Durst Rho 1012 User manual

Rho 1012/1030
Operating Instructions
Issued 07/2013
Keep for future reference!
Original instructions

Rho 1012/1030 Contents
Contents
A About these operating instructions .......................................8
B Safety ..................................................................... 10
C Description ............................................................... 23
D Transport, installation and commissioning ............................ 32
E Operation ................................................................. 33
F Software .................................................................. 95
G Service ................................................................... 118
H Decommissioning and disassembly ..................................142
Appendix .................................................................143
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Table of Contents Rho 1012/1030
Table of Contents
A About these operating instructions.................................. 8
1 Using these operating instructions........................... 8
2 Symbols and markings........................................ 8
2.1 Structure of warnings...................................... 9
B Safety...................................................................... 10
1 Intended use ................................................... 10
1.1 Impermissible use ......................................... 10
2 Duties of the owner............................................ 10
2.1 Safety measures........................................... 10
3 Safety and monitoring equipment............................ 11
3.1 Housing covers............................................. 11
3.2 Protective switches on printer ............................ 11
3.3 Limit switches at the stacking unit ....................... 12
3.4 Signs on printer ............................................ 12
4 Ambient conditions ............................................ 14
5Modifications, attachments and changes in location....... 14
6 Connection of external devices .............................. 14
7 Electromagnetic compatibility ................................ 15
8 Specific types of danger ...................................... 15
8.1 UV light ..................................................... 15
8.2 High temperatures......................................... 15
8.3 Electrical energy ........................................... 16
8.4 Moving parts................................................ 16
8.5 Contact with ink ............................................ 16
8.6 Sharp edges................................................ 17
8.7 Ozone buildup.............................................. 17
8.8 Pneumatic system ......................................... 17
8.9 Danger of falling ........................................... 18
8.10 Weights ..................................................... 18
9 Protective clothing............................................. 18
9.1 Safety goggles and protective gloves.................... 18
9.2 Safety shoes ............................................... 18
10 Maintenance and cleaning.................................... 18
11 Disposal ........................................................ 19
12 Emergencies ................................................... 19
12.1 Emergency-Stop switch................................... 19
12.2 What to do in case of an emergency .................... 19
12.3 Switching on the printer again after an emergency
stop.......................................................... 20
13 Faults ........................................................... 20
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Rho 1012/1030 Table of Contents
13.1 Handling faults ............................................. 20
14 Avoiding damage to property................................. 20
14.1 UV lamps ................................................... 20
14.2 Print head maintenance................................... 20
14.3 Careful handling of the encoder ruler.................... 21
14.4 Media........................................................ 21
14.5 Purge........................................................ 21
14.6 Careful handling of the conveyor belt.................... 22
C Description............................................................... 23
1 Printer........................................................... 23
1.1 Heavy roll tool 30 (optional)............................... 25
1.2 Heavy roll tool 60 (optional)............................... 26
1.3 Stacking unit (optional).................................... 27
1.4 Workstation................................................. 28
1.5 Ink supply unit.............................................. 29
1.6 Cleaning system ........................................... 30
2Workflow........................................................ 31
D Transport,installationandcommissioning......................... 32
E Operation ................................................................. 33
1 Overview of daily operation................................... 33
1.1 Carrying out the daily work ............................... 33
2 Printer........................................................... 34
2.1 Main operating elements and displays .................. 34
2.2 Workstation................................................. 35
3 Automatic feed table .......................................... 36
3.1 Operating modes .......................................... 36
3.2 Operating elements........................................ 37
3.3 Operating the automatic feed table ...................... 38
3.4 Adjusting the front stop.................................... 40
4 Automatic removal table ...................................... 45
4.1 Operating elements........................................ 45
4.2 Docking the automatic removal table.................... 46
4.3 Setting the ejection equipment ........................... 47
5 Registering table (optional)................................... 48
5.1 Operating elements........................................ 48
5.2 Docking the registration table ............................ 49
5.3 Adjusting the press rolls................................... 50
5.4 Adjusting the stops ........................................ 52
6 Heavy roll tool 30 (optional) .................................. 54
6.1 Docking Heavy Roll Tool 30 .............................. 54
6.2 Operating drives of the unwinding and winding units .. 57
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Table of Contents Rho 1012/1030
7 Heavy roll tool 60 (optional) .................................. 57
7.1 Docking Heavy Roll Tool 60 .............................. 57
7.2 Operating drives of the unwinding and winding units .. 59
8 XY Cutter (optional) ........................................... 62
8.1 Operating elements........................................ 62
8.2 Docking the XY Cutter..................................... 63
8.3 Bypass mode............................................... 64
8.4 Adjusting the cutting unit (longitudinal cut).............. 65
9 Stacking unit ................................................... 66
9.1 Operating elements........................................ 66
9.2 Docking and connecting the stacking unit............... 68
9.3 Adjusting the straight impacter ........................... 69
9.4 Adjusting the limiting plates............................... 69
9.5 Adjusting the light barrier for vertical tracking........... 70
10 Loading medium............................................... 70
10.1 Loading a plate medium with an automatic feed table . 70
10.2 Loading the plate medium with the registration table .. 74
10.3 Loading the roll medium (Heavy Roll Tool 30).......... 75
10.4 Loading the roll medium (Heavy Roll Tool 60).......... 86
10.5 Laying a medium through the XY Cutter ................ 92
11 Setting the suction power..................................... 94
F Software................................................................... 95
1 Basic functions................................................. 95
1.1 Installation .................................................. 95
1.2 The menu bar .............................................. 95
1.3 The status bar.............................................. 96
1.4 Basic operation............................................. 96
2 Setting up printer .............................................. 96
2.1 Switching-on time.......................................... 96
2.2 Input queue................................................. 97
2.3 General basic settings..................................... 98
2.4 Media families .............................................. 99
3 Operating printer functions ................................... 100
3.1 Basic functions............................................. 100
3.2 Cleaning functions......................................... 101
3.3 Maintenance................................................ 101
3.4 Ink batch tracking.......................................... 102
3.5 UV lamp tracking........................................... 103
4 Managing media channels.................................... 104
4.1 Buttons on the right edge of the dialog window ........ 104
4.2 Medium type................................................ 104
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Rho 1012/1030 Table of Contents
4.3 Media specification ........................................ 106
4.4 Print options................................................ 107
4.5 Image border and alignment.............................. 108
4.6 Creating, editing and deleting media channels ......... 112
5 Printing.......................................................... 113
5.1 Input queue................................................. 113
5.2 Printing queue.............................................. 116
G Service .................................................................... 118
1 Inspection and cleaning intervals ............................ 118
2 Important information.......................................... 119
3 Initialization after closing the flip doors...................... 119
4 Emptying catch tank........................................... 120
5Refilling ink ..................................................... 120
6 Clean catch tray of scraping blade........................... 122
7 Changing filter of the ink separator .......................... 124
8 Checking and replacing air filter ............................. 125
9 Cleaning housing .............................................. 127
10 Checking fuses ................................................ 127
11 Changing main ink filters...................................... 127
12 Print head maintenance....................................... 130
12.1 Required tools/accessories............................... 130
12.2 Daily print head maintenance ............................ 130
12.3 Weekly print head maintenance.......................... 130
12.4 Preparatory work at the cleaning access point ......... 131
12.5 Purge cycle................................................. 133
12.6 Wiping print heads......................................... 134
12.7 Vacuuming out soiled nozzles............................ 136
12.8 Cleaning the printing plate................................ 140
12.9 Documentation of the print head state................... 141
13 Disposal ........................................................ 141
13.1 Disposing of ink, cleaning cloths and cubitainers ...... 141
H Decommissioningand disassembly................................. 142
Appendix.................................................................. 143
1 Technical data.................................................. 143
1.1 General specifications..................................... 143
1.2 Print specifications......................................... 144
1.3 Media specifications....................................... 145
1.4 Workstation................................................. 145
1.5 Requirements for installation site ........................ 145
2 Accessories and spare parts ................................. 146
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A About these operating instructions Rho 1012/1030
A About these operating instructions
1 Using these operating instructions
These operating instructions are part of the unit.
Ensure that these operating instructions are accessible to personnel
at all times.
Any supplements received from Durst Phototechnik AG are to be included
with these operating instructions.
Give these operating instructions to any subsequent owners or users
of this unit.
2 Symbols and markings
The following symbols are used in these operating instructions:
Symbol Meaning
Requirement for an action
One-step action
1. Stepwithinamulti-stepaction
Result of an action or sequence of actions
Information on easier or safer work
(→Page 23 / Description) Cross reference
Imminently hazardous situation that, if not
avoided, will result in death or serious
injury.
Potentially hazardous situation that, if not
avoided, could result in death or serious
injury.
Potentially hazardous situation that
may result in minor injury if the safety
precautions are not complied with.
Potentially hazardous situation that, if not
avoided, may result in property damage.
The following typographical markings (e.g. bold) are used in these operating
instructions for differentiating between types of information:
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Rho 1012/1030 A About these operating instructions
Example Meaning
Start Queue Operating element on unit, e.g.
buttons, levers etc.
Software element, e.g. menu name,
menu entry, operating elements etc.
start File name, path name
[ALT] Keyboard key
2.1 Structure of warnings
Warnings are structured as follows (in this case, an example for the warning
level WARNING):
Type and source of danger!
Consequence of the danger
Measure for avoiding the danger
Read and observe the warnings.
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B Safety Rho 1012/1030
BSafety
Read these operating instructions before using the printer and ensure
that you have understood everything!
If it is determined that damage has been caused by a person's
non-compliance with these operating instructions, Durst Phototechnik
AG is in no way liable. Safe operation of the printer is only ensured
when the following safety precautions and warnings are observed
exactly.
1 Intended use
The printer is suitable for printing plate and roll media in the industrial field
within the specified limits (→Page 143 / Technical data). The following
framework conditions apply in particular:
The printer may only be operated in closed rooms.
Only Durst-certified inks and media may be used. Other inks or media
may only be used after agreement with Durst Phototechnik AG.
Intended use includes only the activities described in these operating
instructions. Transport, installation, commissioning, decommissioning,
disassembly and disposal of the components may only be performed by
service technicians authorized by Durst Phototechnik AG.
1.1 Impermissible use
The printer may not be used to print the following media:
Foodstuffs
Animals
Media outside the specified limit values
Mediawithanignitionpointof less than 150 °C (302 °F)
2 Duties of the owner
To ensure the safety of personnel, the owner must take the following safety
measures:
2.1 Safety measures
Ensure that the personnel possesses the appropriate qualifications and
is sufficiently trained. Brush up on knowledge by taking training courses
on a regular basis.
Provide the personnel with the stipulated protective equipment.
Keep the warnings on the printer in a legible, visible and clean condition.
Ensure sufficient lighting.
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Rho 1012/1030 B Safety
Keep the concentration of ozone and spray mist of the ink below
the maximum permissible value. For this purpose, ensure sufficient
ventilation in the immediate vicinity the printer.
Ensure sufficient fire protection around the printer and issue instructions
for fire-extinguishing measures.
Observe all regional and national regulations and safety requirements.
3 Safety and monitoring equipment
3.1 Housing covers
The housing covers should prevent the user from being exposed to electrical
or mechanical danger and UV light when loading and unloading media and
ink.
Do not change the way these devices function.
3.2 Protective switches on printer
1 Flip doors (here: shown here using
aflip door as an example)
2 Cleaning access point
Fig. 1 Position of the protective switches
All flip doors must always be closed, and the light trap carrier at the cleaning
access point must be pushed in. The flip doors may only be opened for
maintenance and checks, e.g. checking of the material advance. The light
trap carrier may only be pulled out for print head maintenance.
This is why protective switches are found on all flip doors and at the cleaning
access point. If the flip doors are not closed and the light trap carrier is not
pushed in, the printing process cannot start.
Do not change the method of functioning of the protective switches.
Do not bypass protective switches.
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B Safety Rho 1012/1030
3.3 Limit switches at the stacking unit
If a person's foot is positioned under the table, there is a danger of crushing
when the table is lowered. In order to avoid the danger a safety edge (1)
is installed that is raised in case of obstacles and stops the downward
movement.
Keep your feet away from the area underneath the table.
Do not change the method of functioning of the limit switch.
Do not bypass limit switches.
3.4 Signs on printer
3.4.1 Rating plate
Fig. 2 Rating plate
3.4.2 Safety signs
All safety signs attached to the printer must be observed.
Safety sign Meaning
Wear protective gloves
Wear safety goggles
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Rho 1012/1030 B Safety
Safety sign Meaning
Extremities can be crushed
Extremities can be crushed
The component is energized even when the main switch is
switched off
Warning on UV light
Switch off main switch before opening
Warning on UV light
Warningonhotsurfaces
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B Safety Rho 1012/1030
Safety sign Meaning
Warning on chemical substances
Dispose of the device via a separate collection for electric and
electronic devices in accordance with the locally applicable
regulations
High voltage text sign Caution: high voltage
The mains connection must be disconnected before opening
the device and when changing tubes
Ultraviolet radiation text sign Caution: ultraviolet radiation
UV-C, UV-B, UV-A;
Protect your eyes and skin
4 Ambient conditions
The printer may only be operated under the specified ambient conditions
(→Page 143 / Technical data).
5 Modifications, attachments and changesin
location
The printer is installed and commissioned by authorized Durst service
technicians.
The installation location of the printer may not be changed. Structural
stresses and strains are taken into account during installation. Any
change to the installation location or structural modifications to the
building must be approved by Durst Phototechnik AG.
Opening the printer housing, electronics case and housing covers, except
for routine work, and opening the workstation or unplugging the cable
may only be performed by authorized Durst service technicians.
Print heads may only be replaced by authorized Durst service technicians.
TheUVlampprotectionpreventsreflected light from drying out the ink in
the print head, thus damaging it. The UV lamp protection may therefore
not be removed.
6 Connection of external devices
The printer features SELV connections in accordance with IEC60950. The
computer features two Fast Ethernet connections (SELV) for connection to
LAN/WAN networks. Only SELV-compatible peripheral devices approved by
Durst may be connected to the printer.
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Rho 1012/1030 B Safety
7 Electromagnetic compatibility
For users in the US The printer has been tested and corresponds with the restrictions for a Class
A digital unit in agreement with the regulations of the FCC, Paragraph 15.
These restrictions serve to provide appropriate protection against harmful
interference with equipment used commercially. This printer generates, uses
and radiates energy in the radio frequency range and can, if not installed or
used in accordance with the requirements of these operating instructions,
cause harmful interference in radio communication. The use of the system in
a residential area can lead to such interference. In this case, damage/loss
caused by the interference are the fault of the user.
8Specific types of danger
The printer was built using the best available technology and in compliance
with the recognized safety regulations. Areas of danger which cannot be
avoided through design are provided with appropriate protective equipment. If
the printer is used improperly, however, the user or third parties risk death or
injury. The printer itself or another medium could also be damaged.
8.1 UV light
UV light emitted by the UV lamps onto the print carriage can cause lethal
burns and damage to the eyes. The viewing windows filter out UV rays.
The UV curtain at the media outlet prevents the direct discharge of UV rays.
The UV lamps are not switched off automatically when the flip doors are
opened. Scattered light can thus be discharged.
Do not remove the flip doors.
Check to make sure the flip doors are closed and locked during printing.
Carry out the following measures during print head maintenance:
– Ensure that the UV lamps are switched off.
– Wear safety goggles
When the flip doors are open, do not look at the UV lamps.
Regularly check UV curtain at media outlet for damage.
8.2 High temperatures
The UV lamps on the print carriage are heated up to temperatures exceeding
65 °C (149 °F). Contact with the UV lamps can cause severe burns.
Flammable media can ignite as a result of the UV lamps heating up.
Before carrying out work on the UV lamp head wait at least half an hour
after the unit has been switched off until the lamps have cooled down.
Wear protective gloves when working on the UV lamp head.
During print head maintenance, do not touch UV lamps.
Do not print media which have an ignition point of less than 150°C
(302°F).
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B Safety Rho 1012/1030
Observe sufficient fire protection around the printer and issue instructions
for fire-extinguishing measures.
8.3 Electrical energy
The printer has a leakage current greater than 3.5 mA. Safe operation of the
printer is ensured via a fixed connection to the ground wire.
The entire unit is not de-energized even when the main switch is switched off.
Solely the disconnector switch serves as the power isolator.
The capacitors remain charged for several minutes after switching the printer
off. There is a risk of electric shock if you touch electrical components.
Do not touch any cables or electrical components even when the main
switch is switched off.
8.4 Moving parts
The following dangers are present near moving parts:
Hair, jewelry and clothing being caught and drawn in
Crushing, impacting and cutting of extremities
Dangerous areas include, in particular:
Rollers, rolls, belt drives of the table
Rollers, belt drives and roll mounts of the Heavy Roll Tool
Straight impacter and table of the stacking unit
Gear drive of the ejection equipment
Infeed points of the conveyor belt
Impacting edges between printer and tables when docking.
Impacting edges between printer and Heavy Roll Tool when docking
When reaching into the inlet and outlet openings, there is a danger of impacts
and crushing from movements of the print carriage and danger of cutting
from sharp housing edges.
Lethal injuries could result.
Do not remove the flip doors.
Do not remove the housing covers.
Do not wear long hair, jewelry or loose clothing.
During the printing process, do not reach into the inlet or outlet openings
or near moving parts.
8.5 Contact with ink
Coming into contact with ink is harmful to your health. Sources of danger
include:
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Rho 1012/1030 B Safety
Ink supply unit with Durst Cubitainer
Waste tank
Light trap carrier
Uncured inks on printed media due to insufficient UV exposure
Spray mist of ink droplets in case of large print head distance
Observe the safety data sheets supplied with the ink.
Operate the printer with Durst inks only.
Use only the cubitainers intended for the printer (→Page 146 / Accessories
and spare parts).
Wear protective gloves and safety goggles when cleaning the print
heads, adding ink or emptying the waste tank.
Avoid allowing ink to contact your face or eyes, e.g. by rubbing your eyes
with dirty hands.
If contact with the skin occurs, wash affected areas with pH-neutral soap
and water.
Carry out all specified inspection and cleaning work.
8.6 Sharp edges
Sharp-edged media and housing components can cause cuts.
Wear protective gloves when handling media.
Do not reach into the inlet and outlet openings during the printing process.
8.7 Ozone buildup
To prevent ozone from building up in the room, Durst recommends setting
up the external ventilator with a switch-off time delay. The switch-off time
delay should switch off the ventilator at least 10 minutes after the printer is
switched off.
The external exhaust equipment must be capable of extracting the required
minimum exhaust quantity (→Page 143 / Technical data).
Do not switch off external ventilator for exhaust during printing.
8.8 Pneumatic system
The pneumatic circuits for generating a vacuum at the print head, conveyor
belt and ink transport are under pressure. Ink which is ejected suddenly from
leaky lines and connections or compressed air released suddenly from leaky
lines and connections can cause severe injury.
Ensure that the required service work is carried out regularly by Durst
customer service.
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B Safety Rho 1012/1030
8.9 Danger of falling
There is a danger of falling when climbing components of the printer.
Components can also be damaged.
Do not use components of the printer as climbing aids.
8.10 Weights
Falling media present the following dangers:
Danger of impact and crushing due to heavy weight
Danger of cuts from sharp edges.
Wear safety shoes.
Perform the following measures before loading/unloading:
– Ensure that there are no obstacles near the printer.
– Ensure that the printer has a secure footing.
9 Protective clothing
9.1 Safety goggles and protective gloves
When cleaning the ink supply unit or the print heads, wear the protective
gloves provided for this purpose and recommended safety goggles
(→Page 146 / Accessories and spare parts).
9.2 Safety shoes
Wear safety shoes when loading and unloading media.
10 Maintenance and cleaning
If the service work is not carried out sufficiently, all warranty and
guarantee claims are null and void.
Apart from the activities described in the chapter entitled "Service", the
customer may not perform maintenance or cleaning work. Regular and
additional special service may only be performed by authorized Durst
service technicians.
Only spare parts and consumable media which have been specially
developed and optimized by Durst may be used.
When cleaning the housing or workstation, the printer and workstation
must be switched off and de-energized via the power isolator.
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Rho 1012/1030 B Safety
11 Disposal
Tools and accessories that come into contact with ink must be disposed
of in an environmentally-friendly manner according to local regulations.
This includes, among other things:
– Ink and ink waste
– Cleaning cloths
– Protective gloves
–Airfilters
– Cubitainers
–Inkfilters
Information on proper disposal of Durst inks can be found on the data
sheet for media safety contained in the ink refilling set or which can be
obtained from Durst Phototechnik AG.
12 Emergencies
12.1 Emergency-Stop switch
1 Emergency-Stop switch
Fig. 3 Emergency-Stop switch
Theprintercanbeswitchedoffwiththemainswitchoroneofthe
Emergency-Stop switches (1).
The black-and-yellow Emergency-Stop switches at the docked
components (tables, Heavy Roll Tool, stacking unit, etc.) only switch off
these themselves. The printer is not switched off.
12.2 What to do in case of an emergency
12.2.1 Switching the printer off
Switch off the printer with one of the Emergency-Stop switches if a fault
occurs which could endanger personal safety.
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B Safety Rho 1012/1030
12.2.2 First aid in case ink contacts skin, mucous membranes or
eyes
Wash affected areas with pH-neutral soap and water. Under no
circumstances should solvents be used, as it remove oils from the skin
and increase irritation.
Change your clothes immediately if heavy contamination has occurred.
If some spray has entered your eyes, wash your eyes immediately with
lots water and contact a doctor.
12.3 Switching on the printer again after an emergency
stop
12.3.1 Reactivating an Emergency-Stop switch
Turn Emergency-Stop switch to the right.
Emergency-Stop switch pops out
13 Faults
13.1 Handling faults
If the printer stops unexpectedly:
– Switch off the printer with the Emergency-Stop switch and/or the
main switch.
– Notify the Durst customer service.
If a paper jam occurs, never reach under the housing covers with your
hand.
14 Avoiding damage to property
14.1 UV lamps
If the UV lamps are replaced improperly, these are damaged. The UV lamps
may only be replaced by Durst service technicians.
14.2 Print head maintenance
The print heads can be damaged if the ink dries out.
Carry out all prescribed maintenance work on the print heads.
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