KGK CCS3000L User manual

CCS3000L
Continuous ink jet printer for industrial use
Instruction manual
Introduction
Thank you for purchasing our continuous ink jet printer for industrial use.
In order to properly use this unit, carefully read this instruction manual.
Please keep this instruction manual on hand so that you can consult it whenever any
question and/or trouble arise while in use.

2
Instruction manual - [ Basic ] (hereinafter called "this manual") describes the name of each part, installation,
specifications, outline drawing, etc. of the ink jet printer. Thoroughly read this manual and properly use the
printer.
In addition, read the "Instruction manual - [ Operation/Maintenance ]", "Instruction manual - [ I/O ]", and
"Instruction manual - [ Communication ]" along with this manual.
About this manual
This manual is intended only for the KGK JET CCS3000L series.
This manual shall not be reproduced in part or in whole without our permission. Every effort has been made to
prepare this manual. However, if you have any questions or find any errors in this manual, please contact us.
This manual is subject to change for improvements, etc. without notice.
Disclaimer
We shall not be liable for any damage caused by fault, malfunction or defect of the CCS3000L series
(hereinafter called "this product").
We shall not be liable for any consequences if any parts, options or consumables other than our genuine
parts are used, or any unauthorized modifications, etc. are made.
'QR Code' is registered trademark of DENSO WAVE INCORPORATED in Japan and other
countries.
All other company and product names in this manual are trademarks or registered trademarks of
their respective owners.
In this manual, ™ and ® mark are not specified.
Introduction

3
Safety precautions
Before use, thoroughly read the "Safety precautions" in this manual, and properly use this product to obtain its
best performance.
This manual indicates the safety precautions as follows in order to prevent personal injury and/or property
damage.
Description of the indication
Installation place
If the installation environment of the equipment is not appropriate, an unexpected accident or failure may occur.
Carefully read the cautions in this section to install the equipment properly and safely.
Avoid installing the equipment in the following places. Otherwise, fire, an accident, a malfunction of the
equipment, a printing defect, etc. may occur.
Danger
Indicates that improper handling in disregard of this indication may result in death
or severe injury.
Warning
Indicates that improper handling in disregard of this indication may result in personal
injury or property damage.
Caution
Indicates that improper handling in disregard of this indication may result in poor
performance or breakdown of the product.
Prohibit
This symbol represents "prohibition", indicating what shall not be done.
Direction
This symbol represents "enforcement", indicating what shall be done.
Danger
Prohibit
Place where solvent vapors are likely to remain, such as a closed space
with poor ventilation, a stuffy space, and a narrow space
Solvent poisoning may result. In addition, fire may occur.
Prohibit
Place near a flame
Fire may occur. Never use a flame within 10 m from the equipment.
Prohibit
Avoid installing the equipment in a place with high temperature.
Avoid installing the equipment in a place exposed to direct sunlight or in a place with high
temperature. Otherwise, fire may occur.
Prohibit
Dusty place
Avoid installing and using the equipment in a dusty place. Dust may cause a failure in the
internal circuits, resulting in fire.

4
Introduction
Prohibit
Avoid installing the equipment in a place subject to frequent vibration or
in an unstable place.
Avoid installing the equipment in a place where vibration is directly transmitted to it or in an
unstable place such as a wobbly place. Otherwise, the equipment may fall, causing personal
injury.
Prohibit
Avoid plugging up the vent holes.
Avoid plugging up the vent holes of the equipment. Otherwise, the internal heat does not
dissipate, and the resulting temperature rise may cause fire.
Prohibit
Noisy place
It may be impossible to hear an alarm buzzer sound, etc. Therefore, a response to an
emergency situation may delay.
Prohibit
Place exposed to intense electromagnetic noise from other nearby
equipment
Avoid welding work within 10 m from the equipment. Avoid tying the power cable and other
power lines together in a bundle. Insulate the printhead to avoid direct contact with the conveyor,
etc. Otherwise, a malfunction may occur.
Prohibit
Place in a corrosive gas atmosphere such as acid
Prohibit
Place where ambient temperature and relative humidity are outside the
ranges of 0 to 40°C* and 10 to 85% RH (no-condensing) respectively
* 10 to 40°C depending on the type of ink
Direction
Be sure to establish a ground.
Establish a Class D ground.
Caution
Prohibit
Place exposed to intense electromagnetic noise from other nearby
equipment
Avoid welding work within 10 m from the equipment.
Otherwise, a malfunction may occur.
Direction
Insulation of the photocell sensor
If the photocell sensor is provided with a metal case, insulate it from the conveyor, etc. using
plastic fittings.
Direction
Insulation of the printhead
Insulate the printhead to avoid direct contact with the conveyor, etc.
Danger

5
Power supply
Prohibit
Avoid tying power lines and other wires together in a bundle.
Direction
Air purging in the printhead with dry air
Air purging in the printhead is recommended. Be sure to do that, especially in the case of use in
humid surroundings or using pigment inks.
For specifications of the air, refer to "4-1 Product specifications" on page 50.
Danger
Prohibit
Banning the use of any power other than 100-240V, 50/60Hz
Do not use any power other than 100-240V, 50/60Hz.
Failure to observe this may cause fire or electrical shock.
Prohibit
Handling the power cables
Do not damage, alter or heat the power cable. Do not put any heavy object on it.
Failure to observe this may damage the cable, resulting in a fire or electric shock.
Caution
Prohibit
Prohibited connection/disconnection of the power cables while power is
turned on
Do no connect/disconnect the power cables while power is turned on.
Failure to observe this may damage the equipment.
When you install or transport this product, open the cover, or connect with any equipment, be
sure to connect or disconnect the cables according to the following procedures.
When connecting:
Turn OFF all equipment, including the externally connected sequencer, PC, etc.
Unplug this product.
Connect the cables to this product.
Plug in all the equipment.
Turn ON the power switches of all equipment.
When disconnecting:
Turn OFF all equipment, including externally connected sequencer, PC, etc.
Unplug this product.
Disconnect all cables that have been connected to this product.
Caution

6
Introduction
Checking
In case of emergency
Precautions for handling
Direction
This product is also designed for IT power distribution system with phase-to-phase voltage
230V.
Direction
This AC outlet shall be installed near the equipment and shall be easily accessible.
Danger
Prohibit
No one other than our service personnel may remove any covers unless otherwise instructed.
There are many high-voltage portions inside the equipment, which are hazardous.
Direction
If the power cord, communication cable, or input/output cable is connected or disconnected
while the power is on, the equipment may be damaged. When installing or moving this
product, opening its cover, or connecting the equipment, follow the procedure described in this
document.
Danger
Direction
When the equipment emits smoke
If the equipment emits smoke or gives off an unusual odor, immediately turn off the power, and
disconnect the power plug. Then, contact us. Further use in this condition may cause fire.
Direction
When foreign material enters the equipment
If foreign material (water, dust, etc.) enters the equipment, immediately turn off the power, and
disconnect the power plug. Then, contact us. Further use in this condition may cause fire.
Danger
Direction
Use a container made of conductive material and connect it to ground, if,
during test print or maintenance, print drops are collected in the container.
Print drops are electrically charged in a very small amount. If print drops accumulate, without
connecting the container to ground, the amount of electric charge can become so big to cause
fire.
In normal situations, however, the print substrate moves on the conveyor, hence there is no such
a big amount of accumulation of electric charge to cause fire.
Caution

7
Precautions for using organic solvents, etc.
Precautions for handling
Be sure to close the lid of any organic solvent containers when it is not in use.
Avoid bringing more than the amounts of organic solvents, etc. needed directly for the day's work into the
workplace.
Always perform the work on the windward side where possible to avoid the inhalation of organic solvent
vapor.
Minimize skin contact with organic solvents, etc.
Effects of organic solvents on the human body (major symptoms)
Headache
Lassitude
Dizziness
Anemia
Liver damage
First aid in case of poisoning
Carry the victim of poisoning to a well-ventilated place, and immediately contact the health supervisor and
other persons in charge of health management.
Make the victim of poisoning lie on his or her back or side while keeping his or her head low, and keep his
or her body warm.
If the victim of poisoning is unconscious, remove foreign objects from his or her mouth.
If the victim of poisoning has stopped breathing, immediately give artificial respiration.
Caution
Direction
It may be impossible to achieve satisfactory printing and adhesion properties depending on the
conditions of print targets (material, electrostatic charge, dew condensation, adhesion of oil, etc.)
and transfer conditions (zigzag motion, transfer speed, etc.). Therefore, perform a printing test
before using the equipment.
Direction
When this product is used in combination with other equipment, it may be impossible to achieve
satisfactory functions and performance depending on the operating conditions, environment, etc.
Therefore, give due consideration before use.

8
Introduction
Locations of warning seals
No. Name Description
1Caution label about
ignition
Be careful about the use of flames because a highly flammable solvent is
used.
2Caution label about
rotation
Be careful not to get your fingers or hands caught in the rotating parts.
3Caution/warning label
about electric shocks
A high current is flowing at a high voltage while the product is operating.
4Caution label about
entanglement
Take care not to have your finger or hand in contact with the rotating part.
1
2
4
3
Caution
Be careful about the
use of flames
because a highly
flammable solvent is
used.
1 234

9

10
Introduction 2
Safety precautions ____________________________ 3
Description of the indication___________________ 3
Installation place ___________________________ 3
Power supply ______________________________ 5
Checking _________________________________ 6
In case of emergency _______________________ 6
Precautions for handling _____________________ 6
Precautions for using organic solvents, etc. ______ 7
Locations of warning seals ___________________ 8
Contents 10
11 Before use 12
1-1 Features of the product ____________________ 12
1-2 Product configuration and supplied items _____ 14
Product configuration_______________________ 14
Checking of supplied items __________________ 15
Options _________________________________ 17
1-3 Name of each section ______________________ 18
Main unit (front side and right side) ____________ 18
Main unit (rear side and left side) _____________ 19
Main unit (inside) __________________________ 20
Operation panel ___________________________ 21
Head (appearance and inside) _______________ 22
1-4 Installation and connection _________________ 23
Installation _______________________________ 23
Installation of the main unit __________________ 24
Installation of the printhead __________________ 25
Example of connection with external devices ____ 26
1-5 From startup to termination _________________ 27
Operational flowchart_______________________ 27
Turn on the power _________________________ 28
Create or select message data _______________ 29
Contents

11
Set printing conditions ______________________ 33
Switch the printhead to the stop mode _________ 35
Turn off the power _________________________ 36
2Operation screen 38
2-1 Precautions for the touch panel _____________ 38
2-2 Description of the main screen, the menu screen, and the icon buttons. 38
Main screen ______________________________ 38
Menu screen _____________________________ 40
Icon buttons ______________________________ 41
2-3 Screen transition __________________________ 44
3Ink and solvent 46
3-1 Compatibility of ink, solvent, and cleaning solution 46
3-2 Consumption of ink and solvent _____________ 46
Ink consumption___________________________ 46
Solvent consumption _______________________ 46
3-3 Remaining amounts of ink and solvent _______ 47
Viscosity measurement _____________________ 48
Ink refilling operation in the equipment _________ 49
4Specifications 50
4-1 Product specifications _____________________ 50
5
Dimensional outline drawing 60
5-1 Main unit_________________________________ 60
5-2 Printhead ________________________________ 61

1
12
1-1 Features of the product
This product is a continuous ink jet printer for industrial use, which can print high-quality characters with 26
vertical dots. Major features are as follows.
Nozzle capping system
The auto nozzle capping system seals the nozzle at the end of operation to prevent nozzle clogging arising
from solidified ink at the nozzle section. It is not necessary to perform automatic cleaning with a solvent at the
beginning or end of operation, and solvent consumption is thus reduced.
High-quality characters with 26 vertical dots
The maximum number of vertical dots is 26. The maximum number of font dots is 24 x 24. The maximum
number of printing lines is 5. JIS 1st and 2nd standard Kanji characters, Katakana characters, Hiragana
characters, alphabetical characters, numeric characters, symbols, and user-defined characters can also be
printed.
In addition, this product is suitable for international operating environments because multiple languages are
optionally available.
Ink is automatically circulated even when it is not running
This product has a timer mechanism that automatically circulates ink even when the equipment is not running.
Therefore, there is no need to worry about nozzle clogging arising from dried ink even during a long vacation.
In addition, the timer start/end time can be freely set.
24 dots 5 lines 26 dots
Nozzle
Gutter
Ink
Capped
Before use

13
Design with consideration given to safety
The enclosure is equipped with a waterproof mechanism (equivalent to IP54) and a high-voltage safety circuit,
and has been designed with consideration given to safety.
Improvement in the variety of connections with external devices
This product is equipped with a USB port and a LAN connector. It is possible to copy or back up data using
USB media and to communicate through a network using a 10/100 Mbps Ethernet LAN port.
Improvement in the ease of operation
The advanced settings of each function can be individually made, and the display items can be customized
depending on the user's application.
And, In addition to barcodes, 2D codes as QR codes and data matrices can be printed.
Slave control
In some actions such as running control and selecting message, the operation you perform on a master unit
can be done on slave ones simultaneously by connecting multiple units via LAN.
The highly efficient printhead heater works as an air-conditioner
to cope with the changing temperature
The ink jetted from the nozzle will be heated to thefixed temperature by the heater.
The ink viscosity will be kept within the designed range to print stably.

14
Before use
1
1-2 Product configuration and supplied items
Product configuration
This product is composed of the main unit, the printhead, and the operation panel.
The printhead and the operation panel are individually connected to the main unit with cables, and cannot be
disconnected.
No. Name Description
1Printhead Printhead for printing characters on a workpiece (print target).
2Head cable
Cable for connecting the printhead to the main unit. The length is 3.5 m. This
cable cannot be disconnected from the main unit. (Minimum bending radius:
35 mm)
3Operation panel Panel operated by an operator.
4Main unit An ink circulating system for supplying ink to the printhead and an electronic
circuit for driving and controlling the printhead are also contained.
1
4
3
2

15
Checking of supplied items
Supplied items including this product and its instruction manual.
CCS3000L Instruction manual
Set of maintenance tools
Washing bottle Container Dryer
Safety goggles Phillips screwdrivers
(No.0, No.1, No.2)
Flat-blade screwdriver
Manual pump Set of wrenches Spanners (8mm, 11mm)
Continuous ink jet printer for industrial use
Instruction manual
Introduction
Thank you for purchasing our continuous ink jet printer for industrial use.
In order to properly use this unit, carefully read this instruction manual.
Please keep this instruction manual on hand so that you can consult it whenever any
question and/or trouble arise while in use.
CCS3000L
Continuousink jet printer for industrial use
Instruction manual
Introduction
Thank you for purchasing our continuous ink jet printer for industrial use.
In order to properly use this unit, carefully read this instruction manual.
Please keep this instruction manual on hand so that you can consult it whenever any
question and/or trouble arise while in use.
CCS3000L
Continuous ink jet printer for industrial use
Instruction manual
Introduction
Thank you for purchasing our continuous ink jet printer for industrial use.
In order to properly use this unit, carefully read this instruction manual.
Please keep this instruction manual on hand so that you can consult it whenever any
question and/or trouble arise while in use.
CCS3000L
Continuous ink jet printer for industrial use
Instruction manual
Introduction
Thank you for purchasing our continuous ink jet printer for industrial use.
In order to properly use this unit, carefully read this instruction manual.
Please keep this instruction manual on hand so that you can consult it whenever any
question and/or trouble arise while in use.
CCS3000L

16
Before use
1
Clearance gauge Kaydry Tweezers
Stirring rod
(only for the pigment machine)
Gun unit fixture
Set of maintenance tools
Diaphragm unit or Diaphragm set
(only for the pigment ink)
Name Remarks Quantity
CCS3000L This product 1
Instruction
manual This document 1
Set of
maintenance
tools
Washing bottle Put a cleaning solution into this bottle,
and then use it. 1
Container For cleaning the printhead 1
Dryer For drying the printhead after cleaning it 1
Safety goggles - 1
Phillips screwdrivers (No.0, No.1, No.2) - 1 each
Flat-blade screwdriver - 1
Manual pump For drying the printhead after cleaning it 1
Set of wrenches - 1
Spanners (8mm, 11mm) - 1 each
Clearance gauges For adjusting the clearances of the gutter
and the nozzle 1
Kaydry For cleaning and drying the printhead 1
Tweezers - 1
Stirring rod
For stirring ink
(only for the pigment machine with
agitation mechanism)
1
Gun unit fixture For fixing the gun unit 1
Spare parts of
replacement Diaphragm unit or Diaphragm set Replacement parts for the pump
(only for the pigment ink) 1
ケイドライ
ワイバー 132-5
R
ケイドライ
ワイバー 132-5
R
132-5
R
WIPERS
KAYORYKAYORY
KAYORY
RU

17
Options
The following options are not included with this product, but are useful in improving print quality, maintenance,
etc.
Recommended items
The following recommended items are not sold by us. However, they are useful in making emergency
responses or improving the convenience of backups, etc.
Name Description
Self-supporting stand
For the print direction, side-surface printing or top-surface printing can be selected.
For the mounting method, a self-supporting type or a supported type can be
selected.
Controller table Table on which the controller is placed.
Photocell sensor
For the photocell sensor type, a transmission type or a diffuse reflection type can be
selected. In addition, a conveyor-supported type or a head-supported type can be
selected.
Encoder Allows printing at a constant pitch even if the conveyor speed fluctuates.
Push-button printing
switch Allows manual print checks.
RS-232C cable Needed for RS-232C communication
LAN cable Needed for LAN communication
Signal lamp (flasher) Indicates the operating condition of this product.
Name Description
UPS Uninterruptible power supply unit, which is useful in the event of a power failure.
USB media (USB 2.0) Needed to back up data, etc.
Nut driver (7 mm) Useful for maintenance
Set of spanners Useful for maintenance
Glass beaker
(approximately 100 ml) Used for maintenance
Ultrasonic bath Used for cleaning when the nozzle is clogged.
Torque Driver
(torque value 1.4 N
・ m)
Used when replacing the diaphragm set.
It uses the case of the pigment ink and ink pump (PD1141A1701 and
PD1141A1702).

18
Before use
1
1-3 Name of each section
Main unit (front side and right side)
No. Name Description
1Main switch Main power switch of this product. This is used to turn ON/OFF the main
power.
2Front door Open this door at the time of ink refilling, maintenance, etc.
3Knob Turn this knob to open the front door.
4Handle Handle for transportation. This handle is attached on both the right and left
sides.
1
2
3
4

19
Main unit (rear side and left side)
No. Name Description
1Head cable
Cable for connecting the main unit to the printhead. The length is 3.5 m. This cable
cannot be disconnected from the printhead. (Minimum bending radius: 35 mm)
2Air filter Prevents foreign bodies such as dust from entering the inside. Periodically
perform maintenance.
3Inlet Air intake for ventilation and cooling of the inside of the main unit.
Avoid plugging up the inlet.
4Printhead fixing unit Unit for fixing the printhead at the time of transportation
5Cable holder This is not a handle for transportation. Use the handles on the sides of the main unit.
6Power cable Power cable. This cable cannot be disconnected from the main unit.
7Photocell sensor
connector To use a photocell sensor, connect it to this connector.
8RS-232C connector To use a RS-232C cable, connect it to this connector.
9I/O connector To use an external device, connect it to this connector. When connecting the
PLC, connect according to the instruction manual for PLC.
10 LAN connector To use a LAN communication cable, connect it to this connector.
11 Purge pump connector To use an air purge pump, connect it to this connector.
12 UPS connector To use a UPS, connect it to this connector.
13 Encoder connector To use an encoder, connect it to this connector.
14 Signal lamp connector To use a signal lamp, connect it to this connector.
15 Outlet Discharges heat from the inside of the main unit.
16 Frame ground Connect a ground terminal to this part.
17 Condensate Tank Unit Stores the waste liquid.
18 Air ventilation
(for Japanese use)
Connect this part to a dry air source for printhead purging.
Set the pressure setting to 0.1Mpa.
2
3
6
5
15
16
17
1
18
78
14 13 11
19
12 10
9
4

20
Before use
1
* These may not be attached depending on the model.
Main unit (inside)
Memo
In some types of ink, recovery filter is not equipped. For details,refer to the separate "Ink
compatibility table".
19
Driven pump for air
purging
(for Chinese use)
You can use this where there in no air supply facility.
Not recommended for use in uncontrolled temperature or humidity
environment with high temperature/humidity. Use air ventilation No.18.
No. Name Description
1Ink reservoir Reservoir that holds ink
2Solvent reservoir Reservoir that holds an solvent
3Main reservoir Measures and adjusts the viscosity of ink
4Regulator Regulates the pressure of ink
5Recovery filter Filters out impurities from ink collected from the printhead.
In some types of ink, is not equipped.
6Valve unit Valve for controlling the flow of ink
7Ink discharge Plug for discharging ink
8Ink filter Filters out impurities from ink.
9Ink pump Pump for circulation and collection of ink
10 USB port Insertion port for USB media
11 Backup battery Battery for retaining system settings
No. Name Description
1
3
10 11
6
7
8
9
2
5
4