Weber Markoprint integra PP108 User manual

Copyright ©, Weber Marking Systems GmbH
Translation of the original operating manual
Markoprint integra PP108
Part number of documentation 40075165
(GB) English
Version: 02.01.2019/HJE
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
E-Mail: [e-mail]
http://www.webermarking.de

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Contents 40075165 Markoprint integra PP 108
Page 3 of 104 GB
Contents
GENERAL INFORMATION........................................................................................................................6
GENERAL SURVEY ..................................................................................................................6
LIMITATION OF LIABILITY..........................................................................................................6
WARRANTY CLAUSE................................................................................................................6
CLEANING AND MAINTENANCE..................................................................................................7
COPYRIGHT PROTECTION........................................................................................................7
PURPOSE AND SCOPE OF THIS SERVICE MANUAL ......................................................................7
HINTS FOR USE OF THIS MANUAL.............................................................................................8
EXPLANATION OF TECHNICAL TERMS .......................................................................................9
CUSTOMER SERVICE.............................................................................................................10
SAFETY REGULATIONS ........................................................................................................................11
BEHAVIOR IN CASE OF AN EMERGENCY..................................................................................11
GENERAL SAFETY REGULATIONS...........................................................................................11
Explanation of Danger Degrees.......................................................................................11
INTENDED USE .....................................................................................................................12
REASONABLY FORESEEABLE MISUSE.....................................................................................12
RETROFITTING AND CHANGES AT THE PRINT SYSTEM .............................................................13
WARNING NOTICES AT PRINT SYSTEM....................................................................................13
SPECIAL HAZARDS ................................................................................................................14
REMAINING RISKS.................................................................................................................15
DISPOSAL.............................................................................................................................16
AUTHORIZED PERSONS..........................................................................................................16
PERSONAL PROTECTIVE EQUIPMENT .....................................................................................17
WORKING PLACES OPERATOR PERSONNEL............................................................................18
TECHNICAL SPECIFICATIONS .............................................................................................................19
GENERAL .............................................................................................................................19
ELECTRICAL .........................................................................................................................19
DATA INTERFACES ................................................................................................................19
CONNECTIONS......................................................................................................................20
PERFORMANCE DATA ............................................................................................................21
INKS ..................................................................................................................................22
TRANSPORT, PACKAGING AND STORAGE .......................................................................................23
TRANSPORT .........................................................................................................................23
Scope of delivery .............................................................................................................23
SYMBOLS ON PACKAGING......................................................................................................24
TRANSPORT AND UNPACKAGING............................................................................................25
PACKAGING..........................................................................................................................26
On Packaging..................................................................................................................26
STORAGE.............................................................................................................................27
Controller.........................................................................................................................27
Storage ink bottles...........................................................................................................28
CONSTRUCTION AND FUNCTION........................................................................................................29
BRIEF DESCRIPTION ..............................................................................................................29
SYSTEM UNIT........................................................................................................................29
PRINT HEAD..........................................................................................................................30
INK SYSTEM..........................................................................................................................30
SYSTEM VERSIONS................................................................................................................31
COMPLETE OVERVIEW MARKOPRINT INTEGRA PP108 .............................................................33
Seiko –print head module RC1536L...............................................................................34
NAME PLATE.........................................................................................................................36

Contents 40075165 Markoprint integra PP 108
Page 4 of 104 GB
INSTALLATION AND INITIAL OPERATION..........................................................................................37
INSTALLATION.......................................................................................................................39
Requirements to the Site of Installation............................................................................39
Placing the Print System..................................................................................................40
POSITIONING THE PRINT SYSTEM...........................................................................................41
CONNECTING THE PRINT SYSTEM ..........................................................................................43
Overview of the print system connectors..........................................................................44
Connection of the grounding cable...................................................................................45
Connecting to Supply Voltage..........................................................................................46
Connecting the optional Shaft Encoder............................................................................47
Connecting the optional Product Sensor..........................................................................48
INSTALLATION OF THE MARKOPRINT INTEGRA PP108..............................................................50
RINSING /CLEANING PRINT HEAD...........................................................................................51
WIPE NOZZLE PLATE .............................................................................................................51
Installation of an unfilled system ......................................................................................53
OPERATION ............................................................................................................................................56
USER INTERFACE OF THE PRINT SYSTEM ................................................................................56
SWITCH ON...........................................................................................................................57
SWITCH OFF .........................................................................................................................58
FILLING THE SYSTEM.............................................................................................................59
Insert the ink bottle...........................................................................................................59
PRINT STOP..........................................................................................................................61
PRINT START ........................................................................................................................61
SELECT PRINT IMAGE ............................................................................................................62
LOADING PRINT IMAGE...........................................................................................................63
Load print image with a USB-Stick...................................................................................64
TO SET THE PRINT START DELAY ............................................................................................65
Loading Print Image with iDesign.....................................................................................66
SETTING OF THE PARAMETER BY IDESIGN SOFTWARE (PRINT START DELAY)............................67
WEB-INTERFACE...................................................................................................................68
CONFIGURABLE IN-/OUTPUTS................................................................................................74
SETTINGS BY IDESIGN SOFTWARE..........................................................................................75
IDESIGN...................................................................................................................................................76
CREATE A PRINT IMAGE .........................................................................................................76
ETHERNET CONNECTION ESTABLISHING .................................................................................77
FAULTS....................................................................................................................................................78
SAFETY................................................................................................................................78
Staff ............................................................................................................................78
TROUBLESHOOTING TASKS....................................................................................................80
DISASSEMBLY........................................................................................................................................81
STAFF..................................................................................................................................81
DISASSEMBLY OF PRINT HEAD................................................................................................82
DISPOSAL.............................................................................................................................83
LIST OF ACCESSORIES AND SPARE PARTS.....................................................................................84
HMI-DISPLAY (HUMAN-MACHINE-INTERFACE) ........................................................................85
Description of the HMI-Display.........................................................................................86
APPENDIX ...............................................................................................................................................90
SOFTWARE-UPDATE .............................................................................................................90
Software-update with USB-Stick......................................................................................90
SOFTWARE-UPGRADE...........................................................................................................90

Contents 40075165 Markoprint integra PP 108
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CURRENT SOFTWARE VERSION ..............................................................................................90
USB-STICK FILES .................................................................................................................91
BOOT-LED MESSAGES..........................................................................................................92
PLUG CONNECTIONS .............................................................................................................93
Ethernet...........................................................................................................................93
USB A ............................................................................................................................93
Option ............................................................................................................................94
Splitter cable (72900545).................................................................................................95
Splitter cable HMI (40037993)..........................................................................................96
Adapter cable HMI (40038349)........................................................................................96
Sensors ...........................................................................................................................97
Encoder...........................................................................................................................97
Input / output connection for 15 pin Sub-D socket with examples.....................................98
Examples input: ...............................................................................................................98
Hose system..................................................................................................................100
Mac address..................................................................................................................101
TECHNICAL DRAWINGS ........................................................................................................102
System unit Markoprint integra PP108...........................................................................102
INSTRUCTION SHEET ...........................................................................................................103
PARAMETER LIST ................................................................................................................104

General Information 40075165 Markoprint integra PP 108
Page 6 of 104 GB
General Information
General Survey
Congratulations! You have purchased a high-quality print system. Our concern is to
make sure that you profit from this system to your entire satisfaction over many years. In
order to ensure this, we strongly recommend you to let our experienced specialists
perform the installation.
Limitation of Liability
All pieces of information and notes of this manual have been arranged in consideration
of applicable standards and regulations, state-of-the-art technology as well as our
cognition and experiences over many years.
The manufacturer assumes no liability for damages caused by:
Non-observance of this manual
Non-observance of the intended use
Use of unqualified personnel
Manipulations at the system
Technical changes
Use of spare parts that are not approved by the manufacturer
Contamination of the unit
not been stored in accordance with the intended use
The actual scope of delivery may differ from the explanations and illustrations provided
herein in the case of special designs, additional order options or after recent technical
changes.
The obligations of the supply contract the General Trading Conditions as well as the
Terms of Delivery of the manufacturer and the valid legal regulations at the moment of
conclusion of a contract generally apply.
Technical changes within the scope of improvement and development are subject to
change without notice.
Warranty Clause
The warranty conditions are conforming to the valid General Trading Conditions of the
manufacturer at the moment of purchase.
Warranty or repair claims against the manufacturer will be rejected if it is determined that
the unit has not been stored, installed, handled and maintained in accordance with the
intended use. Contamination of the unit, improper use or unauthorised changes or
repairs of the units are excluded from coverage by warranty.

General Information 40075165 Markoprint integra PP108
Page 7 of 104 GB
Cleaning and maintenance
There are no moving parts in the print head requiring regular maintenance.
However, for printing onto outer packaging (e.g. cartons, trays, sacks, etc.) it must be
expected that dust and fibre particles carried along are freed and adhere to the nozzle
plate of the print head. Over a period of time, this can lead to a worsening of the print
quality (see also  Chapter Faults, page 78).
If the dirt proves to be too stubborn and cannot be removed by wiping with a
cleaning pad or rinsing, please return the device to the manufacturer for
professional cleaning. Please note that this constitutes a service which entails
costs, even during the warranty period.
Copyright Protection
This documentation or parts of this documentation may only be copied, photocopied,
reproduced or translated into other languages for personal use. Without previous
expressed written permission of Weber Marking Systems GmbH a reproduction for
circulation to a third party is not permitted.
Purpose and Scope of this service manual
This manual enables safe and effective use of the Markoprint integra PP108.
The Operating manual is a component of the device and must be stored close to the
device to be accessible to the staff at all times. The staff must have read this manual
thoroughly and understand the content before starting any work. Compliance with all
safety notes and instructions given in this manual is a basic prerequisite to safe
operation.
Furthermore, the local accident prevention regulations and general safety provisions for
the area of application of the device are applicable.
Images in this manual serve to provide a basic understanding and may differ from the
actual device version.
In addition to this manual, the instructions in the annexure on the components included
are also applicable.

General Information 40075165 Markoprint integra PP108
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Hints for Use of this Manual
Please find in the following a detailed explanation of the notations and representations
as used in this manual.
Keys and buttons which you must push appear in squared brackets.
Example: Push [Start] - button to save changes...
Procedures which should be followed in a specific order are listed in numbered
paragraphs.
Step
Procedure
1
Disconnect power plug
Important messages are written in bold text and/or highlighted in grey.
This is an example for an important message!
Special notes:

… refers to a chapter or document.
Images in this manual serve to provide a basic understanding and may differ
from the actual system version. Depictions may be stated without protection
device for clarification.

General Information 40075165 Markoprint integra PP108
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Explanation of Technical Terms
Technical Term
Explanation
Conveyor
The conveyor transports the products, which should be
printed and pass them by the print head
DPI
Dots Per Inch
1 Inch = 25,4mm
Encoder
See shaft encoder
LED
Light emitting diode
Nozzle plate
On the nozzle plate are 500 nozzles arranged, which
ejected the ink.
Print direction
Direction of movement of the product on the conveyor belt
viewed from the control system in the print direction
Print intensity
Contrast of the print image. If necessary this parameter
must be changed to optimize the print image. A higher
intensity gives greater blackening and longer ink drying time
Print speed
Print speed = Speed of the conveyor. The speed of the
conveyor must be keep constant
Print start delay
Offset print, i.e. by how much is printing delayed in
millimeters after the product is detected by the light barrier.
Print width
The number of pixel can be increased or decreased using
this parameter. The print image becomes narrower or
wider.
Product sensor
A sensor for the detection of the product. Mostly used are
optical sensors (photo sensor, light barrier, reflex sensor)
Sensor
See Product-sensor
Shaft encoder
A shaft encoder is used for the automatic detection of the
conveyor speed and defines the print speed
Seiko
Manufacturer of the print head module

General Information 40075165 Markoprint integra PP108
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Customer Service
Please contact your local distributor for technical information.
If failures at the print system occur, you should be prepared with the following
information:
Detailed error description.
All information on the name plate of the print system.
Version number of the system software and of the iDesign Software
Configuration (Print, Basic, Advanced, Pro)
Special functions of the software or hardware
When did the error occur for the first time?
Prior to call our hotline service, please have a look at the manual (  Chapter Faults,
Page 78) for potential references to eliminate the error.
Furthermore, our staffs are always interested in new information and experiences with
the use of the product and which may be valuable for improvements to our products.

Safety Regulations 40075165 Markoprint integra PP108
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Safety Regulations
Behavior in Case of an Emergency
The operating personnel have to be familiar with the operation and the location of safety,
accident notification-, first aid- and rescue devices.
What to do in Case of an Emergency?
Initiate immediately all required emergency measures for injured persons.
Observe valid safety regulations in any case in order to avoid further damages to
persons.
Call medical attendance for injured persons.
Eliminate all accident causes.
General Safety Regulations
Safety regulations provide information in written and symbol form in order to warn you
against dangers and to instruct you to avoid any damage to persons or to properties.
Safety regulations are started by signal words indicating the level of danger.
Safety regulations may be placed directly at the print system or in documents about this
print system.
Explanation of Danger Degrees
This symbol indicates a hazardous situation which, if not
avoided, will result in death or serious injury. All safety
regulations have to be observed to avoid any damage to
persons.
This symbol indicates a hazardous situation which, if not
avoided, could result in death or serious injury. All safety
regulations have to be observed to avoid any damage to
persons.
This symbol indicates a hazardous situation which, if not
avoided, may result in minor or moderate injury. All safety
regulations have to be observed to avoid any damage to
persons.
This symbol indicates a hazardous situation which, if not
avoided, may result in damage to properties. All safety
regulations have to be observed to avoid any damage to
properties.

Safety Regulations 40075165 Markoprint integra PP108
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Intended Use
The working reliability of the print system is ensured only with intended use.
The Markoprint integra PP108 has been designed, built and must be used exclusively for
the intended purpose described.
The Markoprint integra PP108 serves to create print images and to print these from the
top or side onto smooth and absorbent product surfaces. The product must pass the
Markoprint integra PP108, i.e. positioned on a conveyor belt.
All working conditions and instructions, prescribed in this manual, will be observed.
Any use beyond the intended use or any alternative use of the equipment is regarded as
misuse and may lead to hazardous situations.
Misuse of the device may lead to hazardous situations. Refrain, in particular, from
subjecting the apparatus to the following:
Modification, retrofitting or alteration of the apparatus or individual sub-
assemblies.
Any claims arising from damages due to undesignated use are rejected.
Reasonably Foreseeable Misuse
Another use as fixed in the „Intended Use“ or even more applies as not intended!
For damages caused by not intended use
the operator bears the complete responsibility,
the manufacturer assumes no liability.
If you do not use the system according to the regulations, risks may occur!
Not intended uses are e.g.:
operation in explosive atmosphere
the print system comes in contact with food …

Safety Regulations 40075165 Markoprint integra PP108
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Retrofitting and Changes at the Print System
Unauthorized retrofitting and changes at the system lead to an immediate expiration of
liability and warranty covered so far by the manufacturer! This is also valid for
interventions and program changes at programmable control systems as well as
program changes at control units as far as they are not described in this Manual.
The electromagnetic performance of the system can be affected by amendments or
changes of any kind.
Do not arrange any changes or amendments at the systems without consultation and
written approval of the manufacturer.
Warning Notices at Print System
Particular sources of danger at the print system are marked by yellow labels. The used
pictograms point out to following dangers:
Danger to Life

Safety Regulations 40075165 Markoprint integra PP108
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Special hazards
The following section identifies the remaining risks, determined following a risk analysis.
Observe the safety notes listed here and the warnings in other chapters of the
manual to minimize health hazards and avert hazardous situations.
Danger to life through electric shock!
DANGER TO LIFE!
Contact with live parts poses imminent danger to life.
Damaged insulation or individual components can be
lethal.
Therefore:
–Immediately switch off the power supply and initiate
repairs if the insulation is damaged.
–Work on the electrical system may only be performed
by electricians.
–Before working on the electrical system, disconnect
from the mains (remove mains plug) and check that
power is off.
–Always disconnect mains before performing cleaning
and repair tasks.
–Keep moisture from live parts. Moisture may cause a
short-circuit.
Risk of injury through incorrect handling of batteries!
RISK OF INJURY!
Rechargeable and primary batteries contain toxic heavy
metals. They must be treated as special refuse and
deposited at municipal collection points or be disposed of
by a specialized company. Batteries must be handled
with particular care.
Therefore:
–Never throw batteries into a fire or subject batteries to
high temperatures. Explosion hazard.
–Do not charge batteries. Explosion hazard.
–Fluid escaping through incorrect use may cause skin
irritations. Avoid contact with the fluid. In case of
contact with the fluid, rinse with ample water. If the
fluid comes into contact with the eyes, rinse
immediately with water for 10 minutes and consult a
doctor without delay.

Safety Regulations 40075165 Markoprint integra PP108
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Edges and corners pose risk of injury!
RISK OF INJURY!
Sharp edges and pointed corners may cause abrasions
and cuts to the skin.
Therefore:
–Be cautious when working near sharp edges and
pointed corners.
–If in doubt, wear protective gloves.
Risk of stumbling posed by dirt, objects lying about
and connecting lines!
RISK OF INJURY!
Dirt, objects lying about and connecting lines for power,
data- and signal lines may cause slipping and stumbling
resulting in severe injuries.
Therefore:
–Always keep working area clean.
–Remove objects no longer required.
–Mark stumbling areas with yellow-black marking tape.
–Non tension connecting lines to system and pass it
that no places of danger do arise
Remaining Risks
The print system is constructed for a safe operation. Hazards that are not preventable
due to construction purposes are limited as far as possible by protection devices. A
certain amount of risk is always existent! The knowledge about the remaining risks
assists you to arrange your work safer and to avoid incidents. In order to avoid the
dangers, please observe additionally the particular security advice in the single chapters.

Safety Regulations 40075165 Markoprint integra PP108
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Disposal
This print system complies with the RoHS EU-Regulation 2002/95/EG with observance
of the fixed using prohibitions and avoiding pollutants.
Authorized persons
Work at the print system should only be performed by reliable personnel. Please comply
with the legal age!
Only trained personnel are allowed to operate the print system. Trainees, apprentices
etc. must be supervised by an experienced person while working at the print system.
Prior to start running the labeler the operator has to ensure that the manual of the labeler
is available to all users of the machine and that the users have read and understood the
manual. Only then the system may be put in operation.
The responsibility for the different tasks at the print system must be clearly specified and
kept. There must be no ambiguous authorities for this may put the safety of the users at
risk. Arrange a detailed work schedule if several persons work on the machine.
All work on the electrical equipment must be carried out by skilled electricians only.
Failures may be eliminated by authorized personnel only.
All work associated with the assembly, adjustment and maintenance at the machine may
be carried out only by trained or instructed personnel.
The operator of the machine must ensure that the personnel are trained in dealing with
the integrated control system prior to fix machine errors or maintain the system.

Safety Regulations 40075165 Markoprint integra PP108
Page 17 of 104 GB
Personal Protective Equipment
Wear following protective equipment when performing work at the system:
SAFETY SHOES
Wear for protection against falling off parts and slipping.
PROTECTIVE CLOTHING
Are tight-fitting clothes with low tensile strength, with tight sleeve
and without distant parts
Wear a hairnet if applicable
Do not wear jewelry or wrist watches
PROTECTIVE GOGGLES
For protection against splashes of detergents and flying parts
SAFETY GLOVES
For protection against sharp-edged items
Personal Protective Equipment
for the following tasks
Protective
Clothing
Safety
Shoes
Safety
Gloves
Protective
Goggles
Transport
x
x
x
Setting up and connecting of the
system
x
x
x
x
Maintenance Work
x
x
x
The documentation of the manufacturer of the single
system components has to be observed!

Safety Regulations 40075165 Markoprint integra PP108
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Working Places Operator Personnel
The print system is an automatic working system and does not require any operation for
the printing procedure.

Technical Specifications 40075165 Markoprint integra PP108
Page 19 of 104 GB
Technical Specifications
General
Dimensions (H x W x D in mm)
See drawings in appendix
Weight
About 6000g, without ink
Environmental
Temperature:
15 - 40 ° C
Environmental Conditions:
30-85 % relative humidity (non-condensing)
Protection Rating
IP 40
Maximum operating time
The system is designed for continuous operating
Electrical
Input voltage at the device:
90 - 240 V AC / 50-60Hz (1~)
Current consumption:
max. 1,7 A
Power consumption:
max. 150 W
Power consumption 36V
avr:
0,85 A
Power consumption 36V
max:
2,25 A
Power consumption
Standby:
5 W
Data interfaces
EIA 232
Sub-D 15 pole
Ethernet
RJ45
USB
USB-A socket for stick

Technical Specifications 40075165 Markoprint integra PP108
Page 20 of 104 GB
Connections
Sensor
Sub-D 15 pol
Encoder
Sub-D 15 pol
In-/Outputs
Sub-D 15 pol
EIA 232
Sub-D 15 pol
USB
USB-A socket for stick
Ethernet
RJ45