Operator manual - ALE
Contents
1. 450 50 Fig 6 Coral 144 front dimensions Corall 44 Operator Manual 3 ALE Design Print Trace 03 12 2010 dx MM5x 16mm mounting points _ as o0 ae Jacon 225 00 Fig 7 Coral 144 bottom dimensions with M5 mounting points 1 4 Alarm LEDs There are eight red alarm LEDs on top of the print head Each one corresponds to an ink bottle See 1 2 for numbering It starts blinking when the level of ink is too low in the corresponding reservoir which means that the bottle of ink is empty Replace it by following the steps described in 3 1 Ink bottle replacement After a configured number of prints if the ink level is still low in the reservoir the controller stops the printing to avoid defective printings See the controller manual for information on configuring the number of prints after the ink low signal When the ink low is detected the print head sends an alarm signal to the controller which can transfer it to an external device such as a PLC See controller manual for details 2 Start Up 2 1 On line installation Corall 44 Operator Manual 4 ALE Design Print Trace 03 12 2010 2 1 1 Definingthe position of the system After unpacking the printer and checking that the contents correspond to your order and to the delivery note the first operation will be to set the position of the print head on the conveyor The correct print head position can be determined using Codex and its 3D c2. ALE Design Print Trace 03 12 2010 To prime the system proceed as follows e Fromthe print menu Press the Purge key It leads to the Purge Menu Fig 17 aa 2 E Test Message MT x bi 7 Ta Ya 7 is n 5 PALF A E A DO i i i ri Ri AE ll SERIES MRE 21 SOFT WORE 4434 2705 i31 Ti anne MR T 14 20 A 4 D3 DEC 2 010 10 52 41 i GPT eel IM rect Mi we Tee TER if 250mn s DENSITY 1 WIOTH 004 18 Seral KPAD 0 2345 87830 Txt Fig 17 Master Series prime menu access This menu offers 3 options Jet primes the circuit at high pressure Test prints with all nozzles Norm primes the circuit at low pressure e Each print head has to be primed independently e To ink up the circuit from dry the Jet prime is used first Fig 18 Fig 18 MasterPad prime menu e Press amp You should hear the pump load the whirring noise slows down when the pumps fills in with ink Repeat this operation until ink jets out of the print engine A WARNING The pump pressure in inking up mode is maximum and ink will jet out e Prime once more using the Jet function to remove air from the ink circuit Prime at least once using the Normal Prime function This is done to remove the remaining air bubbles from the circuit e Carefully wipe excess ink off Fig 19 Do not touch the nozzle plate it is coated with a special non wetting coating which is self cleaning Corall 44
3. Operator Manual 10 ALE Design Print Trace 03 12 2010 a Fig 19 Carefully and gently wipe the excess ink e Check that all dots are operating prepare a sheet of paper Then in the Purge Menu press blackpad i whilst moving the sheet of paper in front of the print head This function prints a solid rectangle of either heads 1 to 4 or 5 to 8 with no white lines across Otherwise prime again using the Normal Prime option and a bucket Fig 13 and check again if all dots are operating e When the printing is correct on all print heads the collecting bucket can be removed Fig 13 carefully clean the print head Fig 19 Exit the Purge menu of the controller E Set the system for printing back on your production line To make a test print Hold a piece of paper in front of the print head Briefly press Test Print and simultaneously pass the piece of paper across right to left The result should be similar to Fig 20 STATES IME SOP TRARRE I WES 05 151 E Aen BOPLLA At 14 214 16 2 03 0E0 20 0 11 18 22 7 5008 DENSITY 1 WIOTH 00 lb Serial P4D0 012345 57880 Fig 20 Test message Corall 44 Operator Manual 11 ALE Design Print Trace 03 12 2010 2 3 Print heads alignment Once the printer is inked it is important to adjust the print engines with respect to each other to get a perfect print The x parameter is horizontal Its value can be changed freely the y is v
4. products In the interests of safety read the Material Safety Data Sheets carefully before handling the fluids Always wear protective gloves and eye protection when in contact with any inks or solvents The Coral 144 S has been specially built to be used with ALE Solvant colour inks Using any other fluid is likely to severely damage the hydraulic system Corall 44 Operator Manual 8 ALE Design Print Trace 03 12 2010 e Fitting a bottle of ink into the reservoir Using a craft knife or a sharp blade cut the round raised plastic dome on the top of the ink bottle cap Fig 14 Turn the bottle up side down and push into the reservoir Fig 15 po Y al Fig 14 Cutting the plastic cap of the ink bottle Fig 15 fitting a bottle e Switch the controller on From this moment the LCD screen will run through the start up procedure The controller is ready when the red LED goes off The default language is English on all new machines To change the language please report to the controller s user manual e The controller needs to be adjusted to the print head To do this the Setup Wizard is used It can be accessed from the controller s main screen Fig 16 Follow the steps of the Setup Wizard for basic configuration Please report to the controller s user manual for more information Fig 16 MasterPad main screen access to setup wizard Then the ink system needs to be purged of air Corall 44 Operator Manual 9
5. user manual Corall 44 Operator Manual 14
6. ALE DESIGN e PRINT e TRACE OPERATOR MANUAL ALE Design Print Trace 03 12 2010 Disclaimer This manual contains instructions for operating the ALE Coral 140 printer Read it carefully before performing any manipulation All service operations should be undertaken by qualified personnel only Contact us if you need training for our equipment All information written in this Operator Manual was correct at the time indicated in the version table below However the continual enhancement of our products may result in some differences existing between the information contained in this document and your equipment Copyright 2010 ALE Sarl all rights reserved Reproducing this manual in whole or part without permission is expressly prohibited RiX and TraceX are registered trademarks of ALE sarl AII trademarks in this document belong to their respective owners Version history Date Revision Modifications Author 03 12 10 First version Only solvant version AF Coral 144 Operator Manual ALE Design Print Trace 03 12 2010 Contents Disclaimer Contents Notes 1 Description 1 1 Print head description 1 2 Numbering 1 3 Dimensions 1 4 Alarm LEDs 2 Start Up 2 1 On line installation 2 1 1 Defining the position of the system 2 1 2 Installing the system along the conveyor 2 1 3 Photocell installation 2 1 4 Encoder installation 2 2 Ink
7. apabilities Fig 8 Please refer to the Codex manual for details il EZi Codex File1 OFFLINE 2 JU 8 File Edit View Window Object Connect Help la x 08 49 aleja xla ala Ql ae le e Codex Image001 3 Image002 New E Global Settings E Printer 1x72mm80pL H Label Size Auto FE Invert NO Reverse NO DIO i En Continuous Print OFF Line Speed 250mm sec Fixed Photocell Position 15mm ie B Photocell Detection NORMAL ture Invert All Print NO an Ink Low Time out 100 prints Prag Density 1 default HH Shift Code 00 00 8 hours A Z withor i Download size unknown double click to 1 Controller OFFLINE TraceX dongle leve 4 For Help press Fl READY Print Count 249 78 Fig 8 CodeX 3D view with a 72mm print head You must know that the system must be adjusted so that the surfaces to be printed don t touch the print head and are at a maximum distance of 3mm Fig 9 max 3mm Fig 9 Maximum printing distance 3mm Evaluate then set precisely the product distance several times before inking up the printer and printing messages We strongly recommend fitting product guide rails Corall 44 Operator Manual 5 ALE Design Print Trace 03 12 2010 Don t hesitate to contact your distributor in case you have any questions regarding the position of the printer 2 1 2 Installing the system along the conveyor Once the corre
8. ct position of the printer is theoretically determined take the S062 squares out of the box Fig 10 and TTT screw them in the desired position along the conveyor onto a stable independent floor stand Screw the Coral 144 print head to S062s using the M5 holes under the print head enclosure see also packing list The Coral 144 should be fixed with at least 4 sets of M5x16mm screws Fig 10 SO62 Square Due to the risk of vibration it is not recommended to fix the printer directly onto the conveyor Install the controller and connect it to the print head using the supplied IEEE 394 cables but do not power on When the final position of the print head along the conveyor is determined the next step is to ink up the Coral print head as it is shipped dry see next chapter 2 1 3 Photocell installation Install the supplied photocell close to but before the print head This will detect the product just before it passes the print head nozzles Fig 11 Corall 44 Operator Manual 6 ALE Design Print Trace 03 12 2010 Fig 11 Photocell position When installing the photocell ensure that the detection is not confused by reflections or by poor light or colour contrast The two LED lights on the photocell should only light once as it detects the passage of the product If this is not the case adjust the sensitivity by rotating the little screw either left or right see
9. ertical For physical reason it can be adjusted between 1 and 1 The Setup Wizard contains 2 screens to do all the alignments Inter Head Align Fig 21 a screen to adjust between colours It allows to adjust between blue and red for example q Head 1 00 e Y 0 98mm Xx o 000in Y 0 039in Fig 21 i Wizard Inter head Align screen for head 1 Cyan Print engine Align Fig 22 a screen to make adjustments between 2 print engines of the same colour For example if a white line appears in the middle of the print height for the magenta colour then the y value for Print Engine Align Head 2 should be decreased F6 Engine Align Head 1 0 00 0 00 0 00mmi 0 98 0 96 0 98mm X 0 00mm Y 0 98mm x 0 000in Y 0 039in Ep TEST A PRINT Fig 22 Setup Wizard print engine Align screen fro head Cyan Corall 44 Operator Manual 12 ALE Design Print Trace 03 12 2010 3 Printer operation 3 1 Ink bottle replacement While the printer is in operation it is necessary to replace the empty ink bottles before the internal reservoirs go empty as well The printer reservoirs have an optical ink low detection mechanism which will sending warnings just before the reservoirs become empty it will turn on the red LEDs on top of the printer and send an ink low signal to the controller After a configured number of prints if the ink level is still low in the reservoir the controller stop
10. ing up for the first time from dry 2 3 Print heads alignment 3 Printer operation 3 1 Ink bottle replacement 3 2 Printer service 4 Controller usage 4 1 Change parameters 4 2 Make a message N A DW uw A A LHR W 13 13 13 13 13 14 Coral 144 Operator Manual ALE Design Print Trace 03 12 2010 Notes Coral 144 Operator Manual iii ALE Design Print Trace 03 12 2010 1 Description 1 1 Print head description Features 142mm print band Cyan Magenta Yellow and Black colours CMYK print forward only uses ALE 250mL ink bottles 304 Stainless steel enclosure IEEEI394 data cables to connect with a MasterSeries controller Alarm LEDs 250mL Ink bottles Fig 2 24x M5 mounting holes underneath print engines Fig 1 Coral 144 print head front view On top of the Coral 144 print head are 8 alarm LEDs See 1 4 Alarm LEDs for information 1 2 Numbering Each of the 8 printing channels is numbered print engine Alarm LED cable ink reservoir as described by the following drawings Corall 44 Operator Manual ALE Design Print Trace 03 12 2010 Fig 3 print engines numbering front view Fig 4 ink circuits numbering Corall 44 Operator Manual Pa ALE Design Print Trace 03 12 2010 1 3 Dimensions The main dimensions are given in the following drawings Fig 5 566 70 Fig 5 Coral 144 side dimensions 142 00 59 75
11. manufacturers instructions 2 1 4 Encoder installation It is recommended to add an encoder to the system if the production line has an often varying or automatically varying speed barcodes are printed In both cases it is recommended to install the encoder as close as possible from the printing position of the printer along the conveyor to minimize the elastic effects of the conveyor belt Information for connecting the encoder to the controller and for operating the encoder can be found in the controller manual Corall 44 Operator Manual 7 ALE Design Print Trace 03 12 2010 2 2 Inking up for the first time from dry It is recommended that the printer is removed from the production line during this procedure as there is a risk of ink spillage Fix the printer to a suitable support e Support the Coral print head to a floor stand in printing position e With the controller switched off connect it to the print head using the data cables from the Coral print head e Remove the air pins from the ink trays Fig 12 Those pins prevent leaks from the reservoirs during shipment Also remove the caps from the reservoirs Fig 13 Place a collecting bucket in front of the print head Fig 12 Remove air pins and caps e Place a collecting bucket in front of the print head Fig 13 e Fit Ale Solvant colour ink bottles in the correct reservoirs SAFETY WARNING The inks and solvent cleaners are chemical
12. s the printing to avoid defective printings See the controller manual for information on configuring the number of prints after the ink low signal To replace the ink bottle proceed as follows remove the empty ink bottle from the printer Using a craft knife or a sharp blade cut the round raised plastic dome on the top of the new ink bottle cap Fig 14 Turn the bottle up side down and push into the reservoir Fig 15 3 2 Printer service The printer requires a service every year for routine maintenance and inspection filters o rings replacement visual inspection Please contact your ALE distributor to have your printer serviced by fully trained staff 4 Controller usage 4 1 Change parameters All parameters can be modified from the Settings screen which can be accessed from the main screen Corall 44 Operator Manual 13 ALE Design Print Trace 03 12 2010 Fig 23 access to the Settings screen All ALE controllers have large memory stores and will accept a large range of character fonts barcode formats images and logos The procedure for loading files into the controllers is detailed in the Codex reference manual A full explanation of the parameters is detailed in the complete controller manual found in the included CD This reference manual has over 300 pages of explanation and advices 4 2 Make a message For instructions on how to make a message please also read the controller s
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