Ink Dispensing System IDS HP25 User Manual - Vale
Contents
1. After completing the reset process the sounder should stop and the beacon will change from red to combined green and amber The balance will move to the home position at the front of the machine and the secondary air supply regulator will switch on If the dispenser does not reset check that the emergency stop button is released Note If the emergency stop button is depressed release it by turning the button clockwise and allowing it to spring out Ensure that the button is not depressed further whilst turning it or the button will not release After the initial IDS pressurisation turn the air regulators which feed the ink containers to the ON position one at a time ensure the ink container lids are secure and check for any minor air leaks The air regulators are located inside the panel at the front of the machine on the right hand side Ink container air regulators IDS HP25 12 November 2007 val tech 2 3 IDS Beacon Warning Indicator IDS HP25 November 2007 RED Indicates Emergency Stop Switch activated or machine in initial Power ON state AMBER Indicates the balance dispenser is moving GREEN AND AMBER Indicates machine in RESET condition or ready to dispense GREEN Indicates machine is in the process of dispensing ink val amp tech 3 IDS HP25 Ink Set Up 3 1 Setting Ink Names WARNING DO NOT FILL THE INK SUPPLY CONTAINERS WITH INK UNTIL THIS STAGE HAS BEEN COMPLETED The reference or descri2. The Ink Manager Software Training Manual that follows will provide you with the information you need to use all the advanced functions and features along with basic instructions necessary for simple operation of the software It can also act as a complete package for structured onsite training IDS HP25 59 November 2007 SERVICE LOG IDS HP25 November 2007 60 val tech 16 Introduction This Service Log serves to provide contact information should additional assistance be required please refer to the contact details supplied below Forms available at the end of this section allow space for the service history of the machine to be recorded for future reference 16 1 Contact Information If you require any additional assistance or have any queries please contact Vale Tech Telephone 44 0 1638 668593 Fax 44 0 1638 676720 Email technical support vale tech co uk Website www vale tech co uk Address VALE TECH LIMITED Unit 12 Depot Road Newmarket Suffolk CB8 OAL UK IDS HP25 61 November 2007 val amp tech 17 Service History 17 1 Machine Fault Maintenance Log IQne ON Q Date Action Taken FE IDS HP25 November 2007 62 valdtech Machine Fault Maintenance Log cont Date Action Taken Signed IDS HP25 November 2007 63
3. 9411 SP 9076 SP 9327 SP 9109 SP 9316 SP 9159 SP 9158 SP 9310 SP 9069 SP 9408 SP 9634 SP 9635 SP 9200 SP 9469 88 SP 9261 SP 9260 SP 9262 SP 9681 SP 9627 SP 9678 SP 9116 SP 9115 SP 9114 SP 9410 SP 9410 SP 9412 SP 9233 50 valdtech 10 Preventative Maintenance Programme Scale unit Check Comms and power lead are securely connected Scale feet are located correctly and balance is level Balance calibration WEEKLY Locator plates are clean amp undamaged Excessive ink on scale and scale support Container sensor and reflector are clean and functioning AS NECESSARY Carriage Check Drive belt carriage follower rollers and scale unit support castors are free from ink and dust contamination Check linear drive belt for alignment for wear and tear Carriage runs smoothly to its full extent at even speed Linear slide and scale unit support rail are free from ink and dust contamination Roller switch actuator shows no sign of damage and activates all of the roller switches WEEKLY Dispense valves Check Base of valves are clean Ink leakage from actuator fittings Check air lines to actuators are secure and not leaking EACH TIME CONTAINERS ARE CHANGED OR WEEKLY Flow rate configuration WEEKLY Air system Clean Filter and ensure air pressure is set to minimum 82psi 6 bar WEEKLY Ink containers Check Air settings to ink containers and valve actuators and adjust as required Ink supply container vent valves for dam
4. and overalls to protect from splashes and spills For detailed instructions and PPE requirements see your COSHH and risk assessment documentation 5 1 Isolator Switch The main power isolator switch is located on the right side of the machine When maintenance is being carried out the power must be isolated and the switch locked with a padlock 5 2 Door Switch The front door of the machine has a safety system which requires the door to be closed before a dispense operation can be started If the door is opened as a dispense is about to start or while the machine is in operation it will stop The operation will resume once the door is closed Magnetic interlock to disable machine if front door opened Warning IDS HP25 26 November 2007 notice val tech Safety Features cont 5 3 Emergency Stop Switch Pressing the red button labeled Emergency Stop at the front of the machine will activate the emergency stop circuit within the electronics of the machine The machine will require resetting as detailed in Section 2 2 before any operations can be carried out and to stop the alarm sounding lf the Emergency Stop button is depressed during a dispense operation this will be aborted To release the Emergency Stop the button must be turned anti clockwise ensuring that it is not depressed further preventing the button from releasing 5 4 Alarm Sounder The sounder is an alarm which alerts the user to any prob
5. calibration weights centrally on the scale with the balance locked in the home position as shown Click OK The scale will then allow time for the readings to settle before values are displayed and counting up to the calibration weight value This will overshoot up to three times reducing less each time as the calibration point is reached Calibrator Information Calibrating full scale point ml Cancel The final value in this example 9kg will be displayed as the value is stored During this stage it is again important that the scale is not exposed to vibrations draughts or being touched IDS HP25 36 November 2007 val tech Scale Calibration cont Calibrator Information Calibrating full scale point Please wait 9000 0 Cancel E cabreo complete Replace pot locator plate arid tare plate red Test balances operation br placing veighis on Ha bh dente Calibrator 1 Test balance operation by placing weights on the bala 2 Click done when finished 9000 2 me Net EE EE The scale calibration can be tested using this window To do this remove all the weighs from the scale replace the weigh pan and 5kg Container Locator then click on Tare IDS HP25 3 November 2007 val amp tech scale Calibration cont Place the calibration weights on the scale in 1kg increments and record the value displayed at each point again with the balance locked in the home position as sho
6. Folder tab and must be allocated the correct colour reference in the Name field before the valves can be configured for their flow rates For this information please refer to the list in Setting Ink Names in 3 1 Before starting to dispense ink the flow rate for each ink valve needs to be set in order to provide swift but controlled dispensing It is necessary to understand that the viscosity and flow attributes of the ink will affect its actual dispense rate The ink container regulator has been set at 16psi 1bar There is a facility to split the dispense process into stages for ease of control These are coarse feed for the bulk of the dispense down to approximately 100g before completion coarse pulsed feed giving coarse feed control down to approximately 20g before completion fine continuous feed down to approximately 10g before completion and finally fine pulsed feed down to completion of the dispense There can be up to 6 separate stages of dispense although they do not all have to be used For the purpose of this example 200g of ink is to be dispensed utilising only 4 of the stages Name field Folder tabs Falve Co neurg U Supply Container T Supply Contan 2 Supply Cortainer gt ET Container 5 El Name Ink 1 Valve Calibration Container Type Pressurised Active Coarse Pulsed Target Flow da Completion pe Stage CON NN Switched Pump Stage G iw fF B ET Level Senso
7. Green Mains power is no longer lit on the front panel of the machine One or more of the beacon bulbs are not at all lit during the normal operating cycle of the machine Machine will not dispense ink from valves A Comprehensive list of Technical Bulletin Guides Have been produced to help you to resolve the problem These are available from Vale Tech Ensure Digitisers on containers are fully plugged in and working properly Check Min amp Max Levels have been set in Ink Manager Service personnel to ensure that the Ink Level sensor input PCB dip switch settings are correctly configured Check the calibration of the machine If necessary recalibrate Check settings in ink manager are the same as settings in the Hardware Configuration sheet Check side and front doors are all securely closed Service personnel to check 5 8 Stepper Motor Driver Board protection fuse located on Electrical Chassis service personnel to check the mains power supply bulb has not blown fit a replacement if necessary service personnel to check each of the beacon bulbs have not blown fit replacements if necessary Check main air supply is switched on Check the lid of the ink container is correctly fitted and the air tap is turned to the ON position service personnel to check air regulator settings are correct inside electrical chassis Contact your Authorised local Service Agent or contact Vale Tech L
8. Incoming Air Regulator amp 5 Bar Gauge Rex Incoming Air Vent Valve Solenoid Rex Sounder PC inc Windows XP Exc Ink Manager Keyboard Mouse Parts List cont November 2007 SP Code SP 9127 SP 9128 SP 9006 SP 9004 SP 9005 SP 9881 SP 9036 SP 9038 SP 9110 SP 9868 SP 9861 SP 9873 SP 9399 SP 9215 SP 9376 SP 9238 SP 9416 SP 9200 SP 9119 SP 9421 42 SP 9141 SP 9385 SP 9410 SP 9412 SP 9011 SP 9022 SP 9007 SP 9023 SP 9125 SP 9124 SP 9120 SP 9077 SP 9078 SP 9079 SP 9129 SP 9801 SP 9802 SP 9803 SP 9804 SP 9805 SP 9806 SP 9003 SP 9891 49 val tech IDS HP25 Machine User Parts List Page Item 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 15 4 16 4 17 4 18 5 1 5 2 5 3 6 1 6 2 6 3 6 4 IDS HP25 Description Pot Sensor Flexible Chain Assembly Carriage Caster Balance Lock Micro Switch Balance Locking Handle Scale assembly 10kg 280mm Scale assembly 30kg 280mm Universal Pot Locater Home Position Proximity Switch Pot Sensor Reflector Tape Dispense Valve Roller Switch Roller Switch Actuator Dispense Valve Braided Hose Specify Pot number Motor Drive Gearbox 4 1 Stepper Motor Motor Drive Coupling Stepper Gearbox Assembly Complete Carriage Slides Pair Scale Assembly Comms Power Lead Actuator Bellows Air Piston Connecter Block Ink Level Digitiser Jack Plug and Lead Level Probe Assembly November 2007 SP Code SP
9. Switch at back of PC is on then press PC on button Check Power cable is secure press PC on button Check monitor is switched on press button on front of display Check Monitor cable at back of PC is secure plugged in turn monitor off then on again Display is stuck in power save mode turn monitor off then on again Ensure keyboard is secure plugged in then re boot Hard disk fault call Vale Tech Technical Support Call Vale Tech Technical Support Re boot with Ctrl Alt Del keys or switch PC off then on again Call Vale Tech Technical Support Check monitor power is switched on Check monitor is not in power save mode by pressing a mouse button or keyboard space bar Check mains power to machine Check Isolator switch is in ON position Check PC is switched ON 52 val tech IDS Dispense Problems Low no air pressure Slow dispense IDS will not reset IDS HP25 November 2007 Air pressure stays low after containers are turned on Air leaks at supply container Air leaks from lid fittings No air pressure in container Containers not pressurising fast enough because low pressure is used No apparent air leaks Beacon light flashes from green to red Door switch active Emergency Stop activated All doors are closed Check air pressure regulators with containers turned off Valve 5 bar Container 1bar if low check air supply
10. age or air leaks WEEKLY General Check machine for cleanliness and for mechanical integrity WEEKLY General Clean drip wipe roller and doctor blade and empty drip wipe tray AS NECESSARY General Check main air pipes and fittings and electrical cables and fittings for signs of wear WEEKLY General Check safety switches on each ink station door and emergency stop buttons are functioning correctly DAILY General Check and report any mechanical damage or signs of misuse AS NECESSARY IF INANY DOUBT DO NOT USE THE MACHINE UNTIL A VALE TECH OR AN AUTHORISED SERVICE AGENT HAS CLARED THE MACHINE FOR USE IDS HP25 51 November 2007 val amp tech 11 Trouble shooting Guide 11 1 Common Problems PC not coming on bootina IDS power is on but no light on at front of PC PC LED is on but no display PC not getting Into windows Monitor screen has turned dark but PC is switched on Machine does not work at all IDS HP25 November 2007 No Power No Display LED Display LED is on Display LED is amber or red Reports Keyboard error Error message Hard Disk or Boot device Registry device files error message Hangs loading Windows no error message displayed PC still not getting into Windows Monitor appears to be broken or switched off No power to PC or machine Machine appears to be dead Press on button at front of PC If LED still not on check that Power Supply
11. air pressure set at 0 8 1 0 bar Level Sensor Type The IDS HP25 uses capacitive sensing Optional header Tank The header tank is used to contain ink when a bulk container system and pump is used in conjunction with the IDS HP25 IDS HP25 22 November 2007 valdtech 3 6 What happens if the same ink is used in more than one of the ink Supply containers The IDS HP25 is designed to allow the operator to fill more than one of the supply containers with the same ink This is more commonly used for colors that are most frequently consumed In this case the same ink reference has to be given to both of the Folder Tabs when setting the Flow Rates See section Valve Configuration The IDS25 will dispense from the one of the containers until the empty point is reached if this was to happen in the middle of a dispense sequence the IDS HP25 will automatically divert to the second ink container and continue to complete the mix A warning message in Ink Manager will inform the operator that the first container is empty The IDS HP25 will now continue to use the second container until it is empty When the second container reaches the empty level the dispensing will automatically switch back to the first container By this time the first container requires re tilling See Section Loading Ink 3 Dispensing ink For instruction on entering recipes see Ink Manager Training section select the Ink Series to be used from th
12. bed in the Directive as an assembly of linked parts or components at least one of which moves with the appropriate actuators control and power circuits etc joined together for a specific application in particular for the processing treatment moving or packaging of a material The manufacturer is responsible for verifying whether a particular product falls within the scope of the Machinery Directive The Pressure Equipment Directive 97 23 EC The directive provides control over equipment subject to pressure Pressure equipment being vessels piping safety accessories and pressure accessories A pressure assembly being several pieces of pressure equipment assembled to form an integrated functional whole The EMC Directive 89 336 EEC The Directive applies to most electrical and electronic apparatus that is finished products and systems that include electrical and electronic equipment The Low Voltage Directive 73 23 EEC Broadly the Regulations apply to most consumer commercial and industrial electrical equipment designed for use within the voltage ranges 50 V ac to 1 000 V ac and 75 V dc to 1 500 V dc Remarks amp restrictions for this declaration This declaration is no longer valid if any changes are made to the machine which is not corresponding to the abovementioned standards Place and date Newmarket G Adlem Mechanical Engineering C Stapleton Electrical Engineering M Hughes Director N S
13. coarse and fine dispense nozzles are clean Check hose is clean and leak free Ensure pipe clamp is secure 0 Check container seam is leak free OONOOFfWND IDS HP25 41 November 2007 SERVICE MANUAL val tech Dagenseuy Solitons More 9 Spare Parts 9 1 External Parts 4 Beacon SP 9004 5 Beacon bulb SP 9005 6 Monitor 3 SP 9881 Emergency st 7 button Keyboard NIS SP 9036 8 Power on indicator Keyboard cover SP 9127 SP 9038 2 9 Power indicatt Door isolating bulb switch SP 9128 SP 9110 m n Mains power Door handle isolator switch SP 9868 SP 9873 11 L 2 Leveling foot ee SP 9861 1 IDS HP25 43 November 2007 9 2 Ink Supply Container and Valve 2 Lid O ring P 1 D SP 9218 Elliptical HP lid SP 9399 12 3 Ink level probe digitizer lead ENGE Oan P 9412 sie SP 9376 11 R Ink level probe J digitizer SP 9410 4 d Level sensor probe 10 o aes SP 9238 25lt ink reservoir f SP 9387 20 g 5 Baffle plate K Hose clip SP 9141 ae SP 9416 a 8 Ink delivery hose N SP 9469 88 Fe ZN A 6 Dispense valve PEN AE SP 9207 2 IDS HP25 44 November 2007 val amp tech 9 3 Pneumatics and Electronics 13 Sounder SP 9003 SP 9891 8 3 Way Rex Solenoid Manifold 9 Pot Pressure Regulator 1 Bar IDS HP25 November 2007 1 Main Controller Board PCB1014 SP9011 ip w E L C F if jt TA a E 2 Steppe
14. container central to the locator plate WARNING DO NOT USE THE DISPENSER WITHOUT THE CORRECT SIZE LOCATOR PLATE FOR THE CONTAINER Contact your supplier or Vale Tech Ltd direct if you do not have the correct size locator plate for the IDS Position the container to be used onto the locator plate and lift the handle Push the balance back towards the machine until it comes to a stop and then lower the handle into the lock position To ensure it is locked into the home position with the handle down gently try to pull it back out If it is correctly locked into position it will remain in place Note If the handle is not in the locked position the IDS HP25 will not dispense Locater plate adaptor for 1kg and 2 5kg containers Locater plate for 5kg container Balance assembl Balance y handle IDS HP25 30 November 2007 val amp tech 7 2 Overweigh Protection Two photoelectric sensors are mounted in a position to scan across and through the locator plate and detect the following 1 That a container is present 2 The size of the container REG container sensors Batch size limits can be programmed into Ink Manager This ensures a batch cannot be dispensed if it is of greater size than the capacity of the container which has been detected on the balance Note The IDS HP25 will not perform a dispense operation if no container is detected on the locator plate If the IDS HP25 is required to dispense a quan
15. cott Director Representing Vale Tech Ltd 12 Depot Road Newmarket Suffolk CB8 OAL United Kingdom IDS HP25 6 November 2007 val tech 1 Installation 1 1 Pre Install Information IDS HP25 16 24 colour 25kg dispenser 2185mm 474mm 1400mm 474m JEE T E IDS HP25 November 2007 1 1 1 Services Connection Requirements Air Supply 6 Band 100 Litres minute 90 PSQ Gallons minute minimum Electrical Supply 115 230VAC 50 60Hz 650 VA UK 230V Supplied Uninterruptable Power Supply 1200 VA US 115V Recommended Air 8 ly tob ir Supp Regulated and Filtered Electrical TT FE pre i ri AE supplied by Vale Tec MEN Air Supply Allow mm clearance at ihe rear of the machine 6 Bar for connesione ond removgl of the rear panel Minimum AF Lira Bar Mindoro iiach DZI Percale IDS HP25 November 2007 val tech 1 2 Positioning of Machine The IDS HP25 comprises one primary module measuring 1 6m D x 1 4m W x 1 65m H It should be sited in its desired location by moving with a forklift or pallet truck remembering to ensure there is a requirement for a minimum of 300mm of clear space at the rear of the machine for access to enable the connection of primary services and clearance at either side to gain access to the electrical and pneumatic supply cabinets After positioning the IDS HP25 ensure that all the feet are placed flat on the floor before leveling Correct leveling is ac
16. e drop down menu and select the recipes tab at the bottom left of the screen In the recipes window locate and select the recipe to be dispensed place the curser over and highlight it using the right mouse button Pe fee eee Sac ee ee ee RS RE eel ee From the drop down list highlight dispense and select it using the left mouse button IDS HP25 23 November 2007 valdtech Dispensing ink cont Enter the dispense quantity and click ok Enter Dispense Quantity Enter Job Number Please Enter Required Quantity Enter Job Number E Kgs Cancel Enter the job number if required and click ok If the ink is not to be allocated to a job click ok The dispense screen shows details of the ink formulation to be dispensed Select dispense and the machine operation will commence T 91 KTS TS Pie Sper igei Go Men Cp As each component part of the formulation is dispensed the software will control the ink valve as described in 3 6 When the dispense is complete the dispense screen will clear and the container of blended ink can be removed from the scale unit If the software has been configured to allocate the ink to stock a box will appear and the allocation can be confirmed IDS HP25 24 November 2007 val amp tech 4 Hardware Settings Ink Manager requires setting up to work with a particular machine and its requ
17. hieved by placing a spirit level on all four corners and also across the frame Adjustment to the height of the IDS HP25 is done by adjusting each of the corner feet up or down as necessary 1 3 Connecting Electrical Supply Connect mains electrical power rated at either 115V or 230V 50 60 Hz to the UPS Uninterruptible Power Supply as illustrated or inlet power socket mains input if no UPS is fitted This is located inside the machine on the right side and indicated as POWER Removal of side panel is required for access to these connections Power to PC Main electrical power supply from UPS to machine UPS Mains electrical power supply to UPS IDS HP25 9 November 2007 val amp tech 1 4 Connecting Air Supply Connect an airline from an external filtered clean dry regulated air supply to the air input connector This is located on the air manifold assembly within the left side of the IDS HP25 The air is connected via the quick fit air coupling supplied by Vale Tech and requires 8mm hard walled hose for the push fitting Alternatively the air supply can also be fitted using soft wall hose and a Jubilee Clip Use Imp 2 bore or Met 12 70mm Imp 24 or Met 19 20mm o d air hose Air input connection Quick fit Air Coupling IDS HP25 November 2007 1 5 Connecting the PC Connect the Keyboard and Monitor cables to the appropriate ports on the back of the PC refer to the configuration data in the serv
18. ice section Now connect network printer scanner and telephone modem connections to the PC if additionally required Note Before powering on the PC Please ensure that its Power Supply Unit is set to the correct mains power voltage either 115V or 230V Full range PSU s are auto switching 115 230V 2 IDS HP25 Start Up Procedure 2 1 Switching On IDS HP25 Before switching on the PC or IDS HP25 machine make sure that the Ink containers initially have their air valves turned OFF Now switch on the IDS HP25 by turning the mains ON OFF isolator switch on the lower right side of the machine CLOCKWISE to the ON position Now turn on the PC and the monitor The PC is located at the lower right side at the front of the machine and the power button is accessible through the open panel At this point the red light on the beacon will be illuminated and the alarm will be sounding 2 2 Log on and Dispenser Initialisation Once the PC has powered up launch the Ink Manager Software program and log on If there are no user accounts create these by logging on as administrator password supplied separately P N U K d Ink anager Va Le LEeCcH InEMamages IDS HP25 11 November 2007 val amp tech Log on and Dispenser Initialisation cont When Ink Manager opens a formulation list will appear on screen The machine requires a reset to be carried out as follows Highlight Options Dispenser Reset
19. irements From the drop down menu select Options Settings General and the following screen will appear To configure the various fields refer to the Hardware Set Up in the Ink Manager Training Section Database Users Weights and Measures Defaults Visual Preferences Dispenser Type CAN Manual Blending Hardware Manual Balance Port CO M1 Manual Balance Type Vale MkII V1 11 and above Dispensing Hardware Balance Port CO M1 Balance Type Vale Mill V1 11 and above ser Dispenser Port COM2 Queuer Hardware Queuer Port CO M3 Bar code Hardware Default Label Printer Not installed _ Second Label Printer Not installed Label Scanner Port COM4 To configure the ports which the various items of hardware are connected into and which type of balance is being used please refer to the Hardware Configuration information in the Service section of this manual for settings Note Hardware settings should only be changed by authorised personnel engineers IDS HP25 25 November 2007 5 Safety Features The IDS HP25 dispensing machine incorporates safety features which work to prevent any potential injury or harm to the user or to the machine The safety features must not be tampered with When handling ink and lacquer products for use in conjunction with the IDS HP25 suitable protective equipment must be used Use latex or similar gloves eye protection suitable safety shoes
20. is good first then adjust gauges to specified pressures Check for air leaks Check and clean gaskets and lids all sealing surfaces must be clear of ink or contaminants Check lid is securely closed Check air in lines are secure push firmly into container vent finger valves Require engineer adjustment or replacement Check lid is closed and air is turned on Turn all containers off and then turn each container on individually allowing each container to pressurise before next is turned on Check flow rates set in dispenser Setup have not been set too low Call Vale Tech Technical Support Close any doors with sensor switches Release Emergency Stop switch Faulty switch call Support Call Vale Tech Technical Support 53 val tech Ink Levels are incorrect Balance errors Balance carriageway will not move Green Mains power indicator bulb is no longer lit on the front panel One or more of the beacon Red Amber Green bulbs are no longer lit Warning message Feed rate too slow always appears during a dispense My machine problem is not listed here what do I do now IDS HP25 November 2007 The ink level sensors are not reading or are reading incorrectly Ink level sensors appear to be reading incorrect full or empty levels There is no weight output or the weight shown is incorrect Machine resets ok but balance carriageway will not move
21. is not follow the calibration procedure If it is determined that the scale requires re calibration log on to Ink Manger and ensure the scale calibration privileges are available by selecting Options Scale Calibration from the drop down menu If this option is not available see your system manager log in details The following screen will be displayed Calibrator T eX Information al Scale Range Average Value version 1 11 status se range speed Full scale A0 40 zero 034049 Filter S EFFFF serial 4655 ro average This is the basic scale programming information stored on the scale board that Vale Tech Service may ask for if there are problems calibrating the scale Check the scale range is correct The example above shows a 10Kg range Scale Board The average setting should be 02 on all scales IDS HP25 32 November 2007 scale Calibration cont Click OK and the following screen is displayed Calibrator Calibration j Cancel Click OK and the following screen is displayed Calibrator 1 Press Tare 2 Place 10g on the balance and note the final value 3 Remove 10 g weight 4 Remove pot locator plate and tare plate if fitted 5 Press Nest Tare Next Cancel 183 5 Above is the Calibrator screen showing current weight and instructions on creating pre calibration figu
22. ispense stage is as follows and for the example the dispense ink quantity is 200g Stage 1 Is Active or enabled Coarse feed valve continuous dispense From 200g down to the Completion Weight of 100g Total of 100g of ink dispensed into the supply container Stage 2 Is Active or enabled Coarse feed valve will pulse open for 100 milliseconds before closing and dispense at a target flow rate of 5grams second The target flow rate should be adjusted in increments of 10 if the target rate is difficult to achieve if the dispense time is taking too long for example Now down to the new Completion Weight of 20g Total of 180g of Ink dispensed into the container Stage 3 Is Active or enabled Fine feed valve continuous dispense Now down to the new Completion Weight of 10g Total of 190g of Ink dispensed into the container Stage 4 Is Active or enabled Fine feed valve will pulse open for 60 milliseconds before closing and dispense at a target flow rate of 0 3grams second Now down to the new Completion Rate of 0 3g This allows for the ink tail which may form at the outlet of the dispensing valve to be included For thicker inks this can be increased and for thin inks this canbe zero 0g Total of 200g of Ink dispensed into the container WARNING IF STAGE 1 IS DISABLED THEN THE IDS HP25 WILL NOT DISPENSE ANY OTHER STAGES Note Container Type The IDS HP25 uses a pressurised container with the
23. l Probe Assy MKII SP 9233 Ink Level Digitiser IDS SP 9410 3 Jack Plug amp Lead SP 9412 IO IDS HP25 November 2007 val amp tech 9 Parts List IDS HP25 Machine User Parts List Page Item D M M M M M M M M M M N Q CO CO CO G G G G G G G G GO GO CD WW W o NOOA M M GO GO N OO O1 E ND GO MN O O1 O1 O1 O1 BB BR ND wk h G M k wo 14 Description Power on Indicator Power Indicator Bulb Emergency Stop Button Red Amber Green Colour Beacon Beacon Bulb Monitor 15 TFT Keyboard with Tracker ball PS2 Keyboard Cover Door Isolating Switch Reed amp Magnet Front Door Handle Levelling Foot Mains power Isolator Switch Quick Release Lid 1 Bar Lid Gasket Pot Vent Valve 8 mm Level Sensor Probe Hose Clip Dispense Valve 12 3DA BKT 1B 1 Htail Coarse Feed anti drip assembly Ink Delivery Hose Specify Pot Number Baffle Plate 25 Litre Ink Reservoir Ex Lid Ink Level Probe Digitiser Ink Level Probe Digitiser Lead Main Controller Board 1014 Stepper Motor Controller Async Safety Piltz Relay Fuse Board 110 240 Switch 1015 Fuse 20mm 8 Amp Fuse 20mm 5 Amp Linear Power Supply LPS LPS Toroid Transformer LPS Capacitor LPS Rectifier Switch Mode Power Supply Air Control Box Complete Rex 3 Way Pilot Valve Manifold Rex Pot Pressure Regulator amp 1Bar Gauge Rex Air Input Pressure Switch Rex
24. lems that occur with the machine It is located to the left of the Airbox assembly The alarm volume and tone can be adjusted via settings within the sounder For volume adjustment a screw can be found on the underside and by turning this either way the volume can be decreased or increased accordingly For tone adjustment a series of switches which can be placed in various position combinations alter the tone Note It is important that before any adjustment is made the user is reminded that the sounder is a safety feature that must be audible above the ambient noise of the workplace Tone adjustment Sounder Sounder underside top Volume adjustment IDS HP25 27 November 2007 i tec arn 6 Ink Supply Container 6 1 Ink Supply Container lids The supply container lid provides a pressure seal for the container via the gasket To remove a lid turn the air regulator for the container which is to be opened to the OFF position This allows the container to fully vent de pressurise When the pressure has reduced to enable the lid to be removed lift the lid handle allow the lid to drop slightly from its location tip and turn 90 degrees then lift to remove from the ink supply container Ink Supply Container lid Top Ink Supply Container lid witl gasket removed To replace the lid ensure the gasket is clean and securely seated in position Reverse the removal process to place the lid in position Switch the air valve t
25. lve Calibration Container Type Targets El Tar Initia S s Coarse Pulsed Target Flow Period Completion Pressout Stage 1 M T wW Switched Pump Stage2 v v W B 100 M 20 Level Sensor Stage Stage4 l lw 10 Disable Level 03h 60 M 01 Capacitive Stages E E Switch Stage W Calibrate Main Tank Levels Board ID Input Cylinder Up switch nm Cylinder Up frdlay Cylinder Down switch Cylinder Down relay Level Input oo Dispense Valva o Header Tank Vent Valve ic 3 Recirc Agitate Valve Pump Control Drip Wipe Index Coarse pulsed feed Fine pulsed feed By ticking Active this opens a dispense stage If the Coarse or Pulsed options are not selected the ink valve will only dispense from the fine feed outlet Active Coarse this opens the valve to dispense to the Completion preset value of that stage from the coarse feed outlet Active Coarse Pulsed this Pulses the coarse feed to the Completion preset value of that stage at the preset Target Flow rate Active and Pulsed this Pulses the fine feed to the Completion preset value of that Stage at the preset Target Flow rate IDS HP25 21 November 2007 val tech How does the Ink Valve function during a dispense cont The dispense example uses 4 stages to complete the process the break down of each d
26. mber 2007 val tech Daypenjuyr Soie Varne Setting Ink Levels cont Valve Configuration M Ca M M L gi Calibrate Main Tank Levels T Calibrate bead Tank Levels Controller IE Laval Sarsan fe Cranial SIT Or LUN J I Set Empty Indicatio Set Full Indication Note The live value in the boxes Set Empty Indication and Set Full Indication will be recorded into the selected container number into either the full or empty points depending on which button is clicked Therefore it is important to go through the filling of the ink containers and the setting of the low and high level procedure in the correct sequence If the Set Full button is clicked before the container is filled the value indicated will be stored as the full value If the Set Empty button is clicked when the ink container is full the machine will not dispense even though the container is full This is due to the software interpreting the signal sent from the Level Sensor Probe indicating that the container requires re filling IDS HP25 18 November 2007 val tech 3 3 Setting Ink Levels cont The Weight field is optional This will allow a check of approximately how much ink by weight is in a particular container at any time To set this feature select Options Dispenser Ink Level Configuration and enter the quantity of ink by weight which was used to fill the container between the em
27. o the ON position and as it pressurises check for correct seating of the lid and for air leakage IDS HP25 28 November 2007 val amp tech 6 2 Supply Container and Valve Air Regulator Adjustment The air supply enters the left side cabinet of the IDS HP25 through a filter The first air pressure regulator controls the air supply to the ink valve actuators with a pressure of 6bar and the second air pressure regulator controls the air supply to the ink container regulators with a pressure of 5 5 bar Air supply to ink containers Air supply to actuators Incoming air supply Incoming air Ink container air regulator Set to 6bar pressure valve Set to 5 5bar IDS HP25 29 November 2007 7 Balance Assembly 7 1 Using the balance Open the front door of the IDS HP25 and lift UP the handle Pull the balance out SLOWLY Place the correct locator plate on the balance The locator plate is required to ensure the container is positioned in the centre of the balance and secured firmly before the dispense process begins The balance and the locator plates are manufactured to suit customer specific container dimensions and weight requirements The locator assembles are keyed to only fit firmly in one position Ensure the locator plate is the correct size for the blend container to be used Adjustments can be made by re positioning the pins in the drilled slots in the upper locator plate All three must be positioned to keep the
28. p Switch 5 4 Alarm Sounder Ink supply container 6 1 Ink Supply Container Lids 6 2 Supply Container and Valve Air Regulator Adjustment Balance Assembly 7 1 Using the Balance 7 2 Overweigh Protection 7 3 Scale Calibration Cleaning amp Maintenance 8 1 Dispense Valve Assembly 8 2 Carriage Assembly 8 3 Ink Supply Container amp Valve November 2007 25 26 26 26 2 7 27 28 28 29 30 31 31 31 39 39 40 41 val tech Vale Tech IDS HP25 SERVICE MANUAL 9 Spare Parts 9 1 External Parts 9 2 Ink Supply Container and Valve 9 3 Pneumatics and Electronics 9 4 Carriage Assembly 9 5 Dispense Valve 9 6 Ink Level Sensor 9 7 Parts List 10 Preventative Maintenance Programme 11 Trouble shooting Guide 11 1 Common Problems 12 PC Hardware Configuration 13 Ink Manager Hardware Configuration 14 Drawings TRAINING MANUAL 15 Ink Manager Software SERVICE LOG 16 Introduction 16 1 Contact Information 17 service History 17 1 Machine Fault Maintenance Log IDS HP25 November 2007 42 43 43 44 45 46 47 48 49 51 52 52 55 56 57 58 59 60 61 61 62 62 e ba val amp tech Declaration of Conformity amp Quality Vale Tech Limited Hereby Declares That Machine Project Is in conformity with the provisions of the machinery directives as listed below The Machinery Directive 98 37 EC Machinery is descri
29. ption for each ink to be used must be allocated to each of the supply containers to be filled The corresponding ink will be put into the container later when filling commences Complete the Ink Reference names in the space provided below some machines may have a pre determined list setting out which ink should be placed in which supply container In this case this information will be supplied in conjunction with this manual or obtained from the distribution agent Container Series Reference Colour 1 sn 2 nn FN o 2 P NL IIT am 21 N X 24 Extension 3 N Z Ke d D 4 Sy B Vo pm N 18 E N 4 Pot 6 iv N i KL J 20 Extension x e Th 7 4 K ie En 14 15 m 9 L N F Sn z ne iot 10 un F a EN wx f g 10 a GN 11 IX OU OZ S 12 E N re Main Unit d 6 7 L F i 13 T Y N 14 IR ser l SON e HH a aa en 15 ia l 2 3 af N y a s A 17 Front 18 19 20 21 22 23 24 IDS HP25 14 November 2007 valtech 3 2 Loading Ink WARNING NEVER TRY TO REMOVE A SUPPLY CONTAINER LID WHILST UNDER PRESSURE Turn the air valve for the container which is to be refilled to the OFF position This allows the container to fully vent de pressurise When the pressure has reduced to enable the lid to be removed lift the lid handle allow the lid to drop slightly from i
30. pty and full points into the Weight box of the appropriate ink container To view the levels of each of the inks within Dispenser IDS HP25 Level Sensor Configuration Current Level Empty Point Full Point TI G r 4 E 0 5 H b s L TI AALL TT Cancel Ink Levels Supply container Levels INE INK2 INKS INK 4 INES INKE INK INKS INKS INK10 INKETT INKET2 LD om Mm MA Se og Mi me hi C November 2007 TI il AHL TI J LL C Weight Disabled xl X x XI XX X lt XI X 4 0 LOS D Kas 450 Kas 480 Kas S Kgs Kgs 20 Kas 40 Kas Ege Kgs 160 KOS Kgs Curent Level LUI TI LI I Co Empty Point Full Point J U Ta TI 1 Ii J i mm es Set Empty FG Set Full F7 Weight Disabled 4 xI x X lt x the supply containers select Options INK13 INK 4 INK1E INETE INET 7 INET18 Cantainer18 Container Cantainer20 Caontainer21 Caontainer22 Container23 10 0 Kgs Kgs 0 0 Kgs 000 ke 00 kos 00 Kgs GS ka Na 0 0 Kas OG Kg OG LOS Kegs OL Kas 19 val amp tech 3 4 Valve Configuration To allocate settings to each ink container open the Valve Configuration settings Select Options Dispenser Valve Configuration from the drop down menu in Ink Manager Each container has its own
31. r Motor Controller SP 9022 3 Saftey Piltz Relay SP 9007 4 Fuse Board SP 9023 Fuse 20mm 8Amp SP 9125 20mm 5Amp SP 9124 5 Linear Power Supply SP 9120 LPS Toroid Transformer SP 9077 LPS Capacitor SP 9078 LPS Rectifier SP9079 12 Main Vent dump Solenoid Valve SP 9806 11 Main Incoming Air Supply 5 Bar SP 9805 45 val tech 9 4 Carriage Assembly 13 High pressure 1 12 dispense hose l Di SP 9469 88 10 Roller switch Ja 15 Dispense valve Senen Bes Stepper motor roller switch SP 9635 9207 14 SP 9260 SP 9634 Motor drive gearbox SP 9261 9 Pot sensor N a reflector tape a SP 9408 So er vette Pa KE COUPIIN 8 Dar Va Sn G SP 9262 Home position proximity switch 7 Universal pot U locator ela Pot sensor SP 9310 T 2 SP 9411 K AE 9 Flexible chain lt assembly SP 9076 3 Carriage caster SP 9327 Carriage 4 6 slides pair Balance lock micro Scale assembly SP 9627 sm 10kg 2 SP 9109 SP 9159 Balance locking 18 handle scale assembly e assembly SP 9316 comms power lead Note Drip g L SP 9158 SP 9678 wipe assembly not shown IDS HP25 46 November 2007 9 5 Dispense Valve IDS HP25 November 2007 2 1 BARB 3 BSP M Actuator x2 Assy Inc AKD Assy SP 9116 Sub Assy Bellows SP 9175 Air Piston SP 9114 47 valdtech 9 6 Level Sensor 1 Connector Block IDS SP 9410 4 Leve
32. r Stage3 w a L a3 10 Disable Level E Stage4 iw a w 03N afl ot Capacitive Stages L a i mH Switch staget Fo fF i gj 8 Calibrate Main Tank Levels Board ID Input Board ID Output Cylinder Up switch Cylinder Up rgia poo Cylinder Down switch 1 Cylinder Down felay 1 Level Input Do DD Dispense Valve D o nm Header Tank Vent Valve Enabled 5 i ader IE Recirc Agitate Valve DX oo z sep md Fump Control B 4 mg gd ove Ou Drip Wipe Index 0 JJ Ra a m The required speed of The length of time measured The weight remaining to be dispense when the valve is in milliseconds that the valve is dispensed at which this pulsing in gms second open when it begins to pulse stage ends IDS HP25 20 November 2007 val amp tech 3 5 How does the Ink Valve function during a dispense The ink valve is controlled by the Ink Manager Software to open allowing the flow of ink through the large outlet coarse feed and small outlet fine feed Both coarse and fine feeds can be set to complete the end of their dispense operations by pulsing the flow to reach the desired quantity The feed profiles are activated by setting parameters in the Ink Manager software causing the valve to achieve it s pre determined operation Coarse constant feed Fine constant feed Supply Container 1 Supply Container 2 Supply Container 3 Supply Container 4 Supply Container 5 S pply Container 6 Name link 1 Va
33. res which will be required for the purpose of completing a calibration certificate If it has been established that the scale is not out of calibration then recalibration is not required and cancellation of the procedure can be achieved at this point If calibration is required clicking on Next will start the calibration procedure which is irreversible Ensure the required conformance or calibration weights are available along with the Light Weigh Pan as shown IDS HP25 33 November 2007 Scale Calibration cont If the calibration is to take place now before clicking on Next remove the Universal Container Locator the 5kg Container Locator and the Weigh Pan as shown Place the Light Weigh Pan squarely on the Internal Weigh Pan with the balance locked in the home position as shown IDS HP25 34 November 2007 Scale Calibration cont Click Next and the calibration procedure begins The procedure allows the scale to settle before the reading is taken Avoid vibrations draughts and touching the scale during this time The blue progress bar indicates the stage of the procedure Calibrator Information Allowing balance to settle Wait ES reg When the scale has finished recording the Zero value the following screen is displayed IDS HP25 35 November 2007 ua Fi Scale Calibration cont Calibrator Information Calibration Es _ Place 9kg of conformance or
34. robe and ink level indication within the ink container To set the ink levels select Options Dispenser Valve Configuration from the drop down menu in Ink Manager Once this page opens click on Calibrate Main Tank Levels to open the setting up option The diagram below shows the ink level probe and ink level indication within the ink container To begin setting the ink levels ensure the correct colour ink from the Setting Ink Names list in 3 1 is selected and pour in enough ink to cover approx 1inch 25mm above the bottom of the level sensor probe in the container Level Full point Sensor Empty Point IDS HP25 16 November 2007 val tech Dayreniuyr Soie borane Setting Ink Levels cont Select Set Empty button to set the empty level for this colour The numerical value for this will be recorded in the box above Set Empty button This ensures that the container will show the empty point BEFORE the ink reaches the bottom as previously explained il Y d ai a aire Man Tant Le Vil LL Ma P N Continue to fill the container to a maximum level of 1 2 Inch 12mm below the bend at top of the probe When this is done click the Set Full button The numerical value for this will be recorded in the box above the Set Full button The value shown in the box for the full level should be smaller than the value of the empty point level IDS HP25 17 Nove
35. st in fault finding in the unlikely event of the product developing a fault Full Ink Manager Software training is provided within the Training Manual to ensure that the user can feel confident with the machine operation The Service Log at the back of this manual serves to provide contact information Should additional assistance be required please refer to the contact details supplied within this section Forms available in this section allow the service history of the machine to be recorded for future reference IDS HP25 2 November 2007 valetech Vale Tech IDS HP25 Introduction Contents Certificate of Conformity 1 Installation 1 1 Pre Install Information 1 1 1 Services Connection Requirements 1 2 Positioning of Machine 1 3 Connecting Electrical Supply 1 4 Connecting Air Supply 1 5 Connecting the PC 2 IDS Start Up Procedure 2 1 Switching On IDS 2 2 Log on and Dispenser Initialisation 2 3 IDS Beacon Warning Indicator 3 IDS Ink Set Up 3 1 Setting Ink Names 3 2 Loading Ink 3 3 Setting Ink Levels 3 4 Valve Configuration 3 5 How does the Ink Valve function during a dispense 3 6 What happens if the same Ink is used in more than one of the ink supply containers 3 Dispensing Ink IDS HP25 November 2007 10 11 11 11 11 13 14 14 15 16 20 21 23 23 val tech IDS HD25 Vale Tech IDS HP25 Hardware Settings Safety Features 5 1 lsolator Switch 5 2 Door Switch 5 3 Emergency Sto
36. td direct on Office 44 0 1638 668593 Fax 44 0 1638 676720 Email technical suoport vale tech co uk 54 val amp tech 12 PC Hardware Configuration The following information is recorded during the final quality control checks and reflects the PC configuration prior to shipping Any changes made to the configuration after this may not be recorded This record may provide essential information in restoring system operation in the event of system failure Please do not remove it from this folder IDS HP25 November 2007 59 val amp tech 13 Ink Manager Hardware Configuration The following information is recorded during the final quality control checks and reflects the Ink Manager Hardware configuration prior to shipping Any changes made to the configuration after this may not be recorded This record may provide essential information in restoring system operation in the event of system failure Please do not remove it from this folder IDS HP25 56 November 2007 val tech 14 Drawings The following drawings are provided for use by plant engineers authorised service engineers to assist in the servicing of the IDS HP25 and for diagnostic purposes Electrical Main Circuit Diagram Lead 1 Lead 2 Lead 3 Lead 4 Lead 5 Pneumatic Circuit Diagram 1 Circuit Diagram 2 Circuit Diagram 3 Dependant upon machine specification IDS HP25 57 November 2007 TRAINING MANUAL valestech 15 Ink Manager Software
37. tity greater than the capacity of the container on the locator plate a warning will be shown on the screen giving the operator the following choice a Please reduce the batch size b Please increase the container size 7 3 Scale Calibration For the purpose of this example of the procedure a 10kg scale is to be calibrated using 9kg of test weights All Vale Tech scale systems calibrate at zero and then 90 of the full scale capacity For larger capacities using this principle a 30kg scale calibrates at zero and then 27kg and an 80kg scale calibrates at zero and then 72Kg IDS HP25 31 November 2007 valetech Scale Calibration cont Always check the scale accuracy by selecting Show Scales from the drop down menu in Ink Manager and checking accuracy with a known weight before running the Scale Calibration option Always allow the scale to stabilise for 30mins before checking the calibration Select Show Scales and allow the scale to tare If a small amount of fluctuation is seen this can be reset by clicking on Tare Scales If the scale value continues to climb or fall check for touch down of the scale and start again If there is no touch down and the scale will not stabilise contact Vale Tech for further advice Place known weights on to the scale weigh pan conformance weights supplied with the machine and verify the scale is within the allowed tolerance If it is calibration is not required If it
38. ts location tip and turn 90 degrees and lift to remove from the ink supply container Each IDS HP25 ink container is pressure tested using water prior to shipment and so any residual moisture should be fully removed before each container is filled with ink Before loading ink it may be advisable to clean out the containers with an alcohol isopropranol solution taking care not to move or damage the level sensor probes attached to the side of the container IDS HP25 15 November 2007 val amp tech 3 3 Setting Ink Levels Ink level sensing is achieved by monitoring the levels in the individual containers using a probe mounted on the inside of each container The probe comprises 2 insulated steel rods spaced 20mm apart One side is electrically isolated from the container The probe is mounted vertically inside the container with the end of the probe as close to the bottom of the container as possible The way in which the low level value is set ensures that the container empty point registers prior to the container actually becoming empty This eliminates air being drawn through to the dispense valve and ink spitting from the valve which may happen if the container was to actually become completely empty The high level value is set with the ink below the top of the level sensor probe keeping the ink away from the lid and its sealing gasket and well below the container air pressure inlet Figure 10 shows the diagram of the ink level p
39. val tech Ospensing Solutions Worldwide Ink Dispensing System IDS HP25 User Manual VALE TECH LIMITED Unit 12 Depot Road Newmarket Suffolk CB8 OAL UK Tel 44 0 1638 668583 668593 Fax 44 0 1638 676720 E mail sal vale tech co uk GE ail sales vale tech co u November 2007 val amp tech Introduction This User Manual provides the user with a comprehensive guide to the machine The machine may be configured with 16 20 or 24 ink containers each with a maximum capacity of 25kg This comprises 16 containers within the main machine frame with an extension for each 4 additional containers The scale container ranges are 5kg accommodating 1kg 2 5kg and 5kg containers or 30kg accommodating 5kg 10kg and 25kg containers The User Manual identifies the requirements for the initial installation of the machine and continues to provide information for the effective operation of the machine on a day to day basis including maintenance to ensure a high standard of ink dispensing can be consistently achieved The Service section of this manual enables the user to identify any spare parts that may need to be ordered for the machine This product has been manufactured to the highest standards however should any difficulties arise before requesting technical support a speedier resolution can usually be reached by referring to the trouble shooting guide within this section A full set of drawings is also provided to assi
40. wn If the scale is within specification at each of the calibration points click Done Calibration is complete If calibrator screen indicates the weight incorrectly click Done to close the current window and repeat the calibration procedure If repeating the procedure does not achieve the desired results please contact Vale Tech Technical Support IDS HP25 38 November 2007 val amp tech 8 Cleaning amp Maintenance 8 1 Dispense Valve Assembly Check for damage to pipes Check for leaks between fittings and valve assembly Check dispense valve air pipes are free from Check ink leaks container location sensors are clean Check Carriage stop switch is secure Check belt for IDS HP25 damage and ink m November 2007 contamination val amp tech Carriage Assembly cont Ensure castor is clean and free running IDS HP25 November 2007 Check flexi chain IS not damaged and track IS clean Ensure guide rail is clean 40 8 3 Ink Supply Container amp Valve 1 aa aG es Y 5 mn s In 10 b I l H 4 7 D 9 oe b F L Ea m FEE 1 eha RAR Ne TA p QI 7 Ensure container lid and gasket are clean and free from ink and contamination Check for air leaks around lid Check sensor connector cable Check level probe is not damaged Check air lines for leaks Check dispense valve is clean and leak free Check that
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