REA JET SK 7 User manual

Copyright © 2006 REA Elektronik
Rationalisierung Entwicklung Automation
Elektronische Geräte und Systeme
REA-JET Print Heads
SK 7
SK 16
SKP 7
SKP 16
SKS 7
SKS 16
for use with
REA-JET Ink Supply Units
Users Manual
Version 1.1
Published by REA Elektronik GmbH, D-64367 Muehltal-Waschenbach, Germany. All rights
reserved.
Any duplication of this document, in whole or in part, may only be granted with the written
permission of the publisher.
Although this documentation has been compiled with the greatest care, some information may be
incorrect or may contain errors. REA Elektronik accepts no responsibility for damages which might
be caused due to such incorrect information.
As we are continuously striving to improve our products, REA Elektronik GmbH reserves the right
for modifications, document amendments and software updates subject to change without prior
notice.
REA Elektronik GmbH
Teichwiesenstraße 1, D-64367 Mühltal-Waschenbach, Germany
Tel.: + 49 6154/638-0 ∙Fax: + 49 6154/638-195
[email protected] ∙www.rea.de Date: Oktober, 2006

Copyright © 2006 REA Elektronik
Rationalisierung Entwicklung Automation
Elektronische Geräte und Systeme

Copyright © 2006 REA Elektronik
Rationalisierung Entwicklung Automation
Elektronische Geräte und Systeme
Content
1Information on hints and warnings ________________________________________1
2Proper use of equipment ________________________________________________2
3Improper usage of equipment ____________________________________________2
4Scope of supply ________________________________________________________3
5Safety notes ___________________________________________________________4
6Operator requirements __________________________________________________6
7System specification ____________________________________________________7
8Fitting and Comissioning ________________________________________________9
8.1 System components___________________________________________________9
8.2 System assembly instructions__________________________________________14
8.3 Operation of several print heads with one ink supply unit ______________________19
8.4 Adjusting the print image _______________________________________________20
8.5 Adjusting parameters _________________________________________________20
8.6 „Dot-Size“ adjusting procedure_________________________________________20
8.7 Setting of print height_________________________________________________21
9Maintenance __________________________________________________________22
9.1 Cleaning of nozzle plate and ink chamber _______________________________22
9.2 Maintenance plan ____________________________________________________25
9.3 Flushing of print head_________________________________________________25
9.3.1 Flushing a standard system__________________________________________25
9.3.2 Flushing of pigmented system________________________________________26
10 Maintenance __________________________________________________________26
11 Dismantling ___________________________________________________________27
12 Disposal______________________________________________________________27
13 Trouble shooting ______________________________________________________28
14 Appendix _____________________________________________________________30
14.1 Technical data_______________________________________________________30
14.2 Dimensions of print head______________________________________________31
15 Warranty Conditions ___________________________________________________35

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1 Information on hints and warnings
This manual contains general hints and warnings. The meaning of the respective icon is described
below.
Hints and warnings are always highlighted by the prefixed icon.
Danger
This icon indicates that there is direct danger ahead
threatening life or health of people!
Warning
This icon indicates that there could be danger ahead
threatening life or health of people!
Attention
This icon indicates that there could be danger ahead
which could lead to injury of people or damage to
equipment.
Information
This icon indicates that this is a useful hint or
information for the operator of the system.

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2 Proper use of equipment
The REA-JET print head (following: print head) is designed to process low viscosity liquids. Only
REA authorized inks and cleaners are allowed to be used within the print heads.
The print head can only be operated with REA-JET hardware and software. The use of any
equipment, parts or components that are not REA admitted within the REA-JET coding and
marking system the operator has to bear the responsibility for doing so.
The print head is factory adjustedand does not need any additional calibration by the operator (see
also under 5 Safety notes).
For any unintended use of the REA-JET systems the operator carries the responsibility. REA can
not take over any seller´s warranty for damage caused by unintended use of the system.
The present equipment is not meant for use in any explosion hazardous environment.
3 Improper usage of equipment
The coding system is not designed to be operated as a handheld device.
It is forbidden to splash any of the inks or solvent on any persons or living creatures.
The use of any not REA tested and REA approved substances within the REA-JET systems
represents an improper use for which REA Elektronik excludes to take over any liability.

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4 Scope of supply
Based on the many variations the REA equipment can be configurated we resign to list up in detail
all types of available components.
A coding and marking system usually consists of the following components:
REA-JET print head
Controller
Input terminal
Power supply
Product sensor*
Shaft encoder*
Mounting bracket for product sensor*
Mounting bracket for shaft encoder*
Print head bracket*
Ink
Solvent
* optional
Packaging
The equipment will be either delivered and installed by REA technical staff or shipped to your
location in a reusable cardboard container with foam material inlay. This packaging material
should be kept for any service purposes. If this is not desired the container can be disposed
according to applicable standards.

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5 Safety notes
This manual does not claim to contain all necessary
information for safe of the system. There could be more
information relevant in the respective country.
Before operating the system carefully read the manual.
When working on the system it is mandatory to protect
from consumables (ink, solvent) which can injure eyes
and skin.
Relevant information can be taken from relevant
material safety data sheet.
Manipulating the pneumatical, electrical and/or
hydraulical circuits can lead to severe injuries and death
in particular cases.
Changes of specific components are subject to be
carried out by REA staff or REA representatives only.
Please check all system components and hoses on a
regular basis for leakage. In case of a leakage the
system has to be turned off and repaired. In a case like
that please get in touch with REA service department
for support.
Please check all existing connecting lines (electric,
hydraulic, pneumatic) as well as fittings on a regular
basis. Should any components be damaged or should
not be safe anymore make sure to shut the system off
and eliminate the failure.
In a case like that please get in touch with REA service
department for support.
Should a system be taken out of operation for a longer
period of time make sure to flush the system using the
adequate cleaner before putting it back into operation
(see also chapter 9.3 Flushing of print head).

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When shutting down the system it is advisable to drain
all pressurized hoses. This can easily be done by
switching off and venting the system.
Please follow the guidelines in the users manual of the
respective REA-JET ink supply system.
Should a malfunktion occur the system has to be shut
off immediately.
Do not reconnect the system before the technical cause
of the malfunction is found and fixed. To guarantee a
trouble free operation and to preserve warranty
coverage only REA original spare parts are allowed to
be installed.
The present system is not admitted for use in any
explosion hazardous environment.

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6 Operator requirements
To install the REA-JET coding and marking system technical knowledge how to set up electrical
equipment is required.
For operation and maintenance of the coding and marking system a certified training is mandatory.
This training will allow the user to properly work with all system components and will also train for
proper handling of consumables such as inks and cleaner.

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7 System specification
The present REA-JET print head represents the DOD (Drop-On-Demand) technology. The DOD
principle provides a droplet of ink only when ink is needed to print an image or a character.
Contrary to this technology is the principle of CIJ (continuous ink jet) printers where a continuous
jet of ink droplets is generated and only certain droplets which form a character or image are
deflected to arrive on the printing surface (canvas).
The advantage of a DOD system lies in its robustness and sturdiness, the ease of use and the
wide range of applications.
The REA-JET system components can be combined in multiple ways and allow a flexible
combination to meet most customer application requirements.
Technical specification
The print head is made from a pipe which in combination with the back and front panel forms the
housing for the mechanical parts.
Please also see Fig. 7.1 and Fig. 7.2 on the following pages.
The following components are located on the back panel:
Female connector for print head cable
Purge button
Ink connector (a single one for a standard print head, two for a pigmented print head)
The nozzleplate is integrated in the front plate.
Apart from the difference of being a standard or a pigmented print head the heads are constructed
the same way.
Standard print heads are used for dye based inks. These inks don´t need to be circulated
wherefore one ink connector on the back panel of the print head is adequate.
When pigmented inks are used which are mixed with solid particles it is necessary to evenly
dispense these particles at any time. This is the reason why pigmented inks are processed by
using a pigmented ink supply unit. A pump makes sure that the pigmented ink is constantly
circulating between the print head and the ink supply unit. Therefore a pigmented print head has
two ink connectors. One for the ink feed line from ink pump to print head and one for the ink return
from print head to ink pump.
Nozzle plates are available in different nozzle sizes to apply the optimum amount of ink for the
various areas of application. The following nozzle sizes in micron are available:
80 µm
130 µm
180 µm
270 µm
350 µm

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The print heads are also available in a special mounting style. On the front panel there is a small
block sticking out which allows to print in hard to reach areas. These types of print heads have the
nozzle plate mounted on the front side of the block.
The following names describe and classify the REA print heads:
Type
Description
Comment
SK 7
Standard print head, 7 nozzles
SKP 7
Pigmented print head, 7 nozzles
SK 16
Standard print head, 16 nozzles
SKP 16
Pigmented print head, 16 nozzles
SKS 7
Special print head , small mounting style,
7 nozzles
NOT available as a pigmented
version.
SKS 16
Special print head , small mounting style,
16 nozzles
Tab. 7.1: Print head types
Fig. 7.1: View of backpanel of SK7 (left); SKP 16 (right)
View of backpanel of SK7 (left); SKP 16 (right)
Fig. 7.2: Front view SK 7 (left), small mounting style SKS 16 (right)
Purge button
Ink fitting(s)
Connector for
print head cable
nozzleplate-
screw
nozzleplate
nozzle jewel

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8 Fitting and Comissioning
For better understanding of the start up procedure it is described below how to put a system into
operation which consists of the following components:
Print heads SK16
Controller
Input terminal
Ink supply unit
Product sensor
Shaft encoder
When working on the system it is mandatory to protect
from consumables (ink, solvent) which can injure eyes
and skin.
Make sure you have to have means available (cloth
e.g.) to take up escaping consumables.
Before you plug in or plug out any print head
connectors make sure that the controller is switched off.
This way you avoid damage to the electronic
components of the controller and the print head.
With different system configurations the scope of supply can vary. Please always check
with your delivery note for completeness.
8.1 System components
REA-JET
Controller
Input terminal
ST200

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Standard print heads
(SK7- and SK16-nozzles)
Print head cable
Shaft encoder with
mounting plate and
aluminum measuring wheel
Product sensor
(photo electric sensor or reflex detector)

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Cable for product sensor (photo electric
sensor or reflex detector) and shaft
encoder
Ink supply units
TVE = with integrated air supply
TVF = powered by factory air
Ink hose
T-Connector
(for an ink supply unit providing ink for
two ore even more print heads at the
same time)

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Quick connector
Standard system = 1 piece
Pigmented system = 2 pieces
Ink
Cleaner
Mounting brackets for
product sensor and print head
(optional)

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Users manual
(on CD-ROM)

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8.2 System assembly instructions
1. Mount print head bracket in the
required position at the
production line
2. Mount product sensor
(as close as possible to the print
head into direction where
products come from)
3. Mount shaft encoder to be
optimal able to pick up speed of
conveyor belt.
4. Allocate a secure spot for the
input terminal (standard cable
length is 3m)
5. Install the ink supply unit for dye
based inks. Ink supply units for
pigmented inks (TV-PP) can
stand free and do not have to be
mounted.

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6. Connecting cables:
With the bayonet nut connector
you connect the print head to the
connector on the back panel of
the controller (19-pin plug cable
for 7-dot print head, 35-pin plug
for 16-dot print head).
7. Connect the controller on it´s
backside with the print head.
8. Connect the product sensor with
the connecting cable.
9. Connect the shaft encoder to the
controller.
10. Connect the controller on it´s back
panel side with the eight-pin plug
(Y-cable –PS/DG-cable) to the
product sensor and the shaft
encoder.
Connect the input terminal with it´s
12-pin plug to the front panel of
the controller.
Attention: the controller must be
turned off while doing so.

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11. Connect the hoses:
Mount the ink hose to the ink
supply system.
12. Tighten the cap nut on ink hose.
Install ink hose and cut down to
needed length (pay attention to
straight cutting edges).
13. Put up ink hose to ink quick
disconnector (for pigmented ink
supply –TV-PP –two ink quick
disconnectors for each print
head).
Attention: ink hose must not be
bent.
14. Fill in ink into 2 liter ink supply
unit.
For 5 L and 20 L ink supply units
one has to change complete ink
tank.

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15. After all hoses are connected and all cap nuts are tightened thoroughly the controller
and ink supply unit can be connected to power supply respectively to the factory air
supply.
16. Flushing ink hose:
by pushing down the resistance
spring of the fast ink disconnector
the overpressure built up from ink
supply unit is released and ink
starts to leak out.
17. Let ink level rise up close to quick
ink disconnector.
18. Let a small amounts of ink leak
out to clean the ink hose from
any cleaner remains.
19. Shake out remaining ink from ink
quick disconnector and click into
place on print head.
20. Switch on controller.