ISIMAT 1000 P User manual

Operating manual
screen printing machine
1000 P
Year of manufacture: 2007
Machine Number: 10226 / 10227
Manufacturer:
ISIMAT GmbH Siebdruckmaschinen
Rindelbacher Strasse 38 - 40
D-73479 Ellwangen
GERMANY
Phone: [phone] - 886-0
Fax: [phone] - 886-44

The information about this product is published without regard to any possible patent
protection. Trade names are used without guaranteeing free usability. Although the greatest
care has been taken in assembling texts and illustrations, errors cannot be completely
precluded. The publishers and authors cannot assume any legal responsibility or liability for
erroneous information or its consequences. The publisher and authors are always grateful
for suggestions for improvement and reports of any errors.
This operating manual remains the property of ISIMAT and is only handed out to
purchasers of ISIMAT machines. It contains drawings and instructions of a technical nature
and may not be reproduced in whole or in part, distributed or used for purposes of
competition or disclosed to third parties without prior authorization.
(Copyright Law from 09.09.1965 and German Law Against Unfair Competition [UWG] from
07.06.1909)
This manual is only supplied in connection with the corresponding equipment. If the
type plate on the equipment does not comply with the information overleaf, please
report this immediately to:
ISIMAT GmbH Siebdruckmaschinen
Rindelbacher Strasse 38 - 40
D-73479 Ellwangen, Germany
In the footer you will find the version number of this operating manual which is required
for any communication with the manufacturer.
Keep for future use!
© Copyright 2007 ISIMAT GmbH Siebdruckmaschinen

1000 P Table of Contents
TABLE OF CONTENTS:
1Introduction ....................................................................................7
1.1 General ............................................................................................................. 7
1.2 Intended use ..................................................................................................... 8
1.2.1 Obvious misuse...................................................................................... 9
1.3 Print processes - overview .............................................................................. 10
1.3.1 Letterpress ........................................................................................... 11
1.3.2 Flexography ......................................................................................... 11
1.3.3 Pad transfer printing............................................................................. 11
1.3.4 Screen printing ..................................................................................... 12
1.4 Screen printing - printing principles ................................................................. 13
1.4.1 Flat-bed screen printing (flat printing)................................................... 14
1.4.2 Cylindrical printing or round body screen printing ................................ 16
1.4.3 Process advantages............................................................................. 18
1.4.4 Selection of squeegee material ............................................................ 18
1.5 Principle of UV curing systems........................................................................ 19
1.6 Pre-treatment of substrates............................................................................. 20
1.6.1 Flame pre-treatment............................................................................. 22
1.6.2 Corona pre-treatment........................................................................... 23
1.6.3 UVitro®surface treatment ..................................................................... 24
1.6.4 Use of test inks..................................................................................... 24
1.7 Subdivision of printing inks.............................................................................. 26
1.8 Signs, symbols and abbreviations................................................................... 26
1.8.1 Signs and symbols ............................................................................... 26
1.8.2 Symbols and warnings ......................................................................... 27
1.8.3 Abbreviations ....................................................................................... 29
2Safety ............................................................................................30
2.1 Safety requirements ........................................................................................ 30
2.2 Personnel selection......................................................................................... 31
2.3 Process materials............................................................................................ 31
2.4 Hazard sources ............................................................................................... 32
2.5 Safety equipment ............................................................................................ 35
2.5.1 E-Stop switch ....................................................................................... 35
2.5.2 Safety bow ........................................................................................... 36
2.6 Personal protective gear ................................................................................. 37
2.7 Warning signs ................................................................................................. 38
3

Table of Contents
2.8 Operation modes.............................................................................................39
2.9 Work stations...................................................................................................39
3Transport and commissioning ................................................... 40
3.1 Technical data .................................................................................................40
3.2 Transport .........................................................................................................41
3.3 Installation .......................................................................................................43
3.3.1 Pneumatic connection and compressed air preparation.......................43
3.3.2 Setting up the machine.........................................................................44
4Machine description.................................................................... 45
4.1 Machine overview............................................................................................45
4.2 Control console ...............................................................................................46
4.3 Machine framework .........................................................................................46
4.4 Squeegee unit .................................................................................................48
4.5 Squeegee head carriage .................................................................................49
4.6 Screen carriage ...............................................................................................50
4.7 Screen holder ..................................................................................................51
4.8 Rack and pinion drive......................................................................................52
4.9 Article receptacles ...........................................................................................53
4.9.1 Dolly .....................................................................................................54
4.9.2 Neck bottom support ............................................................................54
4.9.3 Optical registration unit.........................................................................56
4.9.4 Neck bottom support with mechanical mark registration ......................58
4.9.5 Angle setter for article receptacles .......................................................60
4.9.6 Receptacle mandrel..............................................................................61
4.9.7 Receptacle mandrel for plastic tubes....................................................61
4.9.8 Oval printing unit...................................................................................62
4.9.9 Printing unit for gas bottles ...................................................................62
4.9.10 Cone printing unit .................................................................................63
4.9.11 Sliding table..........................................................................................64
4.9.12 Vacuum printing table plate ..................................................................64
4.9.13 Cube printing unit .................................................................................66
4.9.14 Inflation device .....................................................................................66
4.9.15 Screen and squeegee heating..............................................................67
4.9.16 Article receptacle for buckets ...............................................................67
4.9.17 Receptacle cross-holder for bottle crates .............................................68
4.10 Squeegee head reinforcement ........................................................................69
4.11 Lift table...........................................................................................................69
4

1000 P Table of Contents
4.12 Compressed air unit and speed control........................................................... 70
4.13 Control unit TD 200 ......................................................................................... 71
4.14 Control unit OP 3............................................................................................. 72
5Operation ......................................................................................73
5.1 Making ready for operation ............................................................................. 74
5.2 Dismantling the article receptacle ................................................................... 74
5.3 Setting up for cylindrical printing ..................................................................... 75
5.4 Setting up for flat printing ................................................................................ 83
5.5 Setting up for cone printing ............................................................................. 90
5.6 Setting up the optical registration unit ............................................................. 90
5.7 Operating the TD 200 control unit ................................................................... 92
5.8 OP 3 - 1000 PK control unit ............................................................................ 96
5.8.1 Error messages display........................................................................ 97
5.8.2 Basic menu .......................................................................................... 97
5.8.3 Operating status display....................................................................... 98
5.8.4 Controller for lift table / screen holder / registration.............................. 98
5.8.5 Continuous operation ........................................................................... 99
5.8.6 Mechanical mark registration ............................................................. 100
5.8.7 Sub-menus......................................................................................... 101
5.9 Operating the OP 3 control unit..................................................................... 104
5.9.1 Error messages display...................................................................... 105
5.9.2 Basic menu ........................................................................................ 105
5.9.3 Operating status display..................................................................... 105
5.9.4 Controller for lift table / screen holder / squeegee head..................... 106
5.9.5 Function choice .................................................................................. 107
5.9.6 Sub-menus......................................................................................... 107
5.10 Operating in automatic mode ........................................................................ 111
5.11 Options.......................................................................................................... 112
5.11.1 Printing on notes boxes...................................................................... 112
5.11.2 Vacuum printing table plate with sliding table..................................... 113
5.11.3 Changing over the machine: from cone printing to cylindrical printing115
5.11.4 Mounting the receptacle cross-holder for bottle crates....................... 119
6Maintenance and disposal ........................................................121
6.1 Personnel selection....................................................................................... 121
6.2 Maintenance.................................................................................................. 122
6.2.1 Maintenance materials ....................................................................... 123
6.2.2 General .............................................................................................. 124
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Table of Contents
6.2.3 Machine framework ............................................................................124
6.2.4 Lubrication..........................................................................................124
6.2.5 Supplier Components .........................................................................126
6.3 Cleaning ........................................................................................................126
6.4 Disposal.........................................................................................................126
6.4.1 Mechanical and electrical components...............................................126
6.4.2 Process materials ...............................................................................126
7Faults .......................................................................................... 127
7.1 Error messages on control unit TD 200 .........................................................127
7.1.1 Setup mode ........................................................................................127
7.1.2 Automatic mode..................................................................................127
7.2 Error messages on control unit OP3..............................................................128
7.3 Electrical system ...........................................................................................129
7.4 Setting the safety bow ...................................................................................130
7.5 Troubleshooting.............................................................................................133
7.6 Problems with the screen stencil ...................................................................134
6

1000 P 1.1 General
1 Introduction
This operating manual is intended to help you become familiar with the
machine and its proper use.
It contains important information on how to operate the machine safely,
properly and economically. Compliance with this information will help
avoid hazards, repair costs and downtime and increase the reliability
and working life of the machine.
1.1 General
Each person working with or performing work on the machine must
follow the information contained in this operating manual.
The prerequisite for this is that only trained specialists will be operating
the machine.
This operating manual provides information about all life phases of the
machine:
• Transport and commissioning
• Description
• Operation
• Maintenance and disposal
• Faults
ISIMAT GmbH Siebdruckmaschinen will not assume responsibility for
• Accidents
• Damage or
• Production losses
resulting from non-observance, ignorance or disregard of the operating
manual.
version p1.10 2007-01-12 7

1 Introduction
1.2 Intended use
The screen printing machine 1000 P is a semi-automatic universal
screen printing machine. Substrates can be printed on the 1000 P using
different printing methods with the corresponding, optional auxiliary
facilities:
Article materials Printing method
• Plastic
• Glass
• Porcelain
• Wood
• Metal
• Cylindrical printing
• Flat printing
• Oval printing
• Cone printing
Solvent, dual component, UV and thermoplastic inks can be printed
using the 1000 P. See section 1.7 Subdivision of printing inks, page 26.
The substrate must be pre-treated depending on the article material.
See section 1.6 Pre-treatment of substrates, page 20.
The machine is equipped with a printing station. The substrate is
inserted into the receptacle by hand; the print process is triggered by a
foot switch. Then the substrate is removed again by hand.
Changing over from cylindrical printing to flat printing only takes a few
minutes. Fine settings are carried out using rotary knobs and micrometer
screws: Screen and squeegee carriages, screen holder, squeegee and
flood bar. Multi-color printing is possible by repeated laying in of the
substrate.
Maintain the values indicated in section 3.1 Technical data.
The machine is intended solely for contractually specified use.
Any other use or any use going beyond this will be considered non-
intended usage. The manufacturer / supplier assumes no liability for
damage resulting from such use. The user solely bears this risk. This
also applies to subsequent changes and modifications to the machine.
Intended use also includes observance of the operating manual and
keeping the inspection and maintenance schedules.
8

1000 P 1.2 Intended use
1.2.1 Obvious misuse
Operate the screen printing machine 1000 P only within the framework
of its intended use. Any other use of the machine or any use going
beyond this may result in hazardous situations.
WARNING
Injuries and damage to the machine caused by misuse of the
machine!
Impermissible use of the machine may result in hazardous situations.
• Never use inks or paints which can form an explosive atmosphere
while drying or evaporating.
• Only print substrates which are intended for the machine.
• Only conduct production procedures for which the machine is
intended.
version p1.10 2007-01-12 9

1 Introduction
1.3 Print processes - overview1
Printing is a process for reproducing information made up of texts or
images in any desired quantity. The essential component in printing is
the forme. The forme is a tool constructed in such a way that a printed
image can be created on a substrate from the print template using ink.
The forme is a print image storage device. The printing template is an
image or text to be reproduced in a printing process.
The mechanical print processes are sub-divided into four main
processes according to the characteristic features of the formes.
Print process Printing forme features Allocation
Relief The image elements to be printed
are raised above the non-image
areas
Letterpress
Flexography
Letterset printing
Gravure The image elements to be printed
are below the non-image areas.
Rotogravure
printing
Recess printing
Pad transfer
printing
Flat printing The image and non-image areas
are almost on the same level
Lithography
Offset printing
Collotype
Through printing The image elements to be printed
are pervious to inks whereas the
non-image elements are impervious
Screen printing
Film printing
Table 1-1: Overview of the main mechanical printing processes
Following the printing principle, the four main print processes are sub-
divided into direct and indirect printing.
Whereas in direct printing the forme transfers the ink directly to the
substrate, indirect printing involves an intermediate carrier for
transferring the ink.
Letterpress and flexography are direct relief processes. In pad transfer
printing, a flexible pad made of silicon putty takes the ink from the
gravure carrier and transfers the image to the substrate. This makes pad
transfer printing an indirect process.
Screen printing is used predominately as a direct through-printing
process.
1Source: Scheer, Siebdruckhandbuch [screen printing manual], ISBN: 3-925402-41-1
10