ALE TC Series Operator Manual UK
Contents
1. OPERATOR MANUAL ssal ALE Design Print Trace 07 07 2011 Disclaimer This manual contains instructions for operating the Ale TC18 TC54 and TC72 print heads 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 2011 Aze Sarl all rights reserved Reproducing this manual in whole or part without permission is expressly prohibited RiX and TraceX are registered trademarks of A sarl All trademarks in this document belong to their respective owners Version history Date Revision Modifications Author 22 03 10 First version AF 11 08 10 2 TC54 AF GP 30 08 10 2 Small corrections AF 06 09 10 2 2 Bottle replacement section AF 07 07 2011 3 TC18 AF TC Series Operator Manual i ALE Design Print Trace 07 07 2011 Contents Disclaimer Contents Notes 1 Description 1 1 Print head description 1 2 Dimensions 1 3 Alarm LED 2 Start Up 2 1 On line installation 2 1 1 Defining the position of the system 2 1 2 Installing the system along2. to operate the TC print head with a J Series controller For instructions on how to operate a TC print head with a Master Pad controller please ask your distributor for a Master Pad user manual e Remove the air pin from the ink tray Fig 12 This pin prevents leaks from the reservoir during shipment Also remove the cap from the reservoir Fig 13 Place a collecting bucket in front of the print head Fig 12 Remove air pin and cap e Place a collecting bucket in front of the print head Fig 13 For the TC72 OIL version fit an ALe BOBET 7X 250mL ink bottle in the reservoir For the TC54 OIL version or TC18 OIL version fit an Ale BOB 250mL ink bottle in the reservoir SAFETY WARNING The inks and solvent cleaners are chemical 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 TC series print heads Operator Manual 7 saal ALLE Design Print Trace 07 07 2011 The TC72 H has been specially built to be used with the Age BOBET7X ink and the TC54 H and TC18 H have been specially built to be used with the Afl BOB ink Using any other fluid is likely to severely damage the hydraulic system 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
3. controller 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 correct position of the printer is theoretically determined take the S062 square out of the box Fig 9 and screw it in the desired position along the conveyor onto a stable independent floor stand Screw the TC print head to S062 using the 4 M5 holes under the print head enclosure see also packing list See Fig 10 TC series print heads Operator Manual 4 sasl ALLE Design Print Trace 07 07 2011 Fig 9 S062 Square Fig 10 Print head mounting 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 data cable 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 TC 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 TC series print heads Operator Manual 5 oH ALLE Design Print Trace 07 07 2011 Fig 11 Photocell position When installing the photocell ensure that the detection is not co
4. ET 2 ee STD rom 4 0 JUL 2011 10 34 5 5 INK SPITX PRINTS 000110 6 INVx REVx PEC 15inm y 7 250mm s DENSITY 1 WIDTH 102 8 Serial MPAD 104767 49435 Fig 20 Successful test message printed with a TC18 1 SERIES J INKJET IC 7 2 2 SOFTWARE V396 S1D rom 3 J16 A 1Z 2b BX amp 4 18 MAR 2Z010 14 40 00 8 5 INKY SPITX PRINTS 00000 6 INVX REVv PEC 15mm 7 600mm s DENSITY 1 WIDTH 1002 amp 8 Fonts 7595 13 26 32 52 104 128 amp Fig 21 Successful test message printed with a TC72 1 SERIES J INKJET 054 2 SOFTWARE v356 S10 rom 3 J16 A 1Z 2b BX 4 18 MAR 2010 14 40 00 5 INKY SPITX PRINTS 00000 amp 6 INVX REVv PEC 1omn 7 600mm s DENSITY 1 WIDTH 1002 8 Fonts 7 595 13 263 325592 104 128 F Fig 22 Successful test message printed with a TC54 It is also possible to make a test print by pressing the prime switch shortly whilst the controller is in PRINT OFF mode see next page TC series print heads Operator Manual conf tL Design Print Trace 07 07 2011 2 3 To enable the prime switch you can use the prime switch see Fig 1 to prime the print head instead of using the controller keyboard This can be useful if the print head is too far away from the controller To enable the prime switch to work at ANY time Press and hold the switch Wait LCD will show ENABLE REMOTE PRIME SWITCH Kee
5. gle Fig 18 with no white lines across Otherwise Fig 19 prime again using the Norm option Right arrow Ed in the Prime menu and a bucket Fig 13 and check again if all dots are operating age anne eS Seen nN NN TN as AnS a TSS SSS annem nnn A eee 35 Hates i 3 f 3 AUH HT 14 HE 3 i j RS 5 N KIITTI TNT en NNN SS SS X ll Fig 18 Correct black pad Fig 19 Incomplete black pad When the printing is correct the collecting bucket can be removed Fig 13 carefully clean the print head Fig 17 Exit the prime menu of the controller X or Set the system for printing back on your production line Prime the system using the prime switch Alternatively you can use the prime switch to prime the print head instead of using the controller keyboard This can be useful if the print head is too far away from the controller See chapter 2 3 To enable the prime switch To make a test print On the controller keypad press the arrow up EO to select the test message message 00 Press the key the screen will then show PRINT OFF Hold a piece of paper in front of the print head Briefly press right arrow Q and simultaneously pass the piece of paper across right to left The result should be similar to Fig 21 TC series print heads Operator Manual 10 oH ALLE Design Print Trace 07 07 2011 1 SERIES M INKJ
6. iew Window Object Connect Help l x iy ie Jet j 3 4 00 m ABC s Hl TE alale Al ar eae kal am Codex Configure Product Line Head Positions View Control Hide a Imageo01 Image002 New Global Settings F Printer 1x72mm80pL 4 Label Size Auto an H Width 100 En Delay 50mm i Eh Continuous Print OFF 2 Photocell Position 15mm i Invert All Print NO Density 1 default Controller OFFLINE Tra For Help press F1 i Invert NO Reverse NO i Line Speed 250mm sec Fixed 30 Photocell Detection NORMAL es Ink Low Time out 100 prints l Shift Code 00 00 8 hours A Z withor Download size unknown double click to 1 ceX dongle leve READY Print Count Fig 7 CodeX 3D view with a TC72 249 78 4 You must know that the system must be adjusted so that the surfaces to be printed don t touch the print head TC series print heads Operator Manual and are at a maximum distance of 3mm Fig 8 sasi ALEZ Design Print Trace 07 07 2011 BEB tere than a printer gt gt gt max 3mm Fig 8 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 Install the controller in such a way that it is not at a wire distance superior to 1 5m from the TC print head J Series
7. nfused 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 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 TC series print heads Operator Manual 6 cof tL Design Print Trace 07 07 2011 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 Support the TC print head to a floor stand in printing position With the controller switched off connect it to the print head using the data cable from the TC series print head Note the TC print head can be connected either to a J Series controller D25 cable format or a Master Pad controller IEEE1394 cable format The following procedure describes how
8. p switch pressed and press OK from keypad Once the prime switch is activated you can use it to prime the system or do a test print To prime using the prime switch on the controller keypad press the prime key If you press the switch once you will get a norm prime To print a test patch all nozzles Fig 18 press and hold the switch for a longer time TC series print heads Operator Manual 12 conf tL Design Print Trace 07 07 2011 3 Printer operation 3 1 Ink bottle replacement While the printer is in operation it is necessary to replace the empty ink bottle before the internal reservoir goes empty as well The printer reservoir has an optical ink low detection mechanism which will sending warnings just before the reservoir becomes empty it will turn on the red LED 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 stops 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 Fig 23 Fig 23 remove the empty ink bottle 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 rese
9. rime the system proceed as follows e Press the prime key B It leads to the prime menu Fig 16 l pooh Fig i J Series prime menu This menu offers 3 options Jet primes the circuit at high pressure v Test prints with all nozzles Norm primes the circuit at low pressure e To ink up the circuit from dry the Jet prime is used first On the display the second line shows H eieSe0hSie Press the arrow left K to get a Jet prime The display now shows HAm e Press 0K 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 AN WARNING The pump pressure in inking up mode is maximum and ink will jet out Prime twice more using the Jet function to remove air from the ink circuit Prime at least once using the Norm function This is done to remove the remaining air bubbles from the circuit e Carefully wipe excess ink off Fig 17 Do not touch the nozzle plate it is coated with a special non wetting podun which is self cleaning ae Fig 17 Carefully and gently wipe the excess ink TC series print heads Operator Manual 9 sasi ALEZ Design Print Trace 07 07 2011 BB tere than a printer gt gt e Check that all dots are operating press arrow down Wi whilst moving a sheet of paper in front of the print head You should print a solid black rectan
10. rvoir 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 TC series print heads Operator Manual 13 saal ALLE Design Print Trace 07 07 2011 4 Controller usage 4 1 Change parameters The basic programmable functions of language print delay calibrate line speed and ink density are directly accessible via the GC key on the keypad All further functions can be found by scrolling further down to the sub menus Print settings Install settings and Other settings Please refer to the set up menu diagram for more information All Aze controllers either series J Z or Master Pad 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 user manual TC series print heads Operator Manual 14
11. sions 42 00 mm Lowest printing nozzle 325mm i Fig 5 TC54 side dimensions fj i 151 5 mm Fig 6 TC Series bottom dimensions with M5 mounting points TC series print heads Operator Manual Z Design Print Trace 07 07 2011 There is a red alarm LED on top of the print head It starts blinking when the level of ink is too low in the 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 det ected 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 2 1 1 On line installation Defining the 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 capabilities Fig 7 f E24 Codex File1 OFFLINE Please refer to the Codex manual for details 15 x File Edit v
12. the conveyor 2 1 3 Photocell installation 2 1 4 Encoder installation 2 2 Inking up for the first time from dry 2 3 To enable the prime switch 3 Printer operation 3 1 Ink bottle replacement 3 2 Printer service 4 Controller usage 4 1 Change parameters 4 2 Make a message TC Series Operator Manual ALE More than a printer gt gt gt Design Print Trace 07 07 2011 Notes TC Series Operator Manual conf tL Design Print Trace 07 07 2011 1 Description 1 1 Print head description Features 18mm print band with the TC18 54mm print band with the TC54 72mm print band with the TC72 print forward only uses Ale 250mL ink bottles 304 Stainless steel enclosure 2 versions D25 data cable to connect with a J Series controller or IEEE1394 data cable to connect with a K Series controller Alarm Data connection Da Prime switch 250mL Ink bottle Fig 2 4x M5 mounting holes underneath print engine Fig 1 TC series print head front view On top of the TC print head is an alarm LED See 1 3 Alarm LED for information Note TC72 H uses ALE BOBET7X 250mL bottles TC18 H and TC54 H use ALE BOB 250mL bottles 1 2 Dimensions The main dimensions are given in the following drawing Fig 4 TC series print heads Operator Manual 1 coef Lm Design Print Trace 07 07 2011 325 mm Fig 3 TC18 side dimensions Fig 4 TC72 side dimen
13. up side down and push into the reservoir Fig 15 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 After a few seconds the controller will emit some beeps This is an automatic set up so there is nothing to do until the screen shows Print msg OT and no text The default language is English on all new machines e To change to the language required press FA and then press the arrow down W3 until you select the language required for example Langue Francais Enter by pushing The screen will display Impr Mess 01 Pas de message Please report to the controller documentation for more information e The controller needs to be adjusted to the print head To check this press A until you reach nsta l settings and press K LCD says head config f your configuration is not already selected press the arrow down U until you reach your configuration For the TC72 If the TC72 has an 80pL print engine the configuration to select is 1xT72mm S80pL Otherwise the configuration to select is x7T72mm For the C54 the configuration to select is x7T54mm and for the TC18 TxT18 amp mn e Press to validate Then the ink system needs to be purged of air TC series print heads Operator Manual 8 conf tL Design Print Trace 07 07 2011 To p
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