KGK KGKJET CCS-R User manual

Model
Continuous Ink Jet Printer for Industrial Use
Instruction Manual
Basic
Thank you very much for purchasing this product.
Please make sure to read this manual thoroughly for correct operation.
Further, please store this manual in a location with easy access.This manual will be
of use if you are unsure of how to operate the machine, or if a malfunction should
occur.

1
Introduction
Int r oduction
The KGKJET CCS-R continuous ink jet printer for industrial use is designed to enable a broad range of
uses as a high-speed marking machine on various production lines.
Also, the appliance ensures no difficult maintenance work, which is required for existing ink jet
printers, by completely eliminating nozzle clogging due to ink dry. Consequently, time and work for
printing preparation has been drastically reduced.
About this Manual
This manual is exclusive for the KGKJET CCS-R.
This manual is described for using other than JAPAN and CHINA.
This manual shall not be reproduced in part or in whole without our prior permission. Every effort has
been made to prepare this manual. However, if you have any questions or find any errors, please
contact us.
This manual is subject to change for improvement etc. without notice.
Liabilities
We shall not be liable for any damage caused by fault, malfunction or defect of this product.
We shall not be liable for the mounting of consumables, options, or parts other than the parts
recommended by our company.
Nor shall we be liable for any unauthorized remodeling of the equipment.
All company and product names in this manual are trademarks or registered
trademarks of their respective owners.
In this manual, TM and (R) mark are not specified.

2
Safety Precautions
Read the "Safety Precautions" thoroughly before use of this appliance and handle it correctly to
achieve the best performance. This manual describes safety guidelines as follows to prevent bodily
injury and property damage from occurring.
Explanation of Symbols
Information Pertaining to Particular Dangers for Man
Installation Sites
Incorrect installation environment of appliance may cause an accident or fault. Be sure to read these
precautions and install the appliance correctly.
Do not install the appliance in the following places. Doing so may cause fire, accident, malfunction of
appliance, print defect, etc.
Danger
Disregarding this mark when handling may cause fatal or serious bodily
injury.
Warning
Disregarding this mark when handling may cause bodily injury or
material damage.
Caution
Disregarding this mark when handling may cause poor performance or
breakdown of this product.
Prohibition
This symbol describes "Prohibited" actions that must never be
performed.
指示
edict
This symbol describes "Compulsory" actions that must be performed.
Danger
Prohibition
Refrain from looking into printing head while the inkjet sysytem is operating. Ink from
printing head may go into your eyes.
After eye contact, rinse opened eye for several minutes under running water and consult
doctor. After swallowing, symptoms persist consult doctor.
Danger
Prohibition
Enclosed or narrow spaces with poor ventilation
etc., and sites where solvent vapor cumulates easily
There is a danger of solvent poisoning. There is also a danger of fire.

3
Introduction
Prohibition
Place near source of fire
There is a danger of fire. Use of fire within 10m around the appliance is
strictly prohibited.
Prohibition
Installation in places at high temperatures is prohibited.
Do not install the appliance in places subject to direct sunlight or high
temperatures for use. Doing so may cause fire.
Prohibition
Dusty places
Do not install the machine in dusty places for use. Troubles may occur
in the internal circuits due to dust, resulting in fire.
Warning
Prohibition
Installation in places subject to oscillation or in unstable
places.
Do not install the machine in place where oscillation directly transmits
to the machine or in unstable places such as wobbling place. The
machine may drop to cause bodily injury.
Prohibition
Plugging up the vent hole is prohibited.
Do not plug up the vent hole. The temperatures may rise, resulting in
fire, because inside heat is not released.
Prohibition
Place with terrible noise
You cannot hear alarm buzzer, etc., resulting in delay for response in emergency case.
Prohibition
Place with much electromagnetic noise from other peripheral
equipment.
Welding works are strictly prohibited within 10 m around the machine. Do not bundle the
power cord and other power lines together. Insulate the print head so that it does not
contact a conveyer, etc. directly. There is a possibility of malfunction.
Prohibition
Place with corrosive gas atmosphere such as acid.
Prohibition
Sites outside the ambient temperature range of 0 to 40 ℃ and
relative humidity range of
10% to 80 % RH
指示
edict
Use only 100VAC±10%, 50/60Hz power supply
指示
edict
Make sure to ground securely
Use a D type ground.
Danger

4
Power Supply
Inspections
Caution
Prohibition
Place with much electromagnetic noise from other peripheral
equipment.
Welding works are strictly prohibited within 10 m around the machine.
There is a possibility of malfunction.
指示
edict
Isolate the photoelectric sensor
If the photoelectric sensor is made of metal case, use the plastic mounting parts to
insulate from the conveyer, etc.
指示
edict
Isolate the print head
Insulate the print head so that it does not contact a conveyer, etc. directly.
Prohibition
Do not bundle the power supply wires and other wires together
Danger
Prohibition
Use of power supply other than specified voltage is prohibited.
Use only 100VAC±10%,50Hz/60Hz or 220VAC±10%,50Hz power supply.
Do not use the power supply other than specified voltage.
Doing so may cause fire or electrical shock.
Prohibition
Prohibitions when handling the power supply cable
Do not damage, alter, nor heat power cables, nor put heavy items on them.
The power supply cables may be damaged to cause fire and electrical shock.
Danger
Prohibition
Only trained and qualified service personnel shall remove the covers on the frontal
side and back side of the main body. It is dangerous because it contains many
high-voltage areas in it.
指示
edict
The machine may be damaged by removing and installing power cords,
communication cables and I/O cables with power ON. Follow the procedures
described in this manual during installation, moving, opening the machine
cover, or connecting the machine.

5
Introduction
Connecting
Turn OFF all appliances including an external connection sequencer, PC, etc.
Unplug the device from the outlet.
Connect the cable to the machine.
Plug in each appliance.
Turn ON the power switches of each appliance.
Removal
Turn OFF all appliances including an external connection sequencer, PC, etc.
Unplug the machine from the outlet.
Remove all cables connecting to this machine.
In Case of Emergency
Danger
指示
edict
If the machine emits smoke
If the machine emits smoke and gives off a strange smell, turn off the power and plug off
as soon as possible, and contact us. Continuous use may cause fire.
指示
edict
If that foreign objects enter machine
If foreign objects ( water, dust, etc. ) enter the machine, turn OFF the power and unplug
from the outlet as soon as possible, and contact us. Continuous use may cause fire.

6
Precautions for Handling
Danger
指示
edict
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 container, hence there is
no such a big amount of accumulation of electric charge to cause fire.
Caution
指示
edict
Perform test printing before use; otherwise it may lead to unsatisfactory printing or poor
ink adhesion depending on the conditions of the target ( such as material properties,
static charges, and the condensation or oil on the target ) or target feeding status ( such
as a zig-zag movement and feed speed ) .
指示
edict
The combined use of this product and other equipment may prevent this product from
delivering its full functions and/or performance, depending on the operating conditions or
environment. Fully examine those points before adopting it.
指示
edict
When you change the printing-contents or printing-condition by UI-operation or
communication-processing during printing, the gap of printing-position and no-printing
are more likely to occur, because the load of CPU for control becomes higher.
(When input the printing-order while making printing data. etc.)

7
Introduction
Reading this Manual
No. Item Explanation
①Chapter heading
②Headline
③Sub-headline
④Bullet point
⑤Operations and
work procedure
Explains how to call function settings screens and the
operations flow, etc.
⑥Supplement Useful information such as operations advice and precautions,
etc.
⑦Page
1
6
7
2
3
4
5

8

9
Contents
Introduction 1
Safety Precautions ________________________________2
Explanation of Symbols__________________________2
Information Pertaining to Particular Dangers for Man _2
Installation Sites ________________________________2
Power Supply __________________________________4
Inspections ____________________________________4
In Case of Emergency ___________________________5
Precautions for Handling_________________________6
Reading this Manual _______________________________7
1 Main Characteristics 17
2 Preparations before Use 19
Checking Package Contents _______________________19
Product Configuration ____________________________22
Basic Configuration ____________________________22
Optional Configurations ___________________________23
3 Part Names 25
CCS-R Main Unit _________________________________25
Appearance ___________________________________25
Interior _______________________________________26
Control Panel _________________________________27
Print Head ______________________________________28
Interior Appearance ____________________________28
4 Basic Use 29
Operation Flow __________________________________29
Turn ON the Power Supply_________________________29
Operating the Head _______________________________30
Printing_________________________________________30
Stopping the Head _______________________________30
Turning OFF the Power Supply _____________________31

10
4Settings ________________________________________32
Setting the Printing of Number ___________________32
Setting the Print Conditions _____________________32
Setting the Print Data ___________________________34
Creating Print Data _______________________________38
Creation Flow _________________________________38
Selecting Message Numbers_____________________39
Setting the Layout Conditions ___________________39
Registering Fixed Characters ____________________40
Changing Character Properties __________________44
Registering Blanks (blank data) at User-set Distances44
Entering Characters Not on the Control Panel ______45
Registering Numbering Characters _______________49
Registering Date Characters _____________________50
Registering Barcode ___________________________52
Saving Message Numbers _______________________54
4
5 Advanced Use 55
Character / Printing Calibration _____________________55
Characters Used _______________________________55
Character Height_______________________________55
Horizontal Dot Pitch ____________________________55
Density_______________________________________55
Interspacing __________________________________55
Print Position _________________________________55
Print Speed ___________________________________56
Print Style ____________________________________56
Filter_________________________________________57
Repeat Printing ________________________________60
Multiple Size Printing __________________________60
Character Spacing Setting_______________________60
Calendar Module _________________________________61
Calendar Characters ___________________________61
Calendar Character Replacement _________________66
Day of the Week Setting_________________________67
PM Switchover Timing Setting ___________________67
Setting the Method to Calculate Expiry Date Displays 67
Start of week number setting ____________________64

11
Contents
5Numbering Module _______________________________68
Numbering Character Replacement _______________68
Changing the Current Numbering Value ___________68
Barcode Module _________________________________69
Printable Barcode______________________________69
Setting Items of Each Code ______________________72
Characters Registerable ________________________73
About Code 128 _______________________________75
Barcode Module Details setting __________________75
Barcode Setting _______________________________77
Interval Module __________________________________78
User Fonts ______________________________________78
Creation Flow _________________________________78
Selecting User Font Storage Numbers_____________78
Editing User Fonts _____________________________80
Entering Explanatory Text _______________________85
Saving the Edited Contents______________________85
Managing Consumables___________________________86
Operations Explanation _________________________86
Settings Procedure_____________________________87
Other Functions _________________________________88
Speed Tracking Printing ________________________88
Interval Operation______________________________88
Tracking Function _____________________________88
Forced Printing ________________________________88
Operations Log Display _________________________88
I/O Test ______________________________________89
System Status Display __________________________89
External I/O _____________________________________89
I/O Signals ____________________________________89
Communications _________________________________89
5

12
6 Explanation of Display Screens 91
Screen Configuration Table ________________________91
Screens Explanation______________________________93
Main Menu ____________________________________93
Unit Information _______________________________94
Unit Information [Detail] (Unit Test) _______________96
Editing _______________________________________97
Select Message________________________________98
Print Condition ________________________________99
Counter Value ________________________________101
Repeat Print Condition_________________________102
Edit Module __________________________________103
Calendar Module Editing _______________________105
Calendar Offset Editing ________________________105
Numbering Module Editing _____________________106
Barcode Module Editing _______________________107
Barcode Module Details________________________107
Interval Module Editing ________________________109
Edit Message (Message Selection) _______________110
Message Editing ______________________________111
Message Layout ______________________________112
Text Module Editing ___________________________113
Character Properties __________________________113
Config ______________________________________114
System Clock ________________________________115
Interval Running ______________________________116
Unit Config __________________________________118
CHG Detect Rectify____________________________119
Interspacing Type_____________________________121
Head Heater Config ___________________________121
Encoder Config_______________________________122
Photo Sensor Monitoring_______________________123
Transmit Config ______________________________124
I/O Output Condition __________________________125
Priority Management __________________________126
Calendar Config ______________________________127
Shift-code Config _____________________________128

13
Contents
6Operation Config _____________________________129
Level Config _________________________________130
Change Password ____________________________131
No. Date Renewal _____________________________132
Replace-character Selection ____________________132
Replace-character Edition (1) ___________________133
Replace-character Edition (2) ___________________133
Barcode Config_______________________________134
Service______________________________________135
System Status________________________________136
Work Log ____________________________________136
History Code Reference________________________137
Unit Log _____________________________________137
Measurement Log_____________________________138
Exp. Management (1) __________________________139
Exp. Management (2) __________________________139
Forced Print _________________________________140
Bleed Process________________________________141
Forced Mixing ________________________________141
Recirculation Process _________________________142
Draining Process _____________________________143
I/O Test _____________________________________144
Head Parameter ______________________________145
6
7 Inspection and Maintenance 147
Periodic Inspections _____________________________147
Daily Inspections________________________________148
Checking Electrode Unit and Gutter Dirt __________148
Checking the Remaining Ink and Solvent Amounts,
and Waste liquid Amounts ____________________149
Checking the Insulation Tape Inside the Head Cover150
Weekly Inspections______________________________151
Checking Ink Pressure_________________________151
Check Sedimentation of Pigment Components
in the Ink Tank ______________________________151
Monthly Inspections _____________________________152
Checking the Extractor Air Filter ________________152
Checking Service Life _________________________153
Inspecting Under Harsh Conditions ________________154
Attention to Stopping Pigment Ink Unit _____________154

14
7Maintenance ___________________________________155
Screens Used in Maintenance Work ________________156
Displaying the Screens ________________________156
Unit Information Screen________________________158
Unit Test Screen ______________________________160
Print Head Maintenance __________________________161
Mounting and Removing the Head Cover _________161
Fixing the Electrode Unit _______________________162
Cleaning the Electrode Unit_____________________163
Cleaning the Gutter and the Ink Outlet____________166
Cleaning the Nozzle ___________________________169
Adjusting the Ink Flow Direction_________________172
Adjusting the Fully-closed Nozzle Sealing ________175
Replacing the Nozzle Gasket in the Nozzle Palette__179
Cleaning the Gutter Slide Unit___________________181
Checking and Adjusting the Clearance
between the Gutter and Nozzle _________________181
Replacing the Head Filter ______________________182
Bleed Processing _____________________________185
Main Unit Maintenance ___________________________186
Replenishing Ink and Solvents __________________186
Disposal the Waste Liquid______________________188
Adjusting Ink Pressure ________________________189
Adjusting Pump Pressure ______________________186
Replacing the Ink Filter ________________________192
Replacing the Large Circulation Filter ____________194
Cleaning and Replacing the Extractor Air Filter ____196
Replacing the Air Pump ________________________198
Replacing the Backup Battery___________________200
Replacing the Diaphragm unit___________________201
Long-term Storage of Pigment Ink Machine _______204
Pigment Ink Machine Restart
after Long-term Storage_______________________206
Dispose this Product ____________________________207
Periodic Replacement Parts_______________________209
Recommended Spare Parts _______________________211
7

15
Contents
8 Troubleshooting 213
Q&A __________________________________________213
Printing Trouble ______________________________213
Print Head Trouble ____________________________215
Main Unit Trouble _____________________________218
Display Panel Trouble _________________________219
Error Codes and History Codes____________________221
Code Tables _________________________________221
History Code Details __________________________223
Error Code Details ____________________________223
Warning Code Details _________________________227
Alarm Code Details____________________________230
Guarantee _____________________________________237
9 Specifications 239
General Specifications ___________________________239
Model-Dependent Specifications
(CCS-R Specifications) ________________________240
Characters and Print Specifications ________________241
Standard Fonts _______________________________241
Messages ___________________________________241
Multi-Step Printing ____________________________242
10 Appendix 249
Dimensional Drawing ____________________________249
Unit_________________________________________249
Print Head ___________________________________250
Position of Label ________________________________251
Unit_________________________________________251
Print Head ___________________________________254

16

1
17
Main Characteristics
Main Characteristics
The KGKJET CCS-R (hereinafter called the "CCS-R") is a continuous ink jet printer for industrial use
that can print high-quality 26-dot characters.
The main features are described below.
Nozzle sealing system
The automatic nozzle sealing system seals the nozzle at the time of terminating operation and
eliminates nozzle clogging caused by ink dry in the nozzle. It reduces solvent consumption, because
automatic cleaning with solvent is not required at the time of startup and termination.
26-dot high quality characters
Character height is up to 26 dots, font type is up to 24×24 dots and number of lines is up to 4.
For using in JAPAN and CHINA, JIS 1st and 2nd standard Chinese characters, Katakana, Hiragana,
alphanumeric characters and symbols can be printed.
For using in other country, Latin and Arabic alphanumeric characters and symbols can be printed.
With standard built-in simplified Chinese fonts, it is suitable for international usage environment.
User characters can be registered.
２４dots
２６dots ４lines

18
Circulating ink automatically during operation stop
The machine has the interval mechanism to circulate the ink automatically during operation stop.
Therefore there is no worry about nozzle clogging caused by ink dry during long holidays. The time
to start and end the interval mechanism can be set arbitrarily using a timer.
Design taking safety into consideration
The housing has the dust-proof and waterproof (IP24) mechanism and is designed taking safety, such
as high voltage protection, into consideration.
Responsive support
We have developed the hardware and software, therefore we can provide you with responsive
customer support.
Pigment sedimentation prevention function by pump circulation
(pigment ink machine only)
In the pigment ink machine, this function stirs the ink using pump circulation to prevent sedimentation
of the pigment components in the ink.This function starts up when the power is turned on. In
combination with the interval function, it eliminates problems due to sedimentation of pigments when
the machine is idle for long periods.
Nozzle
Nozzlesealedwiththegutter
Guttertube
Ink
Noproblem！

2
19
Preparations before Use
Pr ep arationsbefor eUse
Checking Package Contents
One set of CCS-R includes the following:
CCS-R Main Unit Instruction Manual
Maintenance Set
Washing bottle Blower Safety goggles
KayDry wiper Container Phillips screwdrivers
No. 0 / No. 1 / No. 2
Slotted screwdriver
5.5 x 0.7
Wrench set Clearance gauges
(0.2mm / 0.3mm thick)
InstructionManual
Model
Basic
Thankyouverymuchforpurchansingthisproduct.
Pleasemakesuretoreadthismanualthoroughlyforcorrectoperation.
Further,pleasestorethismanualinalocationwitheasyaccess.thismanualwillbe
ofuseifyouareunsureofhowtooperatethemachine,orifamalfunctionshould
occur.
ContinuousInkJetPrinterforIndustrialUse