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Amaco D-FLEX TWO COLOR G4 Manual

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D-FLEX TWO COLOR G4
MANUAL
DIGITAL PIEZO DOD INKJET
Stand: 2020 | V. 1.3.19

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Summary of Contents for Amaco D-FLEX TWO COLOR G4

  • Page 1 D-FLEX TWO COLOR G4 MANUAL DIGITAL PIEZO DOD INKJET Stand: 2020 | V. 1.3.19...

  • Page 2: Table Of Contents

    CONTENTS D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET Identification 04 - 04 Technical Data 05 - 05 Safety recommendations 06 - 09 Safety signs 06 - 06 Working conditions 07 - 07 Safety guidelines 08 - 09 Description 10 - 11 Technology 10 - 10 Overview 11 - 11...
  • Page 3 Q & A 41 - 42 Hardware section 41 - 42 Software section 42 - 42 Flow diagram HMI print 43 - 43 Schema print systm 44 - 44 Compliance information 45 - 45 EMC Directive 46 - 46...

  • Page 4: Identification

    IDENTIFICATION D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET Manufacturer AMACO GmbH Dornbirner Str. 19 6890 Lustenau | Austria www.amaco-solutions.com Model D-FLEX TWO COLOR G4 Copyright ©2018-2020 by AMACO Exclusion of liability Operating instructions, manuals and software We have checked the contents of this do- are protected by copyright.

  • Page 5: Technical Data

    TECHNICAL DATA D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET MODEL D-FLEX 284 D-FLEX 355 D-FLEX 426 Print Technology DOD Piezo Inkjet DOD Piezo Inkjet DOD Piezo Inkjet Print Length max. 400 mm 400 mm 400 mm Print Width max. 284 mm 355 mm 426 mm Print Resolution max.

  • Page 6: Safety Recommendations

    SAFETY RECOMMENDATIONS D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET AMACO‘s main objective is to manufacture inkjet printing systems with high quality and perfor- mance standards. To achieve this, we carry out strict checks during production and assembly of the final product. The guidelines in this chapter are meant as recommendations to operators and administrators in order to use, maintain and repair the equipment without any risks.

  • Page 7: Working Conditions

    Working conditions Before performing any operation with and on the printer and during its operation, the follo- wing working conditions must be adhered to in order to assure safety and prevent subsequent interference by using our devices. Our devices are only to be shipped and stored in their original packaging. Installation and initial start-up of the printer module are only allowed if all the working condi- tions and relevant safety guidelines are adhered to.

  • Page 8: Safety Guidelines

    If the safety data sheet is not contained in the shipment, request a copy from AMACO by specifying the order number. Avoid inhaling ink vapours. Some types of ink are harmful to health. Take...
  • Page 9 Do not smoke while the system is running. Ink vapours might be generated and dissol- ved in the atmosphere during normal opera- tion of the system. There is a risk of explosion and/or flames, which must be strictly preven- ted. Also avoid smoking in areas where ink is stored and used. Do not remove the safety signs and warning signs placed on the system.

  • Page 10: Description

    Some main models can be defined based on the number and type of their components. To be able to adapt to any custom application, it is possible to customise the printer by number and type of components after discussing this with AMACO‘s technical department.

  • Page 11: Overview

    Overview Printer head with matrix plate to assemble the printheads and printed circuit boards. Assembly frame with intermittent paper displacement device. Operator panel to control all printer features. Hydraulic control system to control ink for piezoelectric printheads. Ink cartridge with pump to feed the printhead ink system. Electrical panel to control the electrical connections and the main power supply.

  • Page 12: Installation

    INSTALLATION D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET The following instructions concern the standard procedure to install the printer on the packa- ging machine if no installation by AMACO is required. Warnings: to follow these instructions, you are required to adhere to the general safety rules of your country or community throughout the operation.
  • Page 13 Important warning. After internal tests, we prepare the printer for safe and correct transport. AMACO shall not, for any reason and in any way, be held liable for the state of the goods received by a third-party supplier.

  • Page 14: Mechanical Assembly

    Mechanical assembly As a general rule, the printer must be instal- led in keeping with the specifications of the packaging machine, by checking its position and assembly against the layout supplied. Standard fastening involves four M8 threa- ded holes in the area where the printer is to be placed.
  • Page 15 Take out the protective guard at the back to make it easier to insert the top film. Refer to the label on the operator panel side for correct film threading. Place the printer as much as possible in the middle of the packaging machine, so that the middle of the film that will run through it matches more accurately the middle of the printheads.
  • Page 16 Remove the printer head guard, secured with 5 flat countersunk head screws, which can be taken out with a Ø 3mm Allen wrench. To prevent ink leaks during transport, lower the position of the tanks with the specific pla- Before commissioning, place the support pla- tes up to 20 mm from the maximum possible position.

  • Page 17: Electrical Connection

    AMACO or a person suitably trained by AMACO. AMACO shall not be held liable for any unsteady or unsafe connection that may result in injury to persons or system malfunction.
  • Page 18 INPUT SIGNALS Start printing: The first signal, and the only one required, is the start printing signal and we recommend setting it between 0.2 and 0.5 seconds. Status: A second signal is the status signal: it is sent by the packaging machine and indi- cates whether there are any operations in progress at that moment, thereby inhibiting operation of the printer.
  • Page 20 Connect all the connectors of the branch board for the ink level signals by following the indications on the wiring diagram. The board is used to constantly check the right level of ink in the tanks. Close the guard protecting the tanks again. Activate all the switches installed in the elec- trical panel.

  • Page 21: Pneumatic Connection

    Pneumatic connection Carry out the following operations referring to ACHTUNG: the hydraulic/pneumatic diagram: Adjust the pressure for the printhead Connect the compressed air hose (Ø 6 mm) plate between: from the packaging machine to the right inlet 0.4 Mpa << MN 1 >> on the top of the electrical panel.

  • Page 22: First Start-Up

    FIRST START-UP D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET Ink loading If needed, the ink pump can automatically switch on to top up the ink. Otherwise, if the operator panel shows the LOW INK level alarm, it can be topped up by pressing this message.

  • Page 23: Printhead Alignment

    Remove the heat-shrink sheath positioned on the bottle needle: pay attention to any drops of ink leaking out of the system. Rotation We recommend performing this procedure with the help of another person, who will dab the suction needle as soon as the sheath is removed from its housing.

  • Page 24: Print Positioning

    Proceed by increasing or decreasing the va- lue by pressing the appropriate cell. The alignment is in the second column of the table, while the overlap is in the third. As a wide scale of values is available, we re- commend changing the value by at least ten units at a time.

  • Page 25: Network Connection

    Case B – Pre-printed paper with positioning mark, but printer with no identification pho- tocell: Follow the indications of case A, be- aring in mind that when the position of the phase roller (Picture 4.3.2) is changed, you also need to change the position of the pa- ckaging machine’s photocell, which controls correct centring of the pre-printed paper on the packaging.

  • Page 26: Operator Panel

    OPERATOR PANEL D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET Assembly view Our human-machine interface (HMI), com- monly known as operator panel, consists of an 8” touch-screen panel that automatically starts up after the operating system is loaded. The homepage shows the printer status in real time and lets you access the various menus.
  • Page 27 ON / OFF photocell and other functional set- ups. Speed counters: C/1` mm/1” Cycles per minute Millimetres of film handled per minute Blister counters: A Total from the starts Related to the label currently loaded Users: Name of active operator and login / logout features (by pressing the icon). Log: Log file with preview of the last 5 actions.

  • Page 28: Users

    Administrators, Technicians and Operators. Below is a brief description of each one: you can obtain the version with the full specifica- tions from AMACO. Admin: Administrators are allowed to carry out any action without restrictions, which me- ans they have full access to the labels, set- tings and user management.

  • Page 29: Artworks

    Artworks The main box shows the list of files, which can be easily identified via the search bar in the top section. (2) The printer can store thousands of art- works, making use of the many gigabytes on its SSD disk. They can be loaded via a USB pen drive (1) or via the company’s network (3) by simply selecting the desired source.

  • Page 30: Settings

    Settings A) Label length, non-editable information. B) Additional stroke required to cover the print areas beyond the machine index, whilst still remaining within the pitch sensor limit. C) Displacement start and return position. D) Feed speed, which can be optimised de- pending on the size of the printed ink drop. E) Return speed, logically maintained higher or at least identical to the printing speed.

  • Page 31: Printheads

    1 to 5. Printheads Every printer is already set up during AMACO‘s internal testing, in relation to each one of these values for optimal printing. The drop size 2 (double drop) is set as the standard value.
  • Page 32 Drop size (range 1-3) IP address (read-only) Stitching 2nd voltage (right) °C Temperature (°C, read-only, if available) At the bottom of the page it’s possible to setup the single color printhead offset, useful in case of double-color printer. In fact, this helps to align the two colors with better precision. Express the value in dots, that means a printing point.

  • Page 33: Options

    Color 2 Color 3 Color 4 Options Tab options: When the „Splicing Tape“ cont- rol box is active and the OFFSET has been set, the printhead plate will move up at the right time, letting the splice go through and avoi- ding the risk of nozzle damage.
  • Page 34 For instance, to send artwork from your workstation in the office or for remote support connections. Calendar: Calendar To set the system date and time. Calibration: To recalibrate the touch screen. Updates: Version updates released by AMACO on a USB pen drive. Windows: Exit from the operating system, re- served to AMACO personnel.

  • Page 35: Routine Procedures

    ROUTINE PROCEDURES D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET Printhead maintenance If there are ink residues that formed during normal use of the machine or after a purge, follow this procedure to clean any printheads involved. Use the special pad to soak up the ink on the edge of the printhead, avoiding any collisions with its centre while rubbing with the pad.

  • Page 36: Cleaning The Nozzles

    Perform some printing tests and, if needed, repeat the previous point. If the problem is not solved, you might need to purge the system’s ink circuits. Cleaning the nozzles If there are different lines in various areas of the printhead, or one or two thick lines, normal dabbing might no longer be effective: there might be air bubbles inside the nozzle unit.

  • Page 37: Changing Thee Ink Bottle

    In general, the purging action might start up the ink pump. If after this procedure all the tanks involved have still not been sufficiently replenished, the operator panel will show the LOW INK message. As this is not an alarm mes- sage, it does not indicate a system problem.
  • Page 38 The system is fitted with sensors that constant- ly analyse the ink level: if it gets too low, the LOW INK warning is displayed. In the meanti- me, the yellow light also starts flashing to alert to the changed status. Nothing changes during production: if there is still enough ink in the bottle, the alarm is automatically reset.

  • Page 39: Printer Status

    PRINTER STATUS D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET Information PRINT STATUS MEANING The system is ready to load a layout and receive the printing command from the packaging Pause machine. The system received an alarm signal from the packaging machine. After restoring the correct...

  • Page 40: Alarm

    The PLC is not connected directly or cannot communicate with the internal network. Check the connections and restore them if needed, then press the message to reset it. If this is not the PLC error case, an unexpected complication might have occurred: contact AMACO‘s technical service to solve the failure. A mechanical failure prevented the film brake from operating. Check that the pneumatic sys- Brake error tem is fed with the right pressure and that the indicator shows the correct figure.

  • Page 41: Q & A

    Also check the LEDs on the drivers: a red light indicates an alarm. In this case, triggers alarms during restart the printer via the master switch. If the problem persists, contact AMACO‘s support ser- or after the displace- vice.

  • Page 42: Software Section

    „NO INK“ alarm printer does not need to be turned off), then press the NO INK button on the operator panel homepage until the ink reaches the printhead nozzles and the alarm is automatically cleared. Various printing layout Refer to the relevant AMACO document or send a specific request. composition issues...

  • Page 43: Flow Diagram Hmi Print

    FLOW DIAGRAM HMI PRINT D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET Motor for internal advance Motor- driver Printhead Printhead Printhead Internal printer status and motor control signal Synchronisation with Various internal packaging machine components Internal data External data HUB for external...

  • Page 44: Schema Print Systm

    SCHEMA PRINT SYSTEM D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET Receiving and Send layout loading of Start print cycle TCP / IP layout/artwork Internal PLC Process artwork trigger Electronic boards Printheads...

  • Page 45: Compliance Information

    COMPLIANCE INFORMATION D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET This device complies with Part 15 of the FCC standards. Its operation is subject to the following two conditions: The device cannot cause harmful interference The device must accept the interference received, including in- terference that might cause unwanted operation.

  • Page 46: Emc Directive

    The following guidelines are designed to highlight the most import- ant rules of good practice when installing the D-FLEX TWO COLOR G4 AMACO device, but do not exempt installers from knowledge of the directive, nor do they in any way relieve liability for the equipment...

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