: Do Not Misuse The Gas Springs On The Hinged Hood As
Safety Operating Instructions still open in the areas accessible to the operator, neither can the drives be started nor are any parts energized with high 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.
Page 35 Operating Instructions Safety Fig. 3. Position of the door interlock switches Pos. Function Displayed message Monitoring of the safety door at 66 - “Rear door open” the rear (access to the print head unit and the collection pan) 63 - Monitoring of the hinged hood “Print head unit: hinged hood (access to web guider)
Page 36: Emergency Stop Button Safety Device
Safety Operating Instructions 2.5.7 Emergency Stop button safety device In order to avert acute personal danger, an Emergency Stop button is in- stalled on the control panel of the machine – in an easily accessible place. The button effectuates a controlled shutdown of all mechanical parts of the printer.
Page 37: Emergency Stop Button On The Printer
Operating Instructions Safety Fig. 4. Emergency Stop button on the printer Depiction Meaning Position Emergency Control panel Stop button Effects of an Emergency Stop Pos. Control Effects of an Emergency Stop element Emergency Stop When pressed, it switches off all drives, live com- button ponents, and the pneumatic system, and effectu- ates a controlled shutdown of all mechanical parts...
Page 38 Safety Operating Instructions 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.
Page 39: Main Switch
Operating Instructions Safety 2.5.8 Main switch The main switch is used to switch the power supply to the machine on and off. Fig. 5. Main switch on the printer Meaning Position Main switch Main switch On/Off switch Effects of the Main Switch and the On/Off Switch Pos.
Page 40: Sensors
Safety Operating Instructions 2.5.9 Sensors The sensors constantly monitor the current status of all critical aspects of the 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.
Page 41: Residual Risks
Operating Instructions Safety Residual risks Other risks occur when operating the ITS6 printer, which can be avoided through safety-conscious work habits. Warning Risk of fatal injury due to electrical shock.  Observe the warning signs attached.  Do not remove any covers in the switch cabinet. ...
Page 42: Duties Of The Owner
Safety Operating Instructions Duties of the owner The owner commits himself to only allowing individuals to work on the ma- chine who…  … are familiar with the basic work safety and accident prevention regu- lations,  … are qualified and have been trained to work on the ITS6, ...
Page 43: Requirements Of The Personnel, Due Diligence
Operating Instructions Safety Requirements of the personnel, due diligence 2.8.1 General Warning  All work on the ITS6 printer must be performed only by qualified and instructed personnel in compliance with the safety instructions of these operating instructions! 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.
Page 44: Due Diligence Of The Personnel
Safety Operating Instructions 2.8.2 Due diligence of the personnel The personnel must …  … have read and understood the instruction manual and its safety chapter of the operating instructions for the individual components,  … know the function and location of the control elements and the safe- ty equipment (safety equipment includes, e.g.
Page 45: Training Of The Personnel
Operating Instructions Safety 2.8.3 Training of the personnel Various qualifications are required for the various tasks on the ITS6 printer. The responsibilities of the personnel for the machine’s individual phases of life (transport, commissioning, operation, maintenance, repair, dismantling, and disposal) must be clearly defined. The following table shows the minimum qualifications required for working on the machine.
Page 46: Handling Emergencies
Safety Operating Instructions Handling emergencies Please observe the following points:  The personnel must have been taught how to handle emergencies.  All individuals working on the machine must have been informed about how to shut down the machine quickly. ...
Page 47: Technical Data
Operating Instructions Technical Data Technical Data Dimensions and weight The values listed in the following table relate only to the intrinsic weight and external dimensions of the printer at the time of delivery. The actual space requirement after installation, the weight of the hoses used, and the printing material are not included in this list.
Page 48: Load-Bearing Capacity Of The Foundation
Technical Data Operating Instructions Load-bearing capacity of the foundation Load-bearing capacity of the foundation Weight 1 300 kg 1 400 kg 1 500 kg 1 600 kg Area load 733 kg/m² 790 kg/m² 846 kg/m² 902 kg/m² Average concentrated 325 kg 350 kg 375 kg 400 kg...
Page 49: Pneumatic System
Operating Instructions Technical Data Pneumatic system Pneumatic connections 6 – 8 bar (6 – 8 * 10 Pressure Max. flow rate 10 dm³/min. Condition dry, oil-free Coolant connection Coolant connection Operating pressure 4.5 bar (4.5 * 10 Max. Inlet pressure at max. Max.
Page 50: Interfaces For Signal And Data Transmission
Technical Data Operating Instructions Interfaces for signal and data transmission Interfaces Print data USB-A jack for the transfer of files by means of USB flash drive Ethernet connector RJ 45 10/100 Process interfaces HARTING 5-pole, for signal exchange with ext. cooler Performance range Performance range Type designation...
Page 51: Substrate Specifications
Operating Instructions Technical Data Substrate specifications Depending on the technical equipment involved, every ITS6 printer is ca- pable of printing a host of materials, be it labels or continuous webs of met- al foil, paper, plastic or even textiles. All of them must fulfill the following cri- teria: Requirement Reason...
Page 52 Technical Data Operating Instructions  Labels or self-adhesive materials must have a Barrier coat barrier coat on the side to be printed which pro- vides reliable protection against the adhesive or its solvent from being released.  The printing substrate must pass over rollers Elasticity and change directions several times, but with- out being permanently deformed and causing...
Page 53: Paper-Like Roll-Fed Material
Operating Instructions Technical Data 3.9.1 Paper-like roll-fed material Determining factor, parameter Required property Material thickness of continuous ma- max. 200 µm terial for printing table without ex- changeable deflection rollers Material thickness of continuous ma- max. 600 µm terial for printing table using suitable exchangeable deflection rollers ...
Page 54: Plastic Roll-Fed Material
Technical Data Operating Instructions 3.9.2 Plastic roll-fed material Determining factor, parameter Required property Material thickness of continuous ma- max. 200 µm terial for printing table without ex- changeable deflection rollers Material thickness of continuous ma- max. 600 µm terial for printing table using suitable exchangeable deflection rollers ...
Page 55: Aluminum Foil Roll-Fed Material
Operating Instructions Technical Data 3.9.3 Aluminum foil roll-fed material Determining factor, parameter Required property Material thickness of continuous ma- max. 200 µm terial for printing table without ex- changeable deflection rollers Material thickness of continuous ma- max. 600 µm terial for printing table using suitable exchangeable deflection rollers ...
Page 56: Textile Roll-Fed Material
Technical Data Operating Instructions 3.9.4 Textile roll-fed material Determining factor, parameter Required property Material thickness of continuous ma- max. 200 µm terial for printing table without ex- changeable deflection rollers Material thickness of continuous ma- max. 600 µm terial for printing table using suitable exchangeable deflection rollers Material thickness of continuous ma- max.
Page 57: Label Material Made Out Of Paper
Operating Instructions Technical Data 3.9.5 Label material made out of paper Determining factor, parameter Required property Material thickness of continuous ma- max. 200 µm terial for printing table without ex- changeable deflection rollers Material thickness of continuous ma- max. 600 µm terial for printing table using suitable exchangeable deflection rollers ...
Page 58: Label Material Made Out Of Aluminum Foil
Technical Data Operating Instructions 3.9.6 Label material made out of aluminum foil Determining factor, parameter Required property Material thickness of continuous ma- max. 200 µm terial for printing table without ex- changeable deflection rollers Material thickness of continuous ma- max. 600 µm terial for printing table using suitable exchangeable deflection rollers ...
Page 59: Label Material Made Out Of Plastic
Operating Instructions Technical Data 3.9.7 Label material made out of plastic Determining factor, parameter Required property Material thickness of continuous ma- max. 200 µm terial for printing table without ex- changeable deflection rollers Material thickness of continuous ma- max. 600 µm terial for printing table using suitable exchangeable deflection rollers ...
Page 60: Suitable Printing Substrates
Technical Data Operating Instructions 3.9.8 Suitable printing substrates According to the experience of Markem-Imaje CSAT GmbH, the following printing substrates are suitable for printing – assuming the correct proce- dure is used: Manufac- Face Name of Coating Adhesive Backing turer material material ("Top-...
Page 61: Unsuitable Printing Substrates
Operating Instructions Technical Data 3.9.9 Unsuitable printing substrates Never insert a printing substrate in the printer if at least one of the following points applies:  With printing tables with deflection rollers: Total thickness of the mate- rial above the values mentioned in chapter 3.8. ...
Page 62 Technical Data Operating Instructions Fig. 6. Typical unsuitable printing material: In particular when it is made from plastics, you must ensure that the printing material keeps its shape at a higher temperature:  Perform a forward feed with clamped printing material (button on the control console).
Page 63 Operating Instructions Technical Data 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: Adhesive Tape
Technical Data Operating Instructions 3.10 Adhesive tape Just like the printing substrate itself, the adhesive tape used to join the ends of printing substrate in the cut-and-splice device(s) is of decisive im- portance for the safe operation of the printer. Besides the material thickness and the adhesive power, the heat resistance of the adhesive tape and the printing substrate is of particular importance to ensure they do not fail and come apart in the area of the print head unit and...
Page 65: Noise Level
Operating Instructions Technical Data Notice Unsuitable adhesive tape or improper attachment can cause severe – on the print heads even irreparable – damage. Therefore:  Apply only one layer of adhesive tape on the front and on the rear of the printing substrate. ...
Page 67: Machine Description
Operating Instructions Machine Description Machine Description Functional diagram Fig. 7. Functional diagram of ITS6, part 1 © Copyright by Markem-Imaje CSAT GmbH ITS6_135_Manual_EN.doc Subject to Technical Modifications Page 67 / 370...
Page 68 Machine Description Operating Instructions Fig. 8. Functional diagram of ITS6, part 2 © Copyright by Markem-Imaje CSAT GmbH Page 68 / 370 Subject to Technical Modifications ITS6_135_Manual_EN.doc...
Page 69: Schematic Representation
Operating Instructions Machine Description Schematic representation The printer consists of several components that are linked to one another. The basic schematic structure of the ITS6 printer is described below. 4.2.1 ITS6 components When the printing material comes from the unwinding roll, it passes by var- ious assemblies in the printer as shown by the numbered position in the fol- lowing illustration.
Page 70: Its6 Sensors
Machine Description Operating Instructions 4.2.2 ITS6 sensors All of the printer’s functions are monitored by sensors. The following illus- tration depicts the sensors that take readings related directly to the printing substrate. The numbering of the positions relates to the sequence with which the printing substrate passes through the machine.
Page 71: Workplace At The Printer
Operating Instructions Machine Description Workplace at the printer The swivel-type bottom control console for the printer, that is installed at the right front side, is equipped with a touchscreen. The operator can use it to retrieve the data that is necessary for printing, activate or deactivate indi- vidual components, retrieving and editing actual values and setpoints.
Page 72: Functional Description
Machine Description Operating Instructions Functional description The ITS6 printer is a fully digital continuously-fed printer which converts the imported image data into actual images by means of the UV inkjet process. During printing, the roll installed in the unwinding unit is unwound continu- ously.
Page 73: Path Of The Printing Substrate
Operating Instructions Machine Description Path 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.”).
Page 74: Functional Description Of The Components And Parts
Machine Description Operating Instructions Functional description of the components and parts 4.6.1 Unwinding unit Purpose Roll of printing substrate is secured on the clamping bar mandrel and held into place laterally with end plates. Technical realization A drive unit unwinds the printing substrate continuously from the unwinding unit at a speed adapted to the printing process.
Page 75: Material Sensor On Unwinding Unit
Operating Instructions Machine Description The maximum outer diameter of the material roll is 550 mm. The maximum width of the material roll is 220 mm. Due to the incessant reduction of the outer diameter of the roll of printing substrate, the speed of the unwinder shaft is constantly being readjusted. 4.6.2 Material sensor on unwinding unit Purpose...
Page 76: Printing Substrate Cleaning Module
Machine Description Operating Instructions 4.6.3 Printing substrate cleaning module Purpose Cleaning of the printing substrate from adhering loose particles. Neutralisation of electrostatic charge. Technical realization Loose dirt is removed from the substrate by means of cleaning rollers and transferred to rollers with adhesive foil. Fig.
Page 77 Operating Instructions Machine Description Printing substrate cleaning module This module consists of two practically identical components constructed in mirror image. During the printing procedure, two pneumatic cylinders (cf. illustration above, pos. 3) press the two white rollers with adhesive foil and the grey cleaning rollers against both sides of the printing substrate.
Page 78: Printing Substrate Storage Assembly (Unwinding Unit)
Machine Description Operating Instructions 4.6.4 Printing substrate storage assembly (unwinding unit) Purpose Controls the unwinding speed so that the printing substrate runs evenly through the machine. In addition, it tensions the printing substrate between the 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.
Page 79: Dancer Roller
Operating Instructions Machine Description Pos. Element Meaning dancer roller Guidance of the printing substrate. Swivelling module Generation of the dancer force that keeps the substrate web firmly tightened. Phase angle sen- Capturing of the actual position of the dancer sor (not visible) shaft.
Page 80: Web Tension Control
Machine Description Operating Instructions 4.6.5 Web tension 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.
Page 81: Web Tension Control
Operating Instructions Machine Description Pos. Element Meaning Pressure roller Ensures static friction where the printing sub- Ø 50 mm strate contacts the rubber roller. The parallelism is adjusted by means of the knurled screws. Drive shaft with Tightens the printing substrate rubber roller Ø...
Page 82: Fig. 20. Its6 Pressure Roller
Machine Description Operating Instructions Pressure roller Purpose Regulates the friction force between the printing substrate and the rubber roller of the web tension control. Technical realization The distance between the pressure roller and rubber roller can be adjusted by means of the four knurled screws. Fig.
Page 83 Operating Instructions Machine Description surface. In this case, both pressure roller set screws must be screwed down evenly over the printing substrate but without denting the rubber- coated friction roller: > First loosen the knurled screws #2 at both ends of the pressure roller. >...
Page 84: Cut-And-Splice Device With Integrated Blade
Machine Description Operating Instructions 4.6.6 Cut-and-splice device with integrated blade Purpose The printing substrate is cut off precisely by the blade widthwise. Technical realization Rolling blade with linear guide. Fig. 21. ITS6 cut-and-splice device with integrated blade Pos. Element Meaning Cutting table plate Support for the printing substrate during the cut-and-splice process.
Page 85: Printing Substrate Clamp
Operating Instructions Machine Description 4.6.7 Printing substrate clamp Purpose Securing the printing substrate. Technical realization Pneumatic-driven rubber swivel axis. Fig. 22. ITS6 printing substrate clamp Pos. Element Meaning Button Clamping and release of printing substrate. Clamping drum Secures the printing substrate to the cutting table plate.
Page 86: Corona Treatment
Machine Description Operating Instructions 4.6.8 Corona treatment Purpose To improve the wettability of the particular substrate. Technical realization Printing substrate is exposed to ionized air generated by an electrical high- voltage discharge. Fig. 23. Corona treatment Pos. Element Meaning Corona generator Supplies the medium-frequency high-voltage required for generating the corona.
Page 87 Operating Instructions Machine Description The corona treatment can usually be omitted if open-pored paper or syn- thetic fabric is being printed, since in such cases the capillary effect of the fibers allows the applied ink to spread and coalesce better on the substrate. The corona treatment affects only the surface facing the bar electrode and not the opposite side or the interior of the substrate, so that mechanical properties, such as tensile strength, remain unchanged.
Page 88: Web Guider
Machine Description Operating Instructions 4.6.9 Web guider Purpose This module constantly monitors the edge of the web as it is transported, and corrects deviations automatically. Technical realization The transport of the web is monitored by a sensor. Fig. 24. ITS6 web guider Pos.
Page 89: Fig. 25. The Control Panel Of The Web Guider
Operating Instructions Machine Description Information The device has already been pre-set, so it is very simple to use and its operation is limited to four buttons on its control panel. Information For detailed information on operation, please 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.
Page 90 Machine Description Operating Instructions Pos. Element Meaning Display Setup Mode: Displays the various control parame- ters Automatic mode: Displays the manually induced shifting of the side of the web, measured in millime- ters. “Increase These buttons are needed in the setup mode only. value,”...
Page 91 Operating Instructions Machine Description Pos. Element Meaning Position indi- Indicates in which direction and how far the web has cator shifted with respect to the position of the sensor: If only the LEDs at the bottom are illuminated, then the web has moved closer to the observer, if the LEDs at the top are illuminated, the web has wan- dered away from the observer.
Page 92: Fig. 26. Its6 Sensor Of Web Guider
Machine Description Operating Instructions 4.6.9.4 Web guider sensor Purpose This sensor measures the offset of the web being transported and trans- mits this offset to the web guider to correct 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.
Page 93: Substrate Discharge At The Unwinding Unit
Operating Instructions Machine Description 4.6.10 Substrate discharge at the unwinding unit Purpose Elimination of any electrostatic charges. Technical realization High-voltage electrostatic fields and alternating polarity neutralize any elec- trostatic charges of the material to be printed. Fig. 27. Substrate discharge at the unwinding unit Pos.
Page 94: Substrate Discharge
Machine Description Operating Instructions  the charged substrate could attract oppositely charged particles of dust and dirt and hold them on its surface,  the machine operator could suffer harmless yet unpleasant minor elec- trical shocks when approaching the machine, ...
Page 95 Operating Instructions Machine Description Pure plastic sheets or printing material that contains plastics – such as "peel-push film“ or textiles made from synthetic fiber – accumulate static electricity during the unwinding and deflecting operations. These charges decay only slowly in the air. Since the printing substrate and most of the guide rollers in the printer are not electrically conductive, these electric charges remain "trapped"...
Page 96: Web Retraction System
Machine Description Operating Instructions 4.6.11 Web retraction system 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.
Page 97 Operating Instructions Machine Description Pos. Element Meaning Linear unit Guide system for the carriage Linear unit drive Speed-controlled movement of the carriage Carriage Guide roller support Guide rollers Guidance of the printing substrate Web retraction system This module serves as temporary storage whenever the printing process has to be stopped.
Page 98: Label Sensor
Machine Description Operating Instructions 4.6.12 Label sensor Purpose The sensor monitors the substrate web and recognises labels on the carri- er material. Technical realization Ultrasonic sensor with linear guide and clamping function. Fig. 30. Label sensor Pos. Element Meaning Sends a signal to the printer’s controls which Label sensor initiates the transfer of the corresponding im- Slide...
Page 99 Operating Instructions Machine Description 4.6.12.1 Functional incorporation of the label sensor (in front of printing unit) This sensor is needed for the placement of the printed image on cut label material. When the sensor detects the leading edge of a label, it sends a signal to the printer’s controls which initiates the transfer of the next image as soon as the printing substrate has covered the pre-set distance, "leading edge of label to beginning of printed image."...
Page 100 Machine Description Operating Instructions To set the label sensor, please proceed according to the following instruc- tions. The sequence of the operating steps must be exactly observed. > Switch on the print system and have it start up automatically. In case the print system was already switched on, stop the ongoing printing process and wait until the system has come to a complete standstill.
Page 101: Print Mark Sensor
Operating Instructions Machine Description 4.6.13 Print mark sensor Purpose Sensor for the printing of pre-printed material. The sensor detects so- called print marks or "bars." Technical realization Reflection sensor with linear guide and clamping function. Fig. 31. Positions of the ITS6 print mark sensors Pos.
Page 102 Machine Description Operating Instructions 4.6.13.1 Properties of print mark sensors The so-called print mark sensors or bar sensors are used for synchronized printing of continuously fed material, whereby the distance between the in- dividual images to be printed has been established in advance, and is de- fined by the rectangular print marks, the so-called “bars,”...
Page 103 Operating Instructions Machine Description 4.6.13.2 Calibrating a print mark sensor During so-called calibration, the sensitivity of the sensor is adjusted ideally to the contrast between the color of the print marks and the surface of the particular printing material. It is completely irrelevant whether there are dark print marks against a light background or vice versa.
Page 104: Infeed Height Control
Machine Description Operating Instructions 4.6.14 Infeed height control Purpose 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.
Page 105 Operating Instructions Machine Description Pos. Element Bedeutung Sensor Whenever the permissible material thickness is exceeded, the sensor will trigger the abrupt stop of the machine. Scanning bar Floats normally above the printing material. Is touched and raised by too thick a printing materi- Marks Marks for adjusting the scanning bar to the thick- ness of the employed printing material.
Page 106 Machine Description Operating Instructions Thickness of the Inscription on the Scanning bar ad- printing substrate exchangeable deflec- justment value tion rollers 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...
Page 107: Printing Table
Operating Instructions Machine Description 4.6.15 Printing table 4.6.15.1 Printing table with exchangeable deflection rollers Purpose Ensures a flat and accurate height and lateral position of the printing sub- strate during the printing process. Technical realization Smooth-running, bearing-mounted guide rollers. Fig. 33. ITS6 printing table Pos.
Page 108 Machine Description Operating Instructions Information  The loaded image/printing width must always be narrower than the respective printing substrate!  Any ink that gets onto the deflection rollers must be thoroughly re- moved at once, since it could cure there over time. Likewise, the ink could crawl under the printing substrate and make it stick to the roll- ers after curing.
Page 109 Operating Instructions Machine Description Information  If you are in doubt, always use the deflection rollers for the next thicker printing 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...
Page 110 Machine Description Operating Instructions Item Element Meaning Angular encoder Permanently monitors the rotation of the gauge ring / the infeed roller, and sends the corre- sponding signals to the control system. Gauge ring Rotates together with the infeed roller, thus triggering the signals of the angular encoder.
Page 111: Print Head Unit
Operating Instructions Machine Description 4.6.16 Print head unit Purpose Inkjet print head unit for creating the printed image on the printing 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.
Page 112 Machine Description Operating Instructions 4.6.16.1 Function of the print head unit The printer operates with a print head unit that can be maneuvered when idle. The printing process takes place by means of four print heads aligned behind one another, each of which transfers one of the four primary colors (cyan, magenta, yellow, black).
Page 113: Print Head Unit
Operating Instructions Machine Description Service position Parking position Working position Fig. 36. Standard positions of the print head unit (view from above) Position Operational state When cleaning the wipers, print heads, and lamp Service position modules of the pre-curing unit as well as when per- forming maintenance work on the lines leading to the print head unit.
Page 114 Machine Description Operating Instructions standard and 1½ to 2 minutes for intensive cleaning. This supposed loss of time makes up for itself very quickly when one considers that …  … plugged nozzles cause white stripes to appear lengthwise in the printed image, ...
Page 115 Operating Instructions Machine Description 4.6.16.5 Wiper cleaning action The wipers come into use during standard and intensive cleaning process- es, and can be adjusted individually for each print head under the tab Job\Cleaning. During the cleaning process, first the print head unit is pulled into its park- ing position at the rear of the printer.
Page 116 Machine Description Operating Instructions Information > After each shift, clean the wipers and their holders manually and make sure that they are in good condition and proper working order. > Make sure that, when the wipers are flipped up, they do not reach beyond the print head nozzle plates above them, and that they are aligned exactly parallel to the print head nozzle plates and are in good condition.
Page 117 Operating Instructions Machine Description automatically folded up and, one by one in succession, sprayed on with cleaning fluid from several nozzles. Each wiper unit has its own spray noz- zles that sit on the underside of the print head unit. Simultaneous showering of more than one wiper unit of a printer is not pos- sible.
Page 118: Pre-Curing
Machine Description Operating Instructions 4.6.17 Pre-curing Purpose Pre-curing of the ink applied by the first three rows of print heads by means of chemical cross-linking on the surface. Technical realization The ink that was last applied is cured 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.
Page 119 Operating Instructions Machine Description 4.6.17.1 Layout and function of the pre-curing unit The ink applied by each of the first three print head rows is pre-cured by UV light on its way to the next print head row to the point that an intact mem- brane is formed on the surface which will not allow the mixing of any ink applied later.
Page 120 Machine Description Operating Instructions 4.6.17.2 Correct operation of the pre-curing unit Operating the pre-curing unit involves the risk of light being emitted by its LEDs, which can be partially reflected and slowly harden the film of ink on the underside of the print heads. This would cause the nozzle plates to be- come clogged over time and the print heads, costing several thousand Eu- ros each, would have to be replaced –...
Page 121 Operating Instructions Machine Description 4.6.17.3 Care of the pre-curing unit In general, the cleanliness of the LED strips of the pre-curing unit only has to be checked once a day when the print heads are cleaned by hand. If for- eign objects or ink film and drops are visible on an LED strip, they should be removed using only a soft, lint-free cloth if possible (see Chap.10.7.5.2, "Manual cleaning of the print heads").
Page 122: Main Curing
Machine Description Operating Instructions 4.6.18 Main curing Purpose Fixation 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.
Page 123 Operating Instructions Machine Description Pos. Element Meaning Lamp module 3 Complete curing of the ink Lock Locking and unlocking Handle Pull handle Main curing The applied ink is permanently fixed to the surface of the printing substrate by means of chemical cross-linking when subjected to the UV light from the 3 lamp modules.
Page 124: Air Circulation System
Machine Description Operating Instructions 4.6.19 Air circulation system Purpose The air circulation system circulates and filters the air in the area of opera- tion. Technical realization Continuous suction of air by means of a fan and cleaning by means of an activated charcoal filter.
Page 125: Air Cooling
Operating Instructions Machine Description 4.6.20 Air cooling Purpose Cooling of the printer interior by extracting hot air. Technical realization Permanent extraction of the air via a fan and cleaning via activated char- coal filters. Fig. 45. Air cooling (rear view with open safety door rear) Pos.
Page 126: Caps Server
Machine Description Operating Instructions 4.6.21 CAPS server Task Preparing image files for printing, and 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.
Page 127: Camera System
Operating Instructions Machine Description 4.6.22 Camera system Task Recording the printed image and comparing the recorded image with a reference image. Sending the result of the evaluation to the Label Rejec- tion Controller. Technical implementation Trigger signal from an incremental encoder. Fig.
Page 128: Function Of The Camera System Components
Machine Description Operating Instructions Once the PDF comparison has successfully been completed, the camera system compares each image printed during the subsequent printing op- eration with the reference image only. In addition to the overall printed im- age, the camera system checks other previously defined image sections for deviations.
Page 129: Friction Drive
Operating Instructions Machine Description 4.6.24 Friction drive Purpose The friction drive conveys the material to be printed at a specified speed past the print heads and the curing systems. Technical realization Static friction on rotating rubber rollers Fig. 48. ITS6 friction drive Pos.
Page 130 Machine Description Operating Instructions close to the rubber roller. This is achieved by adjusting the set screws and lock nuts at both ends of the pressure roller. The 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.
Page 131 Operating Instructions Machine Description Pressure roller Purpose Controls the friction force between the printing substrate and the rubber roller of the friction drive Technical realization The distance between the pressure roller and the rubber roller can be ad- justed by means of four knurled screws. Fig.
Page 132 Machine Description Operating Instructions There’s no need to push the pressure roller down hard onto the rubber roll- er in order to achieve sufficient transmission of force. These two rollers only have to meet tightly on rare occasions, for example when processing print- ing substrate with a particularly smooth or slippery surface.
Page 133: Indicators And Control Elements
Operating Instructions Machine Description Indicators and control elements The correct use and reliable shutdown of the printer is ensured by the switches and control elements shown below: 4.7.1 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.
Page 134: Control Panel
Machine Description Operating Instructions 4.7.2 Control panel The ITS6 printer is operated by means of a control panel. The control panel is mounted on a hinged and pivoting cantilever arm, which can be attached to either the right end or left end of the printer ac- cording to customer requirements.
Page 135 Operating Instructions Machine Description Pos. Elements Meaning Retraction / Pushbutton Feed backward The printing substrate is transported in the direction of the unwinding unit. When this button is pushed, the drives of the unwinding and rewinding units and the friction unit will start up. In addition, the curing systems will be switched on.
Page 136: Access Restriction
Machine Description Operating Instructions 4.7.3 Access restriction Print unit is password-protected. The operating panel and its various func- tions are only activated as long as the username of the most recently logged on person in the footer of the touchscreen. If access is blocked or if nobody has logged on, all operating elements and registers of the touchscreen are blocked with the exception of the log-on key and the help page.
Page 137: Using Touch Elements
Operating Instructions Machine Description 4.7.5 Using touch elements Touch elements are areas of the touchscreen which, when touched, cause the system to respond in a certain way, and which can serve, for instance, as buttons or retrieve input screens or selection boxes. The use of these buttons is basically no different than using conventional buttons.
Page 138: Properties Of The Touchscreen
Machine Description Operating Instructions 4.7.6 Properties of the touchscreen With the help of the touchscreen, numerous actions can be carried out from the control panel of the printer:  Numerical and in some cases graphic depictions of actual states and settings.
Page 139: Enabling Switch
Operating Instructions Machine Description 4.7.7 Enabling switch Purpose Intentional bypassing of the door monitoring system for repair work. Technical realization Overriding the door lock switch of the rear door panel Fig. 52. Enabling switch 4.7.7.1 Purpose of the enabling switch The purpose of the enabling switch is to intentionally override the door lock switch of the rear door panel to allow the service personnel to carefully ob- serve the print head cleaning process –...
Page 140 Machine Description Operating Instructions The print head unit will also be stopped if it happens to be underway be- tween the parking and printing position or vice versa. 4.7.7.3 Proper use of the enabling switch Warning The use of the enabling switch renders a basic safety function of the printer inoperative! ...
Page 141: Stack Light
Operating Instructions Machine Description Information If one of the front door panels happens to be opened while the enabling switch is being used, this can disturb the controls of the door monitoring system / the control device no. +400-A145. Remedy: >...
Page 142 Machine Description Operating Instructions Pos. Element Signal Status Meaning type Blinking Heating/cleaning: light The printer was started and is running up to speed. Blue Visual Blinking The ink supply is exhausted and/or light the material supply in the rewinder is almost used up.
Page 143: Interfaces
Operating Instructions Machine Description Interfaces 4.8.1 Overview of interfaces This chapter describes the supply of electricity, water, and compressed air as well as all of the interfaces required for the exchange of data and signals between the printer and the periphery. Notice Dirty interfaces pose a hazard.
Page 144: Power Supply
Machine Description Operating Instructions 4.8.2 Power supply The printer is operated with 400 V three-phase current. The power is sup- plied by means of a 5-pole plug. 4.8.3 Interface external cooling device This permanently installed 4-pole process interface is for the exchange of signals between the printer and the external cooling device.
Page 145: Coolant Connection
Operating Instructions Machine Description 4.8.9 Coolant connection Intake and discharge are standard hose fittings. Required inner diameter of the connecting hoses: 19 mm. © Copyright by Markem-Imaje CSAT GmbH ITS6_135_Manual_EN.doc Subject to Technical Modifications Page 145 / 370...
Page 146: The User Interface Of The Touchscreen
Machine Description Operating Instructions The user interface of the touchscreen Each time the printer is switched on, the touchscreen will boot. As soon as the printer is ready for operation, the home page will be shown first: Fig. 55. Start screen with login button. Whenever the machine is started up, touchscreen and control console but- tons are locked.
Page 147: Logging Off At The Touchscreen
Operating Instructions Machine Description Information Observe the following points when you enter the password:  The background color of the input line changes from red to white as soon as the required minimum number of characters is entered.  A password must be at least six characters long. It must contain num- bers and at least one capital and one small letter, that may be in any sequence.
Page 148: Menu Structure Of The Touchscreen
Machine Description Operating Instructions 4.9.2 Menu structure of the touchscreen Main Menu └ Job └ Job settings └ Layout manager └ Job manager └ Pre-curing └ Main curing └ Web settings └ Print head alignment └ Cleaning └ System └ Settings └...
Page 149: Screen Structure
Operating Instructions Machine Description 4.9.3 Screen structure The basic structure of the screen masks is described here using the exam- ple of the tab Job > Job settings. Fig. 56. Structure of the screen masks With the exception of the homepage, all other screen masks exhibit an identical appearance around the margins and contain the same elements [1] - [12].
Page 150 Machine Description Operating Instructions Pos. Meaning Hitting this key will shut down the curing systems automatically so that the printer can then be switched off. 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.
Page 151: Functions Of The Buttons
Operating Instructions Machine Description 4.9.4 Functions of the buttons The menus of the touchscreen can be accessed using the so-called naviga- tion buttons on the far right edge of the screen. The buttons that are asso- ciated with the menu that’s currently being shown are either highlighted in color or are darker.
Page 152 Machine Description Operating Instructions Meaning Description Back For navigating within a list. Forward One step up For moving the cursor / selection mark within a list One step up For moving the cursor / selection mark within a list. One step down Single se- This key is displayed only when importing...
Page 153 Operating Instructions Machine Description Meaning Description Enter With this key you confirm a selection or call a selected function or file. Reset key Hitting the reset key will reset all of the set- tings or readings (or return them to “0”). Reset key Hitting the reset key will reboot the associat- ed function, e.g.
Page 154 Machine Description Operating Instructions Meaning Description Thumbnail The image file of the highlighted print job will be presented as a thumbnail. Unlock Unlocks a job container. Cancel print This button allows the currently selected print job to be cancelled, but not until con- firmed by a prompt.
Page 155: Symbols In The Screen Masks
Operating Instructions Machine Description 4.9.5 Symbols in the screen masks Symbol Meaning Description Not in target The element in question, e.g. print head unit or position dancer roller, is not in its target position. In target posi- The element in question, e.g. print head unit or tion dancer roller, is in its target position.
Page 156 Machine Description Operating Instructions Everything is OK, 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 General error message that a graphic cannot be displayed be displayed by the HMI.
Page 157: Menu Job
Operating Instructions Machine Description 4.10 Menu Job 4.10.1 Tab Job > Job settings The user controls the printing process on this page. In particular, this in- cludes  how the printing system positions the layout on the printing sub- strate, ...
Page 158 Machine Description Operating Instructions Item Object Meaning Fixed distance When you choose “Fixed distance” the layouts are printed in the length that is set here. If the layout is longer than the set value the layout is cut off. If the layout is shorter than the set value a blank strip is added.
Page 159: Tab Job > Layout Manager
Operating Instructions Machine Description 4.10.2 Tab Job > Layout manager In the layout manager, the user specifies what is printed. It determines the print volume of jobs, determines ranges, and combines multiple jobs into job containers. It sends prepared job containers to the printer. Fig.
Page 160 Machine Description Operating Instructions Item Object Meaning Change order Move the selected job upwards in the order. Delete Delete the selected job. First page The selected job should be printed starting from this page. Last page The selected job should be printed up to this page. Page repetition How often the individual page should be printed.
Page 161: Tab Job > Job Manager
Operating Instructions Machine Description Unlocking a job container > Select the desired job container in the Job container list box. When a job container is locked, the button with the padlock appears with a blue background. > Press the button with the padlock. >...
Page 162: Tab Job > Pre-Curing
Machine Description Operating Instructions 4.10.4 Tab Job > Pre-curing Pre-curing is done with the three UV lamp modules installed between the print heads.Since pre-curing puts extreme stress on the print heads, pre- curing should only be used as sparingly as possible: ...
Page 163: Tab Job > Main Curing
Operating Instructions Machine Description 4.10.5 Tab Job > Main curing Fig. 61. Job > Main curing tab Object Meaning Current The currently measured main curing power in %. power The lower reference speed v1 in m/min. The required power P1 assigned to the lower reference speed The upper reference speed v2 in m/min.
Page 164: Tab Job > Web Settings
Machine Description Operating Instructions 4.10.6 Tab Job > Web settings This tab is used for the basic settings of the unwinding unit and the compo- nents installed there. Fig. 62. Job > Web settings tab Item Object Meaning Direction of Selection buttons to specify which side of the material roll rotation clamped in the unwinding unit should be printed on.
Page 165 Operating Instructions Machine Description Item Object Meaning Sensors lo- Status indicator and ON/OFF switch for locking or releas- cked 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.
Page 166: Tab Job > Print Head Alignment
Machine Description Operating Instructions 4.10.7 Tab Job > Print head alignment This tab is needed in order to compensate for positional discrepancies be- tween the individual printing colors, viewed transverse and parallel to the direction of travel. Fig. 63. Job > Print head alignment tab Item Object Meaning Print head alignment across feed direction.
Page 167 Operating Instructions Machine Description Item Object Meaning Move to Moves the respective color in the direction of the arrow or the right further away from the yellow print head. Each press of the arrow button increases the respective correction value by 1 pixel.
Page 168 Machine Description Operating Instructions 4.10.7.2 Print head alignment across feed direction > Perform a short test print. > Use a scale magnifier to measure how far the image elements printed with the color in question deviate to the left or right from their target positions and determine the offset ΔX, which can be converted to pix- els with the following formula: Pixel...
Page 169 Operating Instructions Machine Description Determine in which order the four colors were printed. This determines whether you must increase or reduce the current value in the "Web specific correction" field. If the colors appear from left to right in the order black – magenta – cyan – yellow as in Fig.
Page 170 Machine Description Operating Instructions Print direction Fig. 65. The value in the "Web specific correction" field must be reduced. © Copyright by Markem-Imaje CSAT GmbH Page 170 / 370 Subject to Technical Modifications ITS6_135_Manual_EN.doc...
Page 171: Tab Job > Cleaning
Operating Instructions Machine Description 4.10.8 Tab Job > Cleaning This tab can be used to monitor and if necessary manipulate the most im- portant parameters of the cleaning process. Fig. 66. Tab Cleaning Pos. Item Meaning Standard Selection key. During standard cleaning, the print heads in cleaning question are rinsed with a small amount of ink.
Page 172 Machine Description Operating Instructions 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: Menu System
Operating Instructions Machine Description 4.11 Menu System The menu System is where general system settings are made, for instance the network configuration or the system time. As a rule, these settings are not job-specific and, therefore, rarely have to be changed. 4.11.1 Tab System >...
Page 174: Tab System > Network
Machine Description Operating Instructions 4.11.2 Tab System > Network This dialog screen can be used by a properly authorized administrator to enter or change network settings in order to be able to exchange data through the local network. Fig. 68. Tab System > Network, top section Pos.
Page 175 Operating Instructions Machine Description Pos. Function Meaning Enable Status indicator and ON/OFF switch for enabling the firewall. Firewall When enabled, a black check mark is shown here. IP address Display of the IP address. This information can be changed after hitting the blue “com- mand prompt”...
Page 176 Machine Description Operating Instructions Pos. Item Meaning This option allows the so-called “project” software to be up- Allow for project dated by external computers via the local network. (HMI) up- This option is displayed in the scenarios "Local Service", date… "Remote Service"...
Page 177: Tab System > File Manager
Operating Instructions Machine Description 4.11.3 Tab System > File manager The tab System > File manager allows the export of files and protocols and the import of files and software packages via Intranet. Fig. 70. Tab System > File manager Pos.
Page 178: Tab System > Machine Info
Machine Description Operating Instructions 4.11.4 Tab System > Machine info This tab lists not only the machine model and serial number, but also the performance data and the most important software versions installed. Fig. 71. Tab System > Machine info Pos.
Page 179 Operating Instructions Machine Description Pos. Item Meaning Total counter, Total quantity of the feeded material, measured in me- total meters 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.
Page 180: Tab System > User Management
Machine Description Operating Instructions 4.11.5 Tab System > User management The purpose of the user management is to create and manage user ac- counts and to assign specific access rights to everyone who works with the printer. In order to ensure the proper functioning of the printer and the safety of the operator, anyone who works with the printer is assigned to various user groups with specific access rights in accordance with their particular job profile and qualifications.
Page 181 Operating Instructions Machine Description Pos. Item Meaning Arrow keys These keys are used for navigating within the list of users. The list is not in alphabetical order, but rather, in chronological order according to when the various user accounts were set Create After hitting this key, an empty screen with empty input lines user ac-...
Page 182 Machine Description Operating Instructions A password must consist of at least six characters in any order, which in- cludes numbers and at least one upper case and lower case letter each. The system will only accept characters that are shown on the keys of the input screen.
Page 183 Operating Instructions Machine Description Pos. Access right Meaning User The user administrator is authorized to set-up or disable administration user accounts or access rights, and to change the pass- word of the particular employee. Modify basic Technicians are allowed to perform maintenance and re- settings pair work, especially on electronic components.
Page 184: Menu Consumables
Machine Description Operating Instructions 4.12 Menu Consumables The various tabs of this menu focus on the fill levels of the containers of liquid, the diameters of the rolls in the unwinding and rewinding units, and the useful life of several expendable parts. If one of the materials listed under the tab Consumables >...
Page 185: Tab Consumables > Fill Levels
Operating Instructions Machine Description 4.12.1 Tab Consumables > Fill levels This tab shows whether there is enough fluid in the tanks for ink and clean- ing fluid. Furthermore, it shows whether the bottle for residual ink and cleaning fluid has reached a critical fill level. If the fill level of each is OK, a green check mark will be shown.
Page 186: Tab Consumables > Reels
Machine Description Operating Instructions 4.12.2 Tab Consumables > Reels This tab is for monitoring the diameter of the substrate roll in the unwinding unit. Fig. 75. Tab Consumables > Reels Pos. Item Meaning Current Indicates the current diameter of the roll of printing substrate in the unwinding unit detected by the sensor.
Page 187: Tab Consumables > Print Heads
Operating Instructions Machine Description 4.12.3 Tab Consumables > Print heads This tab is for monitoring the running time / the useful life of the individual print heads. The basis for calculations is the number of the so-called "shots," that is, how often a print head gives off one or multiple drops simultaneously during printing or during the cleaning processes.
Page 188 Machine Description Operating Instructions Pos. Item Meaning Warning Setpoint at which, when reached, the operator should be threshold 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”...
Page 189: Tab Consumables > Uv Modules
Operating Instructions Machine Description 4.12.4 Tab Consumables > UV modules This tab is used for monitoring the running time / on-period of the individual lamp modules in the pre-curing and main curing units. Fig. 77. Tab Consumables > UV modules Pos.
Page 190 Machine Description Operating Instructions Pos. Item Meaning Usefule life Setpoint at which, when reached, the operator should be pre-curing 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: Tab Consumables > Wipers
Operating Instructions Machine Description 4.12.5 Tab Consumables > Wipers This tab is used for monitoring the lifetime of the small rubber plates used for the automatic cleaning of the underside of the print heads. The reading indicates the number of hours in which one or more of the wip- ers of a certain color was used.
Page 192: Tab Consumables > Drive Rollers
Machine Description Operating Instructions 4.12.6 Tab Consumables > Drive rollers This tab is used to monitor the running time of the rubber rollers installed in the web tension controllers and the friction drive. Fig. 79. Tab Consumables > Drive rollers Pos.
Page 193: Tab Consumables > Air Filters
Operating Instructions Machine Description 4.12.7 Tab Consumables > Air filters This tab is used to monitor the running time of the installed air filters. Fig. 80. Tab Consumables > Air filters Pos. Item Meaning Current Indicates the current running time of all installed air filters, measured in hours.
Page 194: Tab Consumables > Ink Filters
Machine Description Operating Instructions 4.12.8 Tab Consumables > Ink filters This tab is used to monitor the running time of the installed ink filters. Fig. 81. Tab Consumables > Ink filters Pos. Objekt Bedeutung Current Indicates the current running time of all installed ink filters, measured in meters.
Page 195: Menu Documents
Operating Instructions Machine Description 4.13 Menu Documents This menu contains the tabs Audit Trail and Printing Costs, which are of relevance especially to the system administrator. 4.13.1 Tab Documents > Audit trail The so-called audit trail is an automatically generated record which con- tains all of the relevant events in chronological order.
Page 196: Tab Documents > Printing Costs
Machine Description Operating Instructions Pos. Item Meaning Column 3 Description of the particular event. For example, logins and logouts, the changing of settings or the acknowledgement of messages is recorded here. Scroll bar Allows recorded entries to be viewed which momentarily is not visible in this section of the screen.
Page 197: Menu Alarms
Operating Instructions Machine Description 4.14 Menu Alarms This menu lists all of the alarms or irregularities registered at present. The list of errors includes in particular 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"...
Page 198: Menu Manufacturer Service
Machine Description Operating Instructions 4.15 Menu Manufacturer service Tabs of this menu are used primarily to make general basic settings that do not need to be modified for each new print job. Therefore, these tabs are usually only accessible to the local administrator or the manufacturer's cus- tomer service.
Page 199 Operating Instructions Machine Description Item Object Meaning 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.
Page 200: Tab Manufacturer Service > Pv Monitor
Machine Description Operating Instructions 4.15.2 Tab Manufacturer service > PV monitor This tab is only intended for service technicians and the manufacturer's customer service and gives the person viewing it a general overview of all process variables (PVs) that occur in the respective printing system and thus of the current state of the printing system.
Page 201: Tab Manufacturer Service > Synchronization Settings
Operating Instructions Machine Description 4.15.3 Tab Manufacturer service > Synchronization settings This tab displays all settings associated with the respective image synchro- nization mode. The indicators and switches located in the right-hand part of this tab are on- ly enabled or made available depending on the selected image synchroni- zation mode.
Page 202 Machine Description Operating Instructions Item Object Meaning Top enable Status indicator and ON/OFF switch to activate one of the two / Bot enab- print mark sensors. 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.
Page 203: Tab Manufacturer Service > Other Settings
Operating Instructions Machine Description 4.15.4 Tab Manufacturer service > Other settings This tab is primarily for displaying and entering parameters that are identi- cal for most print jobs and only seldom need to be modified. Fig. 87. Manufacturer service > Other settings tab Item Object Meaning Material...
Page 204 Machine Description Operating Instructions Item Object Meaning Dancer For entering a limit value. force The limit value represents the upper limit to which the "Dancer rewinder force rewinder" setting in the Job > Web settings tab is reduced internally; in %. For entering a limit value.
Page 205: Tab Manufacturer Service > Cleaning Settings
Operating Instructions Machine Description 4.15.5 Tab Manufacturer service > Cleaning settings In this tab the most important parameters of the cleaning process can be monitored and influenced if necessary. Fig. 88. Manufacturer service > Cleaning settings tab Item Object Meaning Automatic ON/OFF switch for activating the automatic cleaning of all cleaning...
Page 206 Machine Description Operating Instructions Item Object Meaning Cleaning Allowable pressure deviation during the process of rinsing with fluid: pres- cleaning fluid. Unit: bar sure tole- The value can be modified with the adjacent button. rance Ink: power Setpoint for the power consumption of the pump during the consump- process of rinsing with ink, as a percentage.
Page 207: Tab Manufacturer Service > Process Settings
Operating Instructions Machine Description 4.15.6 Tab Manufacturer service > Process settings Basic settings of the process can be made with this tab. Fig. 89. Manufacturer service > Process settings tab Item Function Meaning Check cooling Selection switch to activate automatic monitoring of the cooling.
Page 208 Machine Description Operating Instructions Item Function Meaning Disable web retraction Selection switch to activate or deactivate web system retraction. Corona Activate corona F+V network check Switch on or off checking of network connection to finishing machine. © Copyright by Markem-Imaje CSAT GmbH Page 208 / 370 Subject to Technical Modifications ITS6_135_Manual_EN.doc...
Page 209: Tab Manufacturer Service > Web Treatment
Operating Instructions Machine Description 4.15.7 Tab Manufacturer service > Web treatment You make the basic settings for the treatment of the printing substrate in this tab. Via this tab you can also get to the tabs for ink pre-heating and print head alignment.
Page 210: Tab Manufacturer Service > Ink Pre-Heating
Machine Description Operating Instructions 4.15.8 Tab Manufacturer 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 Activate pre-heating Option for activating the ink pre-heating for the respective color.
Page 211: Tab Manufacturer Service > Print Head Alignment
Operating Instructions Machine Description 4.15.9 Tab Manufacturer service > Print head alignment The manufacturer specifies the basis values for the alignment of the print heads on this page. The structure of this page is identical to that of the Job / Print head alignment page.
Page 212 Machine Description Operating Instructions Item Object Meaning Move to Moves the respective color in the direction of the arrow or the right further away from the yellow print head. Each press of the arrow button increases the respective correction value by 1 pixel.
Page 213: Transport
Operating Instructions Transport Transport General The means used for lifting and transportation must be appropriate in terms of their form, stability, and load-bearing capacity for the loads they are sup- posed to support (taking into account their weight, shape, volume and type).
Page 214 Transport Operating Instructions  Wear the proper personal protection equipment (PPE).  Danger of tipping over!  Machine components must be held onto by the transport vehicle until they stand securely on the floor. This applies especially dur- ing and after transport with a lifting cart or a forklift. Warning Risk of fatal injuries due to improper transport.
Page 215: Internal Transport
Operating Instructions Transport Internal transport Internal transport means that the printer is transported within the same building across short and level distances as follows:  … by means of forklift,  … by means of lifting cart, The printer remains closed during transport. Any other transport should be treated as an external transport.
Page 216: Transport Securing Device
Transport Operating Instructions 5.4.2 Transport securing device The print head unit must always be fastened down with the transport secur- ing device included with delivery in order to prevent uncontrolled movement of the print head unit and therefore jarring of the components installed in- side.
Page 217 Operating Instructions Transport 5.4.2.2 Mounting the transport securing device of the web guiders > Below the pivoting frame #1 of each web guider, 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.
Page 218: Preparation Of The Transport Route
Transport Operating Instructions 5.4.3 Preparation of the transport route Proceed in the following order: > Before starting the transport, locate a sufficiently wide, obstacle-free transport route with a smooth surface. Obstacles are considered:  door sills,  wires on the floor, ...
Page 219 Operating Instructions Transport The lifting gear touches the upper edg- The lifting gear is attached to the es of the printer. printer. Fig. 97. Prohibited transport by crane © Copyright by Markem-Imaje CSAT GmbH ITS6_135_Manual_EN.doc Subject to Technical Modifications Page 219 / 370...
Page 220: Transporting By Forklift
Transport Operating Instructions 5.5.2 Transporting by forklift Proceed 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, >...
Page 221: External Transport Or Storage For Any Length Of Time
Operating Instructions Transport 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, ...
Page 222 Transport Operating Instructions  Remove the ink cartridges and replace them by cartridges with cleaning fluid (in case of transport and short-term storage) or re- move ink cartridges (in case of longer storage),  Replace the residual ink bottle with an empty bottle, ...
Page 223: Preparation Of The Transport Route
Operating Instructions Transport 5.6.2 Preparation of the transport route Proceed in the following order: > Before starting the transport, locate a sufficiently wide, obstacle-free transport route with a smooth surface. Obstacles are considered:  door sills,  wires on the floor, ...
Page 224: Packing The Printer In The Transport Crate
Transport Operating Instructions 5.6.4 Packing the printer in the transport crate > Wrap the stack light with two layers of bubble wrap. Unscrew its foot plate of the stack light and lay the latter on the upper cover of the printer.
Page 225: Shipping The Transport Crate
Operating Instructions Transport > Write the return address and receiving address clearly on at least two opposite side walls of the transport crate. > Apply the following three pictograms to all four side walls of the transport crate: Fig. 98. Transport pictograms >...
Page 226: Unpacking The Printer From The Transport Crate
Transport Operating Instructions 5.6.6 Unpacking the printer from the transport crate > Check the transport crate immediately upon receipt for any damage (breakage and heavy wetness). Record any damage found and take photographs as evidence. > First unscrew the lid of the transport crate before removing the four side walls.
Page 227: Assembly
Operating Instructions Assembly Assembly The assembly of the individual machine components is carried out under the direction of Markem-Imaje CSAT GmbH. In this chapter, the assembly is described in general terms. The documents enclosed in the appendix of these operating instructions give details about the assembly and connection of hoses and cables.
Page 228: Set-Up At Final Destination
Assembly Operating Instructions Notice Machine can be damaged by using it in an unsuitable environment. The machine should only be used in ambient conditions which are suitable for the machine and the materials being processed. 6.1.1 Set-up at final destination Warning Potential hazard due to lack of stability.
Page 229 Operating Instructions Assembly  The hinged hood and the safety doors of the unwinding and rewind- ing units must be closed.  The printer must be at room temperature. Procedure > Loosen the lock nuts #2 on all of the adjustable feet, see Fig. 99. >...
Page 230 Assembly Operating Instructions Fig. 99. Adjustable foot. Pos. Element Meaning Washer Load distribution Lock nut To lock the levelling foot Thread Guide for height adjustment Lock nut To lock the adjusting nut Adjusting nut To adjust the height Levelling foot Positioning and vibration buffering Fig.
Page 231: Installation Of The Printer's Supply Systems
Operating Instructions Assembly Installation of the printer’s supply systems Warning Installation of the supply lines.  The printer must be connected properly to all supply lines by quali- fied technical personnel.  The commissioning procedure should be carried out in accordance with the operating instructions only.
Page 232: Consumables
Assembly Operating Instructions then tighten it back down on the chassis of the printer with the two knurled screws. > Remove the transport securing device on each web guider. Screw out the cylinder head screws. The cylinder head screws must be labelled for later transports and kept with the print system.
Page 233: Commissioning
Operating Instructions Commissioning Commissioning The assembly and commissioning of the individual machine components takes place under the direction of Markem-Imaje CSAT GmbH. In the set-up mode, the machine may be operated only by especially trained operating and maintenance personnel. Safety information for the initial commissioning Warning Risk of fatal injury from contact with live parts.
Page 234 Commissioning Operating Instructions Caution Danger of injuries and damage to the system.  The commissioning of the printer and connection of supply lines should be carried out by trained technical personnel only.  Carefully reinstall and secure parts that were removed for trans- porting purposes before re-commissioning.
Page 235: Initial Commissioning Procedure
Operating Instructions Commissioning Initial commissioning procedure 7.2.1 Overview of commissioning measures Check all of the printer’s interface connections. > > Switch on the compressed air supply. > Switch on the water supply. > Fill the printer with its consumables. Turn the main switch of the printer to “I.” >...
Page 236: Check The Defaults Of The Printer
Commissioning Operating Instructions > Let the print head unit move to its parking position. > Use only intact material for threading through:  Press the "Center Mode" button on the control panel of the web guiders.  Press the "Feed forward" key on the control panel until the taped seam is no longer between the unwinding unit and the friction drive.
Page 237: Function Test
Operating Instructions Commissioning Function test Caution Potential danger due to incorrect rotation of motors.  Before a general function test is performed on the machine, check the direction of rotation on the individual motors. Information The general function test should start first with a comprehensive test of all manual functions before changing to automatic mode.
Page 238 Commissioning Operating Instructions Test Prerequisite / Expected reaction of the print- If something else Criterion occurs: In the unwind- A corresponding error message Is the required voltage ing unit lower will appear in the top line of the being supplied? touchscreen “1= Unwinding unit, the pressure axis of the cut-...
Page 239: Operation
Operating Instructions Operation Operation Safety instructions for operation Warning The safety of the machine is ensured only when all safety equipment has been properly installed and is active.  The machine may not be operated without locked and functioning safety equipment. ...
Page 240: Starting Requirements
Operation Operating Instructions Starting requirements  All basic and standard functions of the ITS6 printer have to be checked.  All safety equipment has to be in proper working order and activated.  The main switch(es) of the machine is/are turned on. Fig.
Page 241: Preparations
Operating Instructions Operation 8.3.1 Preparations First perform all of the mandatory cleaning and maintenance work: > Check whether the ink cartridges are full or need to be replaced. > Empty residual ink bottles. Clean up any spilled liquids – especially if they contain ink – immedi- >...
Page 242: Switch On Printer
Operation Operating Instructions Switch on printer > Turn on main switch to "I ON" position. > Press the "I" button on the ON/OFF switch. - The white indicator light of the ON/OFF switch will illuminate. > Log in on the touchscreen as soon as the touchscreen has booted and the Main Menu is shown.
Page 243 Operating Instructions Operation > If the printing substrate was shifted perpendicular to the direction 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) ...
Page 244: Switch Off Printer
Operation Operating Instructions Switch off printer The printer can be switched off when the printing process is finished and no more printing substrate is being processed. The last image to be printed is parked in the web retraction system. To switch off the printer, proceed as follows: >...
Page 245: Changing The Roll Of Printing Substrate
Operating Instructions Operation Changing the roll of printing substrate The roll of printing substrate has to be inserted in the unwinding unit so that it unrolls either counterclockwise or clockwise, depending on whether the outside or the inside of the printing substrate is supposed to be printed. The direction of rotation of the roll depends on the winding direction of the printing substrate.
Page 246: Inserting Printing Substrate
Operation Operating Instructions 8.6.1 Inserting printing substrate Information Whenever you want to insert a thick roll of printing substrate, it is rec- ommended that a layer of the white adhesive foil be torn off from the printing substrate cleaning modules beforehand, since due to lack of space this is hard to do when the printing substrate roll is already in- serted.
Page 247: Feeding In The Printing Substrate
Operating Instructions Operation 8.6.2 Feeding in the printing substrate There are two ways for the printing substrate to be fed in:  Mechanical feed-in  Manual feed-in 8.6.2.1 Mechanical feed-in In order for the new printing substrate to be fed in mechanically, the printing substrate used until now has to be left in the printer.
Page 248 Operation Operating Instructions Notice The webs of textile fabric and label backing material cannot be joined very securely with adhesive tape! In order to minimize the risk of the material tearing, the seams of these substrates should never be allowed between the unwinding shaft and the associated partner machine / winding shaft! The printer owner bears sole liability for damage incurred due to using the incorrect procedure!
Page 249 Operating Instructions Operation dancer roller system to the web tension control with the attached cut- and-splice device. > Starting from the cut-and-splice device, use the winding diagram at- tached here as a guide to feed the printing substrate up over the guide rollers to the web guider and to the web retraction system.
Page 250: Login And Logout At The Touchscreen
Operation Operating Instructions Login and logout at the touchscreen Each time the printer is switched on, the touchscreen will boot. As soon as the printer is ready for operation, the home page will be shown first: Information After each start-up, the touchscreen as well as the control buttons above will always be disabled.
Page 251: Touchscreen Login
Operating Instructions Operation 8.7.1 Touchscreen login Each person who uses the printer must log in to the system with his pass- word. Operators, service technicians and administrators have separate logins with different access rights to the individual functions. The input and alteration of data (parameters) is linked to different levels of access and therefore to different passwords.
Page 252: Touchscreen Logout
Operation Operating Instructions Afterwards the following input screen will open: Fig. 104. Innput screen Pos. Item Meaning Command line The user is prompted to enter his user name. ENTER key Confirmation of the user name entered here. Enter your user name and confirm with “Enter.” >...
Page 253 Operating Instructions Operation However, all users can also manually disable the touchscreen at any time, for instance, in order to prevent misuse by unauthorized 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.
Page 254: Preparing And Executing Print Jobs
Operation Operating Instructions Preparing and executing print jobs 8.8.1 Image files and format files The terms “image files,” “printing data” or simply “layouts” all refer to the da- ta which contains nothing but information about the appearance and con- tents of the images to be printed, for example the distance to the left mar- gin, text fonts, type size, number of colors and their assignment to the exist- ing print heads, etc.
Page 255: Working With Format Files
Operating Instructions Operation color will be matched as best as possible. Small nuances in color are una- voidable for technical reasons. Working with format files The settings required for printing are saved as format files. They contain, for example, the curing module power level and the sensors with which the printer is supposed to be operated.
Page 256: Data Exchange
Operation Operating Instructions 8.10 Data exchange The image files used by the printer are always created on external comput- ers, whereas the format files and log files generated in the printer have to be stored in external systems to be on the safe side. Therefore, the printer regularly exchanges data with the outside world using the HMI page System / File manager.
Page 257: Procedure For Data Exchange
Operating Instructions Operation 8.10.2 Procedure for data exchange The tab System > File Manager allows data and protocols to be exported or imported. Procedure > Open the tab System > File Manager. > In the left and center columns select the type of data (e.g. format file, a protocol or a software) that you would like to export or import and then hit the associated white-green key.
Page 258: Troubleshooting
Troubleshooting Operating Instructions Troubleshooting Errors are displayed on the PC monitor on the main control panel. Warning  Troubleshooting of errors in the electrical system and errors which affect the mechanical and pneumatic systems should be carried out by qualified technicians only. The general standards for reme- dial action in accordance with the accident prevention regulations should be observed.
Page 259: Error Messages
Operating Instructions Troubleshooting Error messages 9.1.1 Introduction All safety-related situations, important functions, and the main components of the ITS6 printer are monitored continuously by the controls. Whenever a deviation from the nominal condition of the printer occurs, for example be- cause a sensor has responded or there was an interruption in a line, then depending on the potential danger, the printer will either be stopped (“Emergency Stop”) or shut down like a normal interruption in operation: In...
Page 260 Troubleshooting Operating Instructions Warning Hazards caused by errors.  For major problems, the service technician or the manufacturer’s customer service should be contacted.  Never open or remove parts of housings or components whose exposure or removal is not described explicitly in the respective safety instructions! ...
Page 261: Messages Under The Tab Alarms
Operating Instructions Troubleshooting 9.1.3 Messages under the tab Alarms The Alarms screen displays all of the malfunctions and status messages currently being registered which result in the printing process either being stopped or not being able to be started at all. The printing process cannot be started until no more messages are being displayed on the Alarms screen and all problems have been eliminated.
Page 262 Troubleshooting Operating Instructions List of error messages The following troubleshooting table can be used to locate and eliminate er- rors that occur on the machine. Operator Technician of Abbott External service technician with the appropriate training Customer service of Markem-Imaje CSAT Code Display: Message Cause of the message / Remedial action:...
Page 263 Operating Instructions Troubleshooting Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status "30= Printer not C: Sensor defective or transmission interrupt- S, C ready to START" ed. Fuse +400-F503 has blown. R: Check the fuse, sensor, wiring and contacts, have defective parts replaced (by the CSAT customer service).
Page 264 Troubleshooting Operating Instructions Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "22= Ink man- C: The ink cartridge in question is empty. The O, T agement unit: Ink lower sensor of the intermediate reservoir level ..., error!"...
Page 265 Operating Instructions Troubleshooting Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "34= Unwinding C: Error in the drive of the web tension control S, C unit: web tension of the unwinding unit.
Page 266 Troubleshooting Operating Instructions Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "38= Web ten- C: The running of the three shaft encoders of S, C sion, error" the web tension control +500-B57), friction (+300-FU3) and entry of the printing unit (+100-B56) is not synchronized.
Page 267 Operating Instructions Troubleshooting Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "43= Main curing C: The temperature of the middle main curing S, C 2: Error“ module is too high. The LEDs of this module will be switched off automatically.
Page 268 Troubleshooting Operating Instructions Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "48= Coolant C: No coolant or insufficient supply of coolant. S, C supply: Error" Sensor +300-B52 is responding. "30= Printer not R: Make sure that the cooler is working and ready to START"...
Page 269 Operating Instructions Troubleshooting Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "52= Main curing: C: The temperature of at least one of the lamp S, C temperature too modules in the main curing unit has reached the “Alarm"...
Page 270 Troubleshooting Operating Instructions Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "64= Main curing C: The main curing unit is not in its working O, T, S, unit: out of posi- position, but rather it has been pulled for- tion"...
Page 271 Operating Instructions Troubleshooting Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status "30= Printer not R: After a power failure or a cut-off of the com- ready to START" pressed air supply: Turn the printer off com- pletely.
Page 272 Troubleshooting Operating Instructions Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "87= Residual ink C: The residual ink bottle is full. O, T bottle is full" "0= Printer waiting R: Stop the printing process as quickly as pos- for line start"...
Page 273 Operating Instructions Troubleshooting Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "91= Cleaning C: The cartridge with the cleaning fluid is emp- O, T unit: cartridge empty!" R: Insert a new cartridge with cleaning fluid.
Page 274 Troubleshooting Operating Instructions Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "95= Rewinding C The frame with the pressure roll is unlocked. O, F unit: Pressure The printing substrate is no longer being roller of web ten- pressed by the pressure roller against the sion control un-...
Page 275 Operating Instructions Troubleshooting Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA “104= Degassing C: Vacuum in the degassing system is too low. S, C unit: vacuum too The reading displayed by the sensor +500- low!”...
Page 276 Troubleshooting Operating Instructions Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA "113= Print head C: This message is shown as long as the print O, T is not in working head is situated in the parking position or somewhere between the parking and print- position"...
Page 277 Operating Instructions Troubleshooting Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA 122 = UPS error C: Power supply failure or fluctuation(s) in the O, T, S, power supply. “30= print system R: End print job, shut down and switch off not ready for...
Page 278 Troubleshooting Operating Instructions Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA 177=DigiConvert C DigiConvert is not ready. O, T not ready. 30= printer not R Make DigiConvert ready. ready for START CA 178=DigiConvert C DigiConvert Buffer is full.
Page 279 Operating Instructions Troubleshooting Code Display: Message Cause of the message / Remedial action: To be elimin. CA = Current Alarm; Alarm? S= Status CA LRC Error: Layout C Layout length is below the minimum. O, T length below min- imum Print a label with a sufficient length.
Page 281: Maintenance And Repair
Operating Instructions Maintenance and Repair Maintenance and Repair 10.1 Content and purpose These instructions are intended to provide the owner and the specially trained personnel with all of the information required for performing mainte- nance and repair work and for compiling internal maintenance and repair instructions.
Page 282: Safety Instructions For Maintenance And Repair
Maintenance and Repair Operating Instructions 10.4 Safety instructions for maintenance and repair Warning Danger of injury during maintenance and repair work.  The printer must be shut down before any maintenance and repair work is performed.  Before starting work the printer must be switched off and protected against being switched back on with a padlock.
Page 283 Operating Instructions Maintenance and Repair Warning Danger of injury on mechanical parts that are under tension.  When working on machine components, make sure they are not under tension. Warning Risk of injury upon contact with the electrodes of the printing substrate discharger.
Page 284: Instructions Regarding Hazards Due To Live Parts
Maintenance and Repair Operating Instructions 10.4.1 Instructions regarding hazards due to live parts Whenever there are problems with the machine’s electricity supply, it should be switched off immediately! Switch off power – if required - to machine parts on which inspection, maintenance and repair work is to be performed.
Page 285: Maintenance
Operating Instructions Maintenance and Repair 10.5 Maintenance The “Maintenance” chapter is aimed predominantly at all employees who work with the ITS6 printer during the actual production process, therefore, cleaning personnel, machine operators, and fitters. 10.5.1 Maintenance schedule For the maintenance of the individual machine components, please ob- serve the respective manufacturer’s specifications.
Page 286 Maintenance and Repair Operating Instructions Maintenance Schedule ITS6 Every 2 hours All print heads must undergo a standard or intensive cleaning very two hours at the latest (see Chap. 10.7.5.1 Mechanical cleaning of the nozzles” Daily At the end of the shift, all of the print heads must first undergo a standard cleaning and then be cleaned by hand.
Page 287 Operating Instructions Maintenance and Repair Maintenance Schedule ITS6 any adhering lint or substrate residue with a brush. Use cloths dampened in acetone to clean any ink adhering to the metal contacts. Weekly Check the clamping function of the cut-and splice device. Clean the cleaning rollers of the printing substrate cleaning module, see chap.
Page 288: Maintenance Of Assemblies And Parts
Maintenance and Repair Operating Instructions 10.6 Maintenance of assemblies and parts 10.6.1 Web Tension Control maintenance The mechanics of the web tension control are practically maintenance-free since all of the bearings are 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.
Page 289: Changing Cartridges Filled With Ink And Cleaning Fluid
Operating Instructions Maintenance and Repair 10.6.2 Changing cartridges filled with ink and cleaning fluid The cartridges filled with ink and cleaning fluid are consumables and have to be replaced on a regular basis. When a low level of ink is reported by the touchscreen, the ink cartridge in question has to be replaced.
Page 290 Maintenance and Repair Operating Instructions > Remove the empty cartridge. > Provide a new cartridge with the same color and type of ink. > Remove the two caps from both ends oft he cartridge. > Slowly insert a new car- tridge #1 with the same ink in- to the retainer until the car- tridge sits on the locking ele-...
Page 291 Operating Instructions Maintenance and Repair > 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: Designation Pos. Cleaning fluid Yellow Cyan Magenta Black >...
Page 292: Changing The Wipers On The Print Heads
Maintenance and Repair Operating Instructions 10.6.3 Changing the wipers on the print heads In order to change the wipers on the print heads, the entire print head unit has to be pushed back. Required equipment: Clean, solvent-resistant protective gloves (cf. chapter 2.5.5 Personal pro- tection equipment).
Page 293 Operating Instructions Maintenance and Repair When all wipers are ex- changed, 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: >...
Page 294: Maintaining The Separator Of The Degassing System
Maintenance and Repair Operating Instructions 10.6.4 Maintaining the separator of the degassing system 10.6.4.1 Creating the conditions for the maintenance of the 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.
Page 295 Operating Instructions Maintenance and Repair 10.6.4.3 Draining the separator Required accessories: Clean, solvent-resistant protective gloves (refer to Chapter 2.5.5 “Personal protection equipment”). > Loosen the two screws on the clamping plate, see Fig. 108. Re- move the clamping plate. > Unscrew and remove the separator. >...
Page 296: Changing The Residual Ink Bottle
Maintenance and Repair Operating Instructions 10.6.5 Changing the residual ink bottle The residual ink bottle has to be emptied regularly. Supplies needed:  Clean, solvent-resistant protective gloves (see Chap. 2.5.5 Personal protection equipment)  Replacement residual ink bottle (order no.: ZE1010-09 Caution Permanent damage to skin can be caused by contact with machine...
Page 297 Operating Instructions Maintenance and Repair > Remove residual ink bottle from the holder. > Seal the removed residual ink bottle immediately with its screw top. – Screw tight! > Insert new residual ink bot- tle and close the door. > The residual ink bottle is monitored by sensors.
Page 298: Changing The Rubber Rollers Of The Friction Drive And The Web Tension Control
Maintenance and Repair Operating Instructions 10.6.6 Changing the rubber rollers of the friction drive and the web tension control The rubber-coated rollers of the friction drive and web tension control are consumables and have to be replaced on a regular basis. Once the touchscreen indicates that the defined useful life of 300,000 m has expired, then the roller in question has to be replaced.
Page 299 Operating Instructions Maintenance and Repair > Grab the rubber roller with both hands and pull it out. This might require quite a bit of effort in some cases. > Remove the 3 outer screws #6 from the old rubber roller. >...
Page 300 Maintenance and Repair Operating Instructions > Place the rubber roller on the drive shaft #6 and align it so that the hole #7 fits right over the dowel pin #8. > Shove the rubber roller all of the way onto the drive shaft. >...
Page 301 Operating Instructions Maintenance and Repair > 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.
Page 302: Maintenance Of The Printing Substrate Cleaning Module
Maintenance and Repair Operating Instructions 10.6.7 Maintenance of the printing substrate cleaning module The printing substrate cleaning module is a purchased part. The manufac- turer’s documentation for this part with detailed information can be found in the appendix. 10.6.7.1 Removal of used adhesive foil The adhesive foil rolls pick up dust, fibers and other dirt during the printing process and binds them to its surface.
Page 303 Operating Instructions Maintenance and Repair Notice The grey cleaning rollers are very delicate!  Touch the cleaning rollers only with clean white cotton gloves!  Clean the surface of the grey cleaning rollers only with the espe- cially provided Tewkipes. Never use solvents! 10.6.7.2 Maintenance operations recommended by the manufacturer The manufacturer teknek recommends the following maintenance opera- tions for the printing substrate cleaning module:...
Page 304: Changing The Filters Of The Air Circulation System
Maintenance and Repair Operating Instructions 10.6.8 Changing the filters of the air circulation system The air circulation system is for cleaning the air that circulates inside the printer. The suctioned air is conveyed through two consecutive filters which, depending on their nature, serve to separate out airborne particles or to neutralize ozone and odors.
Page 305 Operating Instructions Maintenance and Repair > 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.
Page 306 Maintenance and Repair Operating Instructions 10.6.8.2 Changing the activated charcoal filters of the air cooling The air cooling of the ITS6 has two activated charcoal filters (order no.: ) which eliminates ozone and other odors from the suctioned ZEOI.000.00.Z air. All activated charcoal filters generally have to be replaced after 250 hours of use.
Page 307: Replacing The Guide Rollers Of The Printing Table And Adjusting The Infeed Height Control Unit
Operating Instructions Maintenance and Repair 10.6.9 Replacing the guide rollers of the printing table and adjusting the in- feed height control unit Always replace the five guide rollers of the printing table before you pro- cess a printing substrate of a very different material thickness. After each replacement of the guide rollers, additionally adjust the scanning bar of the infeed height control unit.
Page 308 Maintenance and Repair Operating Instructions Replacing the guide roller Use the following procedure to replace the guide rollers: > Stop the printing process. > Wait until the printing system has stopped. > Press the button on the control panel to move the print head unit to its parking position.
Page 309 Operating Instructions Maintenance and Repair > Tighten the two attachment blocks. > Ensure that the guide roller is straight and does not wobble. > Following these instructions, also replace the other four guide rollers one by one in succession. > Push the cover back onto the guide frame of the print head unit.
Page 310: 10.6.10 Replacing The Lighting Unit On The Camera System
Maintenance and Repair Operating Instructions 10.6.10 Replacing the lighting unit on the camera system Information When you replace the lighting unit on the camera system, pay particular attention to the deflecting mirror and the camera. Avoid any damage to deflecting mirror and camera lens, and any change of the camera ad- justment.
Page 311 Operating Instructions Maintenance and Repair > Loosen and remove the Allen screw #4 on the lighting unit #5. > Carefully pull out the lighting unit. > Carefully insert the new lighting unit. Ensure that the lighting unit is inserted into the guide pins #6. >...
Page 312: Cleaning The Printing System
Maintenance and Repair Operating Instructions 10.7 Cleaning the printing system 10.7.1 Necessity of regular cleaning In order to achieve a sustained high printing quality, the printer’s compo- nents have to be cleaned on a regular basis during which dirt and deposits are removed from the assemblies.
Page 313 Operating Instructions Maintenance and Repair Notice Risk of damaging machine components by improper cleaning.  Never spray or pour cleaning agents directly onto the machine, but rather, on- to the cleaning accessory only (cloth, cleaning swab). Penetrating moisture can destroy covered components. ...
Page 314: Cleaning Agents And Aids For Cleaning Work
Maintenance and Repair Operating Instructions 10.7.3 Cleaning agents and aids for cleaning work For the various cleaning tasks, use only the following cleaning substances and aids. Any other cleaning agents are prohibited! Especially when using solvents, make sure to check whether the surfaces are solvent-resistant! 10.7.3.1 Approved cleansers Cleanser Suitable for...
Page 315 Operating Instructions Maintenance and Repair 10.7.3.2 Approved cleaning aids Utensil Suitable for: Unsuitable for: Bristle (Housing), cleaning of large surfaces brush, corners and niches, size 0 or 2 sensors Hand brush Rough pre-cleaning of Cleaning work around large external surfaces. the print head unit Removal of dry dust, small parts, etc.
Page 316: Cleaning The Printer
Maintenance and Repair Operating Instructions Notice Any other cleaning agents are prohibited! 10.7.4 Cleaning the printer The various components of the printer should be cleaned in accordance with the specifications in the following table. Please comply with the re- strictions regarding the use of cleaning substances and aids! 10.7.4.1 Outer surface, panels Component: Cleaning...
Page 317 Operating Instructions Maintenance and Repair Compo- Cleaning in- Should be cleaned by: Approved cleaners and nent: terval: utensils: Rubber at the begin- Specially trained (!) machine Cleaning cloths no. wipers ning and end of operators and service tech- FF100252100 , cleaning fluid each shift nicians suitable for the type of UV...
Page 318 Maintenance and Repair Operating Instructions Compo- Cleaning in- Should be cleaned by: Approved cleaners and nent: terval: utensils: Rubber- 1x per shift Machine operators, Soft cloths, isopropyl alco- coated roll- cleaning personnel ers of the NEVER use acetone or web tension other solvents controller ...
Page 319 Operating Instructions Maintenance and Repair 10.7.4.6 Rollers of the friction drive Compo- Cleaning in- Should be cleaned by: Approved cleaners and nent: terval: utensils: Rollers of As needed Machine operator, Soft cloths, isopropyl alco- the friction cleaning personnel hol, drive 10.7.4.7 UV curing unit Compo- Cleaning in-...
Page 320 Maintenance and Repair Operating Instructions 10.7.4.3 The printing substrate cleaning module The printing substrate cleaning module is a purchased part manufactured by Teknek Ltd. The manufacturer’s documentation for the part with detailed information can be found in the appendix. Notice When cleaning the rollers of the printing substrate cleaning module, use the specified cleaning agent only.
Page 321: Cleaning The Print Heads
Operating Instructions Maintenance and Repair 10.7.5 Cleaning the print heads In order to achieve a high printing quality at all times during printing, all print heads of the ITS6 printer have to be cleaned on a regular basis. When Manual cleaning Standard or intensive cleaning After switching on...
Page 322 Maintenance and Repair Operating Instructions Type of cleaning Function Standard cleaning Light soiling During standard cleaning, the print heads in question are rinsed with a small amount of ink. Intensive cleaning Heavy soiling During standard cleaning, the print heads in question are rinsed with a greater amount of ink.
Page 323 Operating Instructions Maintenance and Repair How to proceed > Open the tab Job > Cleaning on the touchscreen. > Select the print heads to be cleaned. These will then be marked with a check mark. > Select the cleaning procedure. >...
Page 324 Maintenance and Repair Operating Instructions > Stop the printing process. > Wait until the printer has come to a complete stop. > Place the print head unit into the parking position: Press the button on the touchscreen. > Open the middle door on the rear of the printer.
Page 325 Operating Instructions Maintenance and Repair > 1x lengthwise IMPORTANT !  Never place the cloth being used aside ei- ther before or during cleaning!  Always use only clean sections of the cloth for cleaning. > Wrap the folded cloth around your index finger.
Page 326 Maintenance and Repair Operating Instructions > Use backlighting to check the condition of all of the wipers:  All wipers must point backwards,  all wipers must be seated all the way down in their holders,  wipers that are bent or torn or contain foreign bodies must be replaced immediately (See...
Page 327 Operating Instructions Maintenance and Repair > Apply the cloth carefully to the front third of the print head. > Push – without exerting pres- sure on the nozzle plate – the cloth carefully to the other end of the nozzle plate while rotating your finger counterclockwise: >...
Page 328 Maintenance and Repair Operating Instructions > Carefully apply the cloth to the back third of the print > Pull – without exerting pres- sure on the nozzle plate – the cloth carefully to the other end of the nozzle plate while rotating your finger clockwise: >...
Page 329 Operating Instructions Maintenance and Repair > Push the print head unit back in until the black knob locks in 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.
Page 330: Inspection And Cleaning Of The Main Curing Unit
Maintenance and Repair Operating Instructions 10.7.6 Inspection and cleaning of the main curing unit Notice Prevent any damage to the main curing unit due to incorrect cleaning.  Any cleaning of the main cleaning unit may only be performed after the printer was switched off completely.
Page 331: Checking And Cleaning The Pre-Curing Unit
Operating Instructions Maintenance and Repair 10.7.7 Checking and cleaning the pre-curing unit The lamp modules of the precuring unit located beneath each print head always have to be kept clean. If they become too dirty, not enough light can be transmitted to the applied ink. As a result, the ink might not be properly crosslinked and the different colors could run into each other.
Page 332 Maintenance and Repair Operating Instructions > 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.
Page 333 Operating Instructions Maintenance and Repair > Wrap the folded cloth around your index finger. > Moisten the cloth with a little bit of cleaning fluid suitable for the type of UV ink used. IMPORTANT !  Never place the cloth being used aside either before or during clean- ing!
Page 334 Maintenance and Repair Operating Instructions > 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 >...
Page 335: Repairs
Operating Instructions Maintenance and Repair 10.8 Repairs The “Repairs” chapter is intended predominantly for service technicians or qualified persons 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.
Page 336: Backup & Restore - Data Protection
Maintenance and Repair Operating Instructions Backup & Restore – data protection 10.9 The necessity of regular back-ups The ITS6 printer backs up data by means of an integrated PC with its own hard disk. This is where all of the data needed for printing, such as the op- erating system, image and format files, as well as the log files, which are needed for the uninterrupted documentation of the production process, are stored.
Page 337 Operating Instructions Maintenance and Repair Procedure Please comply with the sequence of steps. > Stop any ongoing printing pro- cess. > Shut down the printer and its UV curing system and switch off the printer completely: > Press the red “0” button of the ON/OFF switch for this purpose >...
Page 338 Maintenance and Repair Operating Instructions > The following selection menu will be shown: > Tap once on the particular F- key “F__” next to the data you want to select to be copied onto the USB flash drive. > To correct an entry, tap again on that particular F-key.
Page 339 Operating Instructions Maintenance and Repair The data are packed. This process can take several minutes. > When the data block has been transmitted successfully, the system will always show the fol- lowing screen. > Tap on the "ESC" key to con- tinue with the backup.
Page 340: Performing A Restore Operation
Maintenance and Repair Operating Instructions 10.9.2 Performing a restore operation With a restore operation, you can replace deleted or destroyed data sets from the printer with the data sets saved during the last backup. All or part of the data blocks saved on the USB flash drive will be copied to the hard disk of the printer.
Page 341 Operating Instructions Maintenance and Repair > Turn the round main switch to the “I” or “ON” position. > The following menu will be shown on the display: > Select “F3 – Restore data.” > Tap on the particular function key “F__” to select which of the data blocks on the hard disk of the printer you want to replace with the data on the USB flash...
Page 342 Maintenance and Repair Operating Instructions > The following screen will ap- pear. Please select: > Start the backup with the “F10” key. > Cancel the restore process with the “ESC” key. This might be needed, for instance, when data on the hard disk would be overwrit- ten without having been saved.
Page 343 Operating Instructions Maintenance and Repair 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”...
Page 344: Replacing A Hard Disk
Maintenance and Repair Operating Instructions 10.9.3 Replacing a hard disk If the printer does not respond at all to commands or entries, or if it exhibits a conspicuous number of malfunctions for which there is no other reasona- ble explanation, if the printer does not start up at all after being switched on, this could be caused by a damaged hard disk in the printer.
Page 345 Operating Instructions Maintenance and Repair Information Avoid malfunctioning of the printer,:  The smaller “ON/OFF” switch must be left switched off during the restore operation!  No other cables should be removed or especially be mixed up with one another! >...
Page 346 Maintenance and Repair Operating Instructions > Turn the round main switch to “I” or “ON.” > The following menu will appear on the display: > Select “F4 - Prepare new hard disk (format).” > The following screen will ap- pear. Please select: >...
Page 347: Consumables Concept
Operating Instructions Maintenance and Repair 10.10 Consumables concept The consumables of the ITS6 printer:   Cleaning fluid  Rubber covered rollers of the friction drive and web tension controls  Print heads  Pre-curing units  Lamp module of main curing unit ...
Page 348: 10.10.1 Auxiliary Supplies
Maintenance and Repair Operating Instructions 10.10.1 Auxiliary supplies “Auxiliary supplies” refers in general to all work supplies that are needed to maintain the availability of a means of production, and which do not be- come part of the particular end product – the printed material in this case. In addition to power, most notably water and lubricants and cleansers are considered classic auxiliary materials.
Page 349 Operating Instructions 10.11 Schedule for the replacement of consumable components Consumable Order no. Usual life cycle HT4001201 CSAT ITS6 UV Ink Cyan G2, 1000 ml When required HT4001202 CSAT ITS6 UV Ink Magenta G2, 1000 ml When required HT4001203 CSAT ITS6 UV Ink Yellow G2, 1000 ml When required HT4001204 CSAT ITS6 UV Ink Black G2, 1000 ml...
Page 350 Operating Instructions Consumable Order no. Usual life cycle FF100318100 Residual ink bottle When required FF100319100 Filter fleece below residual ink bottle When required FF100320100 Filter fleece drain module, 65 x 35 x 15 mm When required EG7TB021000 Ink filter module (incl. 5 ink filters) 2 000 h ZE1010-43 Cleaning set ITS6...
Page 351 Operating Instructions edged, however in this event the manufacturer will accept no liability or guarantee. The respective owner would bear all risks solely. Components that need to be reconditioned should always be returned in their custom packaging to the manufacturer Markem-Imaje CSAT GmbH. Information Return the dismantled components exclusively in their customized packaging and fill out the accompanying return receipt carefully and...
Page 352 Storage Operating Instructions Storage According to the experience of Markem-Imaje CSAT GmbH, all replace- ment parts and consumables for the ITS6 printer can be kept indefinitely when stored properly. If individual articles have a limited lifetime due to special circumstances, this will be indicated on the package.
Page 353 Operating Instructions Storage 11.1.1 Storage of ink and cleaning fluid The storage life of ink and cleaning fluid is limited . When you store inks and cleaning fluids, observe the corresponding information on the cartridg- es. Do not use ink and cleaning fluid beyond the expiration date that is printed on the cartridges.
Page 354 Storage Operating Instructions 11.1.3 Storage of replacement parts and consumables Electronic 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.
Page 355 Operating Instructions Disassembly and Disposal Disassembly and Disposal Disassembly and disposal should be carried out only in coordination with Markem-Imaje CSAT GmbH. Information When disassembling and disposing of the machine or machine com- ponents, please observe the documentation of the supply companies (see appendix of this manual).
Page 356 Disassembly and Disposal Operating Instructions Caution  Direct contact with leaking operating fluids can cause damage to skin.  Wear solvent-resistant gloves and protective eyewear when han- dling the media.  Avoid contact with operating supplies and cleansers!  Wash exposed skin parts thoroughly. If skin irritation persists, see a doctor.
Page 357 Operating Instructions Disassembly and Disposal 12.2 Disassembly of the machine When the machine has to be disassembled at the end of its service life, this work should be assigned to qualified personnel. > For the disassembly, the printer must be disconnected properly and thoroughly from the power supply.
Page 358 Disassembly and Disposal Operating Instructions 12.3 Safety information for the disposal of the machine When the machine has to be disposed of at the end of its service life, this work should be assigned to qualified personnel. 12.4 Disposal of the machine The ITS6 printer was designed in compliance with the RoHS directive (on the restriction of the use of certain hazardous substances in electrical and electronic equipment) and does not contain any harmful substances.
Page 359 Operating Instructions Disassembly and Disposal 12.5 Safety instructions for the disposal of production waste The disposal of operating liquids and any harmful cleaning agents is strictly governed by environmental laws and their regulations.  Collect used materials in containers and have them disposed of properly by the waste disposal company.
Page 360 List of figures Operating Instructions List of figures Figure ..................Page Fig. 1. Safety doors with position monitor (view from above) Fig. 2. Do not misuse the gas springs on the hinged hood as handles! Fig. 3. Position of the door interlock switches Fig.
Page 361 Operating Instructions List of figures Fig. 28. The power supply unit of the printing substrate discharge unit Fig. 29. ITS6 web retraction system Fig. 30. Label sensor Fig. 31. Positions of the ITS6 print mark sensors Fig. 32. Infeed height control Fig.
Page 362 List of figures Operating Instructions Fig. 58. Manage layouts in the layout manager. Fig. 59. Tab Job manager Fig. 60. Job > Pre-curing tab Fig. 61. Job > Main curing tab Fig. 62. Job > Web settings tab Fig. 63. Job > Print head alignment tab Fig.
Page 363 Operating Instructions List of figures Fig. 88. Manufacturer service > Cleaning settings tab Fig. 89. Manufacturer service > Process settings tab Fig. 90. Manufacturer service > Web treatment tab Fig. 91. Manufacturer service > Ink pre-heating tab Fig. 92. Manufacturer service > Print head alignment tab Fig.
Page 364 Index Operating Instructions Index clamping bar 74 clamping bar mandrel 74 access restriction 136 cleaning fluid acetone 314 change cartridge 289 activated charcoal filter how to order 349 change 349 indicate fill levels 185 adhesive tape 64 safety data sheets see order 350 appendix A of the operating air circulation system 124...
Page 365 Operating Instructions Index the operating instructions schedule for the replacement emergencies 46 emergency stop button 36, 134 consumables (touchscreen menu) 184 enabling switch 139 control panel 134 engine software 178 coolant ethernet connector 50 connection 49 corona 86 Activating with the „Job / Job feed backward 135 settings menu“...
Page 366 Index Operating Instructions image file 254 label material prepare PDF 254 made out of aluminum foil 58 resolution 254 made out of paper 57 infeed height control 104 made out of plastic 59 infeed height control unit label sensor 98 adjusting the scanning bar 307 calibration 99 lock/unlock 165...
Page 367 Operating Instructions Index calibration 103 lock/unlock 165 PANTONE color chart 254 printing data see image file paper-like roll-fed material 53 printing length 50 parking position 113 printing speed 50 passage width 50 adjust 165 password printing substrate change 173 aluminum foil roll-fed material path of the printing substrate 73 PDF, preparing data for 4C digital printing label material made out of...
Page 368 Index Operating Instructions on unwinding unit 78 safety concept 29 printing table 107 safety symbols 20 angular encoder 110 training of the personnel 45 exchangeable deflection rollers safety data sheets see appendix A of the operating instructions replacing the guide rollers 307 safety doors 33 printing width 50 safety instructions...
Page 369 Operating Instructions Index total counter USB port 50, 135 hours 179 UV curing printed meters 178 abrasive pad for cleaning 350 total meters 179 clean 319 touchscreen 136, 146 clean the main curing 330 control structure 148 clean the pre-curing 331 logging off 147 Display current power of the main curing unit 163...
Page 370 Index Operating Instructions time of the rubber roller 192 change 292 web-specific correction 168 monitoring lifetime 191 weight of the printer 47 set warning threshold 191 width of the printing substrate 50 wipers (touchscreen menu) 191 wiper wiring diagram see appendix A of the operating instructions change 349 work zone 29...