Dover markem imaje CSAT ITS6 210 User manual

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

Operating Instructions
© Copyright by Markem-Imaje CSAT GmbH
Page 2/370
Subject to Technical Modifications
ITS6_135_Manual_EN.doc
Revision
Date
Version
Chapter
Reason
Responsible
Nov. 30, 2016
1.0
All
New
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. Please contact us:
Markem-Imaje CSAT GmbH
Daimlerstr. 32
D-76344 Eggenstein-Leopoldshafen
Telefon: +49 721 / 97315-88
Fax:+49 721 / 97315-99
E-Mail: [e-mail]
Unauthorized reproduction, even of excerpts, is not permitted.

Operating Instructions
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ITS6_135_Manual_EN.doc
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Table of Contents
Chapter.......................................................................................Page
1General Remarks 11
1.1 Introduction 11
1.2 Notes to the customer 11
1.3 Scope of delivery and responsibilities 12
1.4 Liability, warranty, guarantee 12
1.4.1 General 12
1.4.2 Warranty in connection with print heads 14
1.5 Identification 15
1.6 Understanding and handling these operating instructions 15
1.7 Other valid documentation 16
1.8 Notations in the text and abbreviations 16
2Safety 17
2.1 Intended use 17
2.2 Foreseeable misuse 17
2.3 Safety symbols 20
2.3.1 Safety symbols and their meaning 21
2.3.2 Safety symbols in the operating instructions 21
2.3.3 Safety symbols on the machine 24
2.3.4 Safety symbols on the cartridges for ink and
cleaning fluid 25
2.4 Safety instructions 26
2.5 Safety concept 29
2.5.1 Safety zones 29
2.5.2 Safety measures 30
2.5.3 Safety equipment 30
2.5.4 Organizational safety concept 31
2.5.5 Personal protection equipment 32
2.5.6 Safety doors with position monitor 33
2.5.7 Emergency Stop button safety device 36
2.5.8 Main switch 39
2.5.9 Sensors 40
2.6 Residual risks 41
2.7 Duties of the owner 42
2.8 Requirements of the personnel, due diligence 43
2.8.1 General 43

Operating Instructions
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2.8.2 Due diligence of the personnel 44
2.8.3 Training of the personnel 45
2.8.4 Minimum age 45
2.9 Handling emergencies 46
3Technical Data 47
3.1 Dimensions and weight 47
3.2 Load-bearing capacity of the foundation 48
3.3 Ambient conditions 48
3.4 Electrical connections 48
3.5 Pneumatic system 49
3.6 Coolant connection 49
3.7 Interfaces for signal and data transmission 50
3.8 Performance range 50
3.9 Substrate specifications 51
3.9.1 Paper-like roll-fed material 53
3.9.2 Plastic roll-fed material 54
3.9.3 Aluminum foil roll-fed material 55
3.9.4 Textile roll-fed material 56
3.9.5 Label material made out of paper 57
3.9.6 Label material made out of aluminum foil 58
3.9.7 Label material made out of plastic 59
3.9.8 Suitable printing substrates 60
3.9.9 Unsuitable printing substrates 61
3.10 Adhesive tape 64
3.11 Noise level 65
3.12 Device protection class 65
4Machine Description 67
4.1 Functional diagram 67
4.2 Schematic representation 69
4.2.1 ITS6 components 69
4.2.2 ITS6 sensors 70
4.3 Workplace at the printer 71
4.4 Functional description 72
4.5 Path of the printing substrate 73
4.6 Functional description of the components and parts 74
4.6.1 Unwinding unit 74

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4.6.2 Material sensor on unwinding unit 75
4.6.3 Printing substrate cleaning module 76
4.6.4 Printing substrate storage assembly (unwinding
unit) 78
4.6.5 Web tension control 80
4.6.6 Cut-and-splice device with integrated blade 84
4.6.7 Printing substrate clamp 85
4.6.8 Corona treatment 86
4.6.9 Web guider 88
4.6.10 Substrate discharge at the unwinding unit 93
4.6.11 Web retraction system 96
4.6.12 Label sensor 98
4.6.13 Print mark sensor 101
4.6.14 Infeed height control 104
4.6.15 Printing table 107
4.6.16 Print head unit 111
4.6.17 Pre-curing 118
4.6.18 Main curing 122
4.6.19 Air circulation system 124
4.6.20 Air cooling 125
4.6.21 CAPS server 126
4.6.22 Camera system 127
4.6.23 Function of the camera system components 128
4.6.24 Friction drive 129
4.7 Indicators and control elements 133
4.7.1 Main switch and ON/OFF switch 133
4.7.2 Control panel 134
4.7.3 Access restriction 136
4.7.4 The printer’s display 136
4.7.5 Using touch elements 137
4.7.6 Properties of the touchscreen 138
4.7.7 Enabling switch 139
4.7.8 Stack light 141
4.8 Interfaces 143
4.8.1 Overview of interfaces 143
4.8.2 Power supply 144
4.8.3 Interface external cooling device 144
4.8.4 Network interfaces 144
4.8.5 Compressed air connection 144
4.8.6 Connection cables to the CAPS server 144
4.8.7 Connection cables to the camera system
computer 144
4.8.8 Connection cable of the corona generator 144
4.8.9 Coolant connection 145

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4.9 The user interface of the touchscreen 146
4.9.1 Logging off at the touchscreen 147
4.9.2 Menu structure of the touchscreen 148
4.9.3 Screen structure 149
4.9.4 Functions of the buttons 151
4.9.5 Symbols in the screen masks 155
4.10 Menu Job 157
4.10.1 Tab Job > Job settings 157
4.10.2 Tab Job > Layout manager 159
4.10.3 Tab Job > Job manager 161
4.10.4 Tab Job > Pre-curing 162
4.10.5 Tab Job > Main curing 163
4.10.6 Tab Job > Web settings 164
4.10.7 Tab Job > Print head alignment 166
4.10.8 Tab Job > Cleaning 171
4.11 Menu System 173
4.11.1 Tab System > Settings 173
4.11.2 Tab System > Network 174
4.11.3 Tab System > File manager 177
4.11.4 Tab System > Machine info 178
4.11.5 Tab System > User management 180
4.12 Menu Consumables 184
4.12.1 Tab Consumables > Fill levels 185
4.12.2 Tab Consumables > Reels 186
4.12.3 Tab Consumables > Print heads 187
4.12.4 Tab Consumables > UV modules 189
4.12.5 Tab Consumables > Wipers 191
4.12.6 Tab Consumables > Drive rollers 192
4.12.7 Tab Consumables > Air filters 193
4.12.8 Tab Consumables > Ink filters 194
4.13 Menu Documents 195
4.13.1 Tab Documents > Audit trail 195
4.13.2 Tab Documents > Printing costs 196
4.14 Menu Alarms 197
4.15 Menu Manufacturer service 198
4.15.1 Tab Manufacturer service > Service 1 198
4.15.2 Tab Manufacturer service > PV monitor 200
4.15.3 Tab Manufacturer service > Synchronization
settings 201
4.15.4 Tab Manufacturer service > Other settings 203
4.15.5 Tab Manufacturer service > Cleaning settings 205
4.15.6 Tab Manufacturer service > Process settings 207
4.15.7 Tab Manufacturer service > Web treatment 209
4.15.8 Tab Manufacturer service > Ink pre-heating 210

Operating Instructions
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4.15.9 Tab Manufacturer service > Print head alignment 211
5Transport 213
5.1 General 213
5.2 Methods of transport 213
5.3 Safety instructions for the transport 213
5.4 Internal transport 215
5.4.1 Transport preparations 215
5.4.2 Transport securing device 216
5.4.3 Preparation of the transport route 218
5.5 Executing the transport 218
5.5.1 Transport by crane 218
5.5.2 Transporting by forklift 220
5.6 External transport or storage for any length of time 221
5.6.1 Transport preparations 221
5.6.2 Preparation of the transport route 223
5.6.3 Carrying out external transports 223
5.6.4 Packing the printer in the transport crate 224
5.6.5 Shipping the transport crate 225
5.6.6 Unpacking the printer from the transport crate 226
6Assembly 227
6.1 Safety instructions for the assembly 227
6.1.1 Set-up at final destination 228
6.2 Installation of the printer’s supply systems 231
6.2.1 Electrical connection 231
6.2.2 Pneumatic system 231
6.2.3 Interfaces 231
6.2.4 Transport securing devices 231
6.2.5 Consumables 232
7Commissioning 233
7.1 Safety information for the initial commissioning 233
7.2 Initial commissioning procedure 235
7.2.1 Overview of commissioning measures 235
7.2.2 Ambient conditions 235
7.2.3 Reconnection and preparation of the printer 235

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7.3 Check the defaults of the printer 236
7.4 Function test 237
8Operation 239
8.1 Safety instructions for operation 239
8.2 Check the printer EACH TIME before switching it on 239
8.3 Starting requirements 240
8.3.1 Preparations 241
8.3.2 Switching on the cooler 241
8.3.3 Switch on corona treatment 241
8.4 Switch on printer 242
8.5 Switch off printer 244
8.6 Changing the roll of printing substrate 245
8.6.1 Inserting printing substrate 246
8.6.2 Feeding in the printing substrate 247
8.7 Login and logout at the touchscreen 250
8.7.1 Touchscreen login 251
8.7.2 Touchscreen logout 252
8.8 Preparing and executing print jobs 254
8.8.1 Image files and format files 254
8.8.2 Preparing data for 4C digital printing 254
8.9 Working with format files 255
8.9.1 Loading format files 255
8.10 Data exchange 256
8.10.1 Media for data exchange 256
8.10.2 Procedure for data exchange 257
9Troubleshooting 258
9.1 Error messages 259
9.1.1 Introduction 259
9.1.2 Basic procedure when errors are reported. 259
9.1.3 Messages under the tab Alarms 261
9.1.4 Messages in the “Current Alarm” and
“Stopreason” lines 261

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10 Maintenance and Repair 281
10.1 Content and purpose 281
10.2 Area of validity 281
10.3 Safety through regular maintenance 281
10.4 Safety instructions for maintenance and repair 282
10.4.1 Instructions regarding hazards due to live parts 284
10.4.2 Instructions regarding hazards due to hot
operating materials 284
10.5 Maintenance 285
10.5.1 Maintenance schedule 285
10.6 Maintenance of assemblies and parts 288
10.6.1 Web Tension Control maintenance 288
10.6.2 Changing cartridges filled with ink and cleaning
fluid 289
10.6.3 Changing the wipers on the print heads 292
10.6.4 Maintaining the separator of the degassing
system 294
10.6.5 Changing the residual ink bottle 296
10.6.6 Changing the rubber rollers of the friction drive
and the web tension control 298
10.6.7 Maintenance of the printing substrate cleaning
module 302
10.6.8 Changing the filters of the air circulation system 304
10.6.9 Replacing the guide rollers of the printing table
and adjusting the infeed height control unit 307
10.6.10 Replacing the lighting unit on the camera system 310
10.7 Cleaning the printing system 312
10.7.1 Necessity of regular cleaning 312
10.7.2 Safety instructions for cleaning 312
10.7.3 Cleaning agents and aids for cleaning work 314
10.7.4 Cleaning the printer 316
10.7.5 Cleaning the print heads 321
10.7.6 Inspection and cleaning of the main curing unit 330
10.7.7 Checking and cleaning the pre-curing unit 331
10.8 Repairs 335
10.9 Backup & Restore –data protection 336
10.9.1 Making a backup 336
10.9.2 Performing a restore operation 340
10.9.3 Replacing a hard disk 344
10.10Consumables concept 347
10.10.1 Auxiliary supplies 348

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10.11Schedule for the replacement of consumable components 349
11 Storage 352
11.1 Printer 352
11.1.1 Storage of ink and cleaning fluid 353
11.1.2 Storage of cleaning agents 353
11.1.3 Storage of replacement parts and consumables 354
12 Disassembly and Disposal 355
12.1 Safety instructions for disassembly of the machine 355
12.2 Disassembly of the machine 357
12.3 Safety information for the disposal of the machine 358
12.4 Disposal of the machine 358
12.5 Safety instructions for the disposal of production waste 359
12.6 Disposal of production waste 359
13 List of figures 360
14 Index 364