AMA D-FLEX TWO COLOR G4 User manual

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

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Identication 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
Installation 12-21
Unpacking 12 - 13
Mechanical assembly 14 - 16
Electrical connection 17 - 20
Pneumatic connection 21 - 21
Firststart-up 22-25
Ink loading 22 - 23
Printhead alignment 23 - 24
Print positioning 24 - 25
Network connection 25 - 25
Operatorpanel 26-34
Assembly view 26 - 27
Users 28 - 28
Artworks 29 - 29
Settings 30 - 31
Printheads 31 - 33
Options 33 - 34
Routineprocedures 35-38
Printhead cleaning 35 - 36
Cleaning the nozzles 36 - 37
Changing thee ink bottle 37 - 38
Printerstatus 39-40
Information 39 - 39
Notes 39 - 40
Alarm 40 - 40
CONTENTS
D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET

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

4
IDENTIFICATION
D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET
Copyright©2018-2020byAMACO
Operating instructions, manuals and software
are protected by copyright. Copying, co-
pying, translating or converting to any elec-
tronic medium or machine-readable form
in whole or in part is not permitted. All other
rights to the software are set out in the license
terms.
The naming of non-AMACO products is for in-
formational purposes only and does not cons-
titute a trademark abuse. AMACO makes no
warranty as to the selection, performance or
usability of these products.
All rights reserved.
Exclusionofliability
We have checked the contents of this do-
cument for compliance with the hardware /
software described. Nevertheless, deviations
can not be ruled out, so we assume no liability
for the complete agreement. The information
in this publication is reviewed regularly and
necessary corrections are included in subse-
quent editions. Suggestions for improvement
are welcomed.
AMACO reserves the right to make technical
changes without prior notice.
Manufacturer AMACO GmbH
Dornbirner Str. 19
6890 Lustenau | Austria
www.amaco-solutions.com
Model D-FLEX TWO COLOR G4

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TECHNICALDATA
D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET
Print Technology DOD Piezo Inkjet DOD Piezo InkjetDOD Piezo Inkjet
Print Length max. 400 mm
355 mm
400 mm
426 mm
400 mm
284 mm
Print Width max.
Print Resolution max. 360 x 360 DPI 360 x 360 DPI360 x 360 DPI
Top Web max.
Weigth approx.
440 mm 600 mm
115 kg 115 kg
320 mm
110 kg
MODEL D-FLEX284 D-FLEX355 D-FLEX426
* Custom versions upon request.
Numberofcycle/min.max. Up to 30 cycles / sec. depending on printing density and format
Numberoflanesalongprintingwidth Flexible according to print area
Supplyvoltage 220 / 240 V | 50 / 60 Hz
Inputpower 0.6 kVA
Airconsumption Negligible
Printformat Fullycongurableviasoftware
Datatransfer USB drive and Ethernet 10/100
Kindofobjects&codeprintables Fixed texts with TrueType typeface
Graphics and logos
Linear and two-dimensional barcodes
Operatordatainput|variabledata Yes
Dimensions max. 690 x 415 x 760 mm 690 x 415 x 760 mm
540 x 415 x 760 mm

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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nal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. A general re-
commendation is to carefully read and understand this chapter in its entirety before starting any
activity with the printer.
D-FLEX TWO COLOR G4 printer is designed to be powered at 230V 50-60Hz.
Only connect the printer to an electric line with an earthing contact.
Before connecting or disconnecting any power supply, disconnect all the devices involved.
Use the printer in a dry environment and avoid remaining in contact with any form of water.
Only perform the actions described in these operating instructions.
Any other action not described herein must only be carried out by specialised personnel or by
technical personnel suitably trained beforehand.
Safety signs
Warnings: they identify a potential hazard
that may lead to serious injury or even death
if adequate precautions are not taken.
Notices: they identify actions that must be
carefully understood before proceeding.
Informationen:they identify additional notes
that help the operator optimise operations.

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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.
Initial operations, programming, standard operation, cleaning and maintenance on our prin-
ter are recommended only after carefully studying our manuals and only by personnel trained
and informed beforehand.
Carefully read the following safety guidelines.
Only use original spare parts.
Attend training on a regular basis.
Working conditions

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Carefully read and understand the content
of the specic Material Safety Data Sheet
(MSDS)foryourapplication.
A safety data sheet is provided for every type
of ink or purge primer used with the printer,
which must be read and understood by the
operator before using it. A copy of the MSDS
should also be stored in an area near the ma-
chine if you plan to store a large amount of
liquids in your production plant. Every ink or
primer order comes with a copy of the MSDS:
please check if you received the right uid
and if the safety data sheet refers to the ac-
tual product shipped. 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
the due precautions when handling bottles
of ink or when you come in contact with ink,
for instance near the printhead nozzles.
In the event of inhalation, immediately seek
medical advice.
Avoiddirectcontactwiththeinkwithoutskin
protection.
Wherever there is the risk of coming in con-
tact with the ink or if the specic procedu-
re may lead to contact with it, wear suitable
skin protection. In the event of contaminati-
on, immediately seek local medical attention
and provide the necessary information about
the substance (see MSDS).
Follow local regulations to safely dispose of
inkcontainersandwasteink.
Every container with ink or ink residues due to
normal use or as a result of the purge proce-
dure must be disposed of according to local
disposal regulations. Do not discard the con-
tainers or ink into the waterworks or public
sewage system. If in doubt, please contact
your local body in charge of disposal of spe-
cial products.
Safety guidelines

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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ames,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.
Removing, tampering with or obstructing sa-
fety advice is strictly prohibited in any way
and for any reason.
In the event of an accident, this may involve
serious harm for the operator and shall relieve
the supplier from any liability.
Keepallconsumablesinacontrolledarea.
Someuids,suchasinkorpurgeprimers,are
potentially hazardous.
Ink and primer have an expiry data and are
sensitive to moisture. Store them in an en-
closed space with no light and periodically
check their expiry date.
Highvoltagehazard.
Disconnect the master power supply cable of
the system before accessing any parts inside
the machine.
Avoiddirectcontactoftheinkwiththeeyes
withoutprotection.
Do not use the printer in such a way as to
spray ink in the eyes. This might cause serious
eye injuries.
Avoid touching the printhead nozzles with
anyobject.
Accidental contact with the printhead noz-
zles may lead to a printing defect and lo-
wer quality and/or prevent the nozzles from
spraying. Also avoid working with metal tools
near the printheads, as this may lead to elec-
trostatic discharges and/or electrocution.

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D-FLEXTWOCOLORG4printersaremodularsystemsthatcanbeconguredtoadapttoa
widerangeofapplications.Somemainmodelscanbedened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.
DESCRIPTION
D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET
Technology
Print Technology DOD Piezo Inkjet DOD Piezo InkjetDOD Piezo Inkjet
Print Length max. 400 mm
355 mm
400 mm
426 mm
400 mm
284 mm
Print Width max.
Print Resolution max. 360 x 360 DPI 360 x 360 DPI360 x 360 DPI
Top Web max.
Weigth approx.
440 mm 600 mm
115 kg 115 kg
320 mm
110 kg
MODEL D-FLEX284 D-FLEX355 D-FLEX426
Dimensions max. 690 x 415 x 760 mm 690 x 415 x 760 mm
540 x 415 x 760 mm

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1. Printer head with matrix plate to assemble the printheads and printed circuit boards.
2. Assembly frame with intermittent paper displacement device.
3. Operator panel to control all printer features.
4. Hydraulic control system to control ink for piezoelectric printheads.
5. Ink cartridge with pump to feed the printhead ink system.
6. Electrical panel to control the electrical connections and the main power supply.
Overview
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3
4
5
6

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The following instructions concern the standard procedure to install the printer on the packa-
ging machine if no installation by AMACO is required.
INSTALLATION
D-FLEX TWO COLOR G4 | DIGITAL PIEZO DOD INKJET
Warnings:to follow these instructions, you are
required to adhere to the general safety rules
of your country or community throughout the
operation.
Tobeable to carryouta more efcientjob
and prevent the risk of injuries and/or da-
mage as much as possible, these operations
must be performed simultaneously by at least
two people.
AMACO shall not be held liable, for any rea-
son and in any way, for any damage to the
system or injury to personnel operating on the
system.
Unpacking
The contents have been packed with the greatest possible care to reduce the risk of damage
toaminimum,althoughpotentialdamageduringtransportcannotbedenitelyruledout.
Please contact the supplier if the packaging has visible external damage or stains from liquids.
Usecuttingtoolswithshortblade.
Insidethepackagingtherearesomeplastichoses,partofthenalproduct,thatmaybeda-
maged by cutting tools. Pay attention in order to avoid damaging them.
Donotturnthepackageupsidedownordropit.
The machine has ink tanks that communicate directly with the external atmosphere. When
the packaging is opened, you may notice a smell of ink or solvent. For the above reasons, this
is to be regarded as something normal, especially if the packaging was in transit for a long
time or it was left in direct sunlight. If one of these cases occurs, we recommend leaving the
packaging open for a suitable length of time before continuing unpacking.

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Followthesafetyprecautionsbelow.
We recommend using suitable machinery and wearing protective clothing when taking out
and handling the machine, such as:
Liftingsystem.
The total dry weight of the machine is more
than 100 kilograms. We recommend using a
suitable lifting system when moving the ma-
chine to take it out of the packaging and
duringinstallationinthenaldestinationsite.
Safetygloves.
For all unpacking and installation operations,
wear gloves suitable to the type of work to
be carried out. Pay special attention when
handling ink contained in the machine, as
contact with skin may cause irritation. In this
case, we recommend using latex-free gloves.
Overalls.
For all unpacking and installation operations,
use special gowns or overalls according to
the type of work to be carried out. Pay spe-
cial attention to ink contained in the machi-
ne,asitisverydifculttoremovestainsfrom
fabrics.
Safetyfootwear.
Although the complete machine consists of a
single solid piece of hardware, a screw may
loosen during transport, causing some pieces
to detach from the main frame. We recom-
mend wearing safety footwear to avoid ac-
cidental contact.
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.

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As a general rule, the printer must be instal-
ledin keeping with the specications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.
Pay special attention to ensuring the printer is
parallel to the packaging machine, by taking
the sealing bell as a reference. Also use a le-
vel to assure perfect levelling.
Secure the printer with 4 M8 screws in the holes.
Isolate the printer from any source of electri-
city. Stand in a safe, steady position next to
the printer, with the space needed to opera-
te. Move the printer head outwards.
Mechanical assembly
X mm
X mm

15
Take out the protective guard at the back to
makeiteasiertoinsertthetoplm.
Refer to the label on the operator panel side
forcorrectlmthreading.
Place the printer as much as possible in the
middle of the packaging machine, so that
themiddleofthe lmthatwillrunthroughit
matches more accurately the middle of the
printheads.
To preserve the most sensitive components,
block the printhead plate on its shorter side.
Before commissioning, remove the 2 screws
securing this plate.
X mm X mm

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Remove the printer head guard, secured with
5at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specicpla-
te.
Before commissioning, place the support pla-
tes up to 20 mm from the maximum possible
position.

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Electrical connection
Alltheelectricalconnectionsmustbecarriedoutbyfollowingthespecictechnicaldiagrams
of the printer model you are installing. Also adhere to the general safety rules of your country or
community and work under the supervision of a technician authorised by 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.
Provide suitable electromagnetic protection
[EMC]:some system cables work at high vol-
tages. If these cables need to be replaced,
please use screened cables whenever possi-
ble to provide suitable protection from noise
and insulation from RF (radiofrequency) emis-
sions.
When available, some cables with quick release plug are designed to ensure they can only be
reconnected in the right direction, thereby avoiding polarity inversion or incorrect plugging in.
The customer is responsible for ensuring the cables are in good working order and preventing their
contact with liquids.
In the event of visible damage, rust or cut cables, replace them immediately. Contact AMACO‘s
technical department for details about how to order new original parts. The printer is designed to
be able to work with an external system, receiving its input signals and transmitting other output
signals.Thevoltageofthesesignalsisalways24VDC,unlessotherwisespecied.
Loosen the 4 M6 screws to take out the guard
protecting the electrical panel. Connect the
power supply cable to a steady source of
electricity. Preferably use a safety switch or a
designated fuse for the printer, which is usual-
ly inside the packaging machine.
If not available, we recommend providing for
one. If this is not possible, connect directly to
the power supply of the packaging machine.
The printer must always be powered at 230V
AC.
ATTENTION:
Connect the signal
cable from the prin-
ter to the packaging
machine.
The printer can
receive and send
various synchronisa-
tion signals,
which will be explai-
ned in the following
pages.

18
INPUT SIGNALS
Startprinting:Therst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. As in the other cases,
this signal is optional and disabled by default.
OUTPUT SIGNALS
Stopprinting:This is a dry contact that can be
controlled directly by the packaging machi-
ne. Its purpose is to inform you that the prin-
ting cycle has been completed and a new
one will subsequently start.
Alarm:Generic alarm signal of a fault status
to the packaging machine which stops its
work cycle.
Ink low: Non-blocking warning signal, useful
to trigger audio or visual low ink alerts or if the
ink has run out.

19

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.
After double checking all the wiring and con-
nections, close the electrical panel protecti-
ve guard again.