Installation & training Guide for the

Barak5 & Barak3 Printers Head Office Matan Digital Printers Ltd., 14 Amal Street, Park Afek, Rosh Ha'ayin 48092, Israel. Tel: (+972) 3 9002720 Fax: (972) 3 9002721 Email: [email protected] U.S. Office Matan USA Inc., 90, Earhart Drive, Suite 4, Williamsville NY 14221. Tel: (+1) 716 631 3770 Fax: (1) 716 631 3576 Email for customer support: [email protected] Europe Office

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Matan EU, C/ Rosalia de Castro, 21, 08025, Barcelona, Spain. Tel: (+34) 902 932825 Fax: (+34) 902 932826 Email for customer support: [email protected] User’s Guide Version Number: Revision _26 May 2010 by CPA

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Barak Printer Acceptance Form On the installation’s completion, the following form must be completed by Matan’s Technician, signed by the customer, and sent to Matan’s head office. Training date: Company name: Company address

Contact person:

Phone number: Fax number: Email address: Barak Model: Printer’s serial number: Barak FE software version: OPTIONS

RIP Type & Version: Multi-roll (Yes/No)

FlatBed Yes/No and Sets #:

BackLit Yes/No (Manual/Camera)

BARAK Hasp ID

RIP Hasp ID

Installation start date: Installation finish date: Technician’s name: Trainee’s name: Authorized signatory:

Signature: Technician’s signature: Date: Remarks:

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1. Installation The instructions for installing the printer have been formatted as a check list. This will help you confirm that each stage has been correctly dealt with, in the correct order. Note: Details of the equipment required for unloading and unpacking the Barak printer can be found in the Site preparation guide

Printer Installation





Conditions at the Working Area. Storage area (Temp to match Ink spec). Make sure the temperature of the storage area does not change dramatically. (eg. Days vs. Nights, Working days vs Idle days, weekends…)






Temperature range 20ºC – 29ºC (68ºF – 84ºF). Relative humidity 50% – 80%. Air pressure at 6 Bar (87 psi), minimum. - OBSERVE the compressor capabilities and ONLY advise the customer in relation with the performances expected. The parameters need from this compressor is: Dry & oil-free air supply at 6 bar (87 psi), airflow capability of a minimum 7 liters/sec.




Check there is no apparent damage due to transportation. Note: Before you uncrate check the TILT indicators, if they show signs of tilting take a picture. Inspect the equipment for scratches, deformations, nicks, paint alterations.




Check there are no missing parts in the starter kit: Inks C-M-Y-K, Flushing Fluid type F, UV Filters, Spare Ink Pump, Cleaning Paper (pads), Protective Gloves, Absorbing cloth for Mesh, Blue light MiniTorch, Tool box, Open Wrench kit, O-rings for head, O-ring for SIT, Service Door-Key,Network-Cross-Cable,Caldera-License-Dongle.




Remove all protective materials from the printer, including the rollers, cable chain & Carriage.




Remove Carriage Stopper (2 x Screws & T-Nuts ) Note: Remove also the Nuts from Aluminum Bar, store in the Tool Box the Stopper together with the screws and the nuts.

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Remove the two Yellow Shipping Bars and L-shaped lifting brackets. Note: For any further equipment move: Instruct the customer to save the Shipping, L-Bars, screws and T-nuts.





Install the Workstation Tray by securing it to the base with four Allen screws.




Place the Barak computer on its stand; Place the Monitor on workstation tray together with the mouse and the keyboard.

Open the side cover of Barak PC- Check that all the PCBs in the Barak Computer are firmly connected.

Note: If the keyboard and mouse are USB use the included USB/PS2 adaptor. Route the Monitor, mouse, keyboard and power cables down through the hole in the tray toward the Barak PC.




Connect the cables to the Barak PC. Note: 1. Do not turn ON the PC at this Stage, but only after checking that the Voltage is OK. 2. Connect the data cables to their corresponding serial connectors, pay attention to the marks or stickers they have. Later on you may need to correct these positions with the Engineering Mode window or by swapping mis-paired connections. 3. Plug the Barak HASP key into a rear USB slot.





Uncap the Ink purge tube/ Make sure the waste ink tank is in place Assemble feeder ports (4 or 6), docking stations and shafts. Make sure the Multi Roll Shafts goes easily into the docking stations’ notches.




Check all the important screws (Electric Cabinet, Heads Cables, PCBs, Electronic Devices- such PLCs, SSRs, SSR Holders, Power Supplies, LEKS) and if necessary, tighten them.





Check that all the electric and electronic cables/wires are connected properly.




In case Print Heads Plate not Installed, proceed as per next instructions:

In case Print Heads Plate is installed: Remove Protection Bed below Print Heads by manually raising the Carriage assy (black knob).

Disconnect the voltage wires from all the ink pumps Remove the carriage covers. Assembly the print heads plate to the carriage. Connect the ink and vacuum pipes to the SITs.

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Assembly the print heads drivers into their slots. Connect all the drivers’ flat cables from the backplane to the print head drivers. Connect the 100 pin flat cables from the BBC to the backplane.






Check all air and ink connections, if necessary tighten them.






Connect and Check Vacuum table is working Ok.




Power up the electricity and check all Power Supply voltages (48VDC, 24VAC, 24VDC, 5VDC, 220VAC).

Install the Back Protection Guard ( for UVISTAR Printers ) Install Buzzer/Alarm using the 3 screws and secure the power cable with straps.

Connect the air supply to the printer on the Pneumatic Panel. Check the 3-Phase supply and Ground. Prior to this operation make sure the 3-Phases are fused. If possible, have the confirmation from an authorized HVAC electrician. Do not perform any modifications on the customer supply network! Do not accept a (rest) of drop voltage between Earth and Neutral (if they use this).

Note: DO NOT start the Barak FE at this stage; limit the action on checking the power sections. Turn off the equipment after this check.




If the Power Up checks result is OK: Proceed with Level the printer (see the related Procedure). Note: 1. one you may need to raise up the Hood. 2. For safety, disconnect the Ink Pumps (the red wire, at least).









Once finished the Leveling, make sure the Ink Pumps are disconnected. Power up the Equipment and make sure Barak computer works. Check that the Barak FE software is working. Check all Serial Cables are well connected (HelpAbout). Turn-off the equipment. Disconnect the X-Motor power plug. 

Make sure the PH Carriage is high enough



Make sure the Wings are Down

With the equipment off, check that the rails are undamaged, manually move the Carriage forwards and backwards over the entire length of the rails.

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Plug back the X Motor power connector. At end, make sure the Carriage assy is on Home Position. Turn on equipment. After PC booting, activate Engineer Mode, open Barak FE application.




Check Manually in I/O Control that the Limit Switches are working Left Limit Switches Right Limit Switches




Perform and Check INIT function is working ( put your hand on Emergency Stop just in case )




Activate the UV Lamps, close the Hood and Check that when Emergency Stop is activated : UV lamps must turn OFF Press Pistons are DOWN Free Fall &/or Flatbed Pistons are open Hood Cover is OPEN / raise up




Recover the Emergency status, and check again with Emergency Stop Cord




Check that all Motors are working:








X

X Motor Y Motor Z Motor T Motor

T

Y Back of Printer

Front of Printer Z

F

F Motor ( For HS )




Check that the X Motor and the Gear are firmly attached to each other. If necessary, remove all the screws and use Loctite #222 to attach the components again.




Check that in Y Motor all screws are tight. If necessary, remove all the screws and use Loctite #222 to attach the components again.




Run the Y and T rollers for several minutes to enable them to release any tension they might be subjected to.

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Check all the pistons are working. Media Press roller ( adjust if needed/ target: media feed ok, no wrinkles ) Y & T (Flatbed Shaft) rollers are moving up to FlatBed position. Free Fall pistons. Flatbed pistons. Hood piston. Mesh Wings Pistons ( front and back )


Check all the sensors are working (watch with I/O- where is the case).
Media measure sensor.
End of media sensor.
Vacuum sensor valve (between 0.8 -1.0).
Sink sensor.
Hood/Print cover (UV protection cover).
Flatbed Press
Flatbed Shaft
Media Press
Free-fall Press
Mesh Wings
Buzzer
Red Lamp Buzzer



Check ratings of both UV Power Supplies (3600 Watts/ watch decals). Check that Both Q1 and Q2 in PDU for UV Lamps are on the same Level.

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Check that LEFT UV lamp is working at the correct power setting.









Yes

No

Shutter Open/Close :

Yes

No

Fan Working :

Yes

No

Check Correct Power Supply is working Wait till Status is “READY” then turn OFF

Check that RIGHT UV lamp is working at the correct power setting.









Turn ON :

Turn ON :

Yes

No

Shutter Open/Close :

Yes

No

Fan Working :

Yes

No

Check Correct Power Supply is working Wait till Status is “READY” then turn OFF

Continue Leveling the Printer Vacuum Table and Heads Plate. See the related document/ Tech Note.




Level the printing vacuum table and the rubber rollers upper position (up to ±0.1 mm).




Level the Heads Plate VIS the Print Table (±0.1 mm).




Calibrate the Carriage position to 2mm height from the Print Table and set the gauge to zero ( make sure that stopper screw is installed )




Check that the heaters are working properly, by turning off or on, depending on the current temperature.




In case SITs are filled with Solvent or Flushing Fluid, perform a purge to all the Print Heads, until they are all empty.





Make sure that the SIT connectors are disconnected.




Connect the SIT plugs. Connect NOW the Ink Pumps (red) connectors.

Fill the main ink tank with Yellow ink & check that the ink indicators (software and hardware) are working. You can physically check by opening the Ink System Doors and listening to the pump.

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Filling Ink in Yellow SIT Fill the Yellow Main Ink tank Check that the ink indicators (Software and Hardware) are working correctly. If not, open, clean them and install again. Connect the Yellow Pump Fill the Yellow SIT by closing and opening the Barak FE application (~7 times / ~ 21 seconds) or activate Eng. Mode and do it with I/O. Check that the ink pump is working. In case not filling, use a syringe to pull ink into the pump. Avoid Overflow!!! Watch all time the correspondent vacuum tubes!!! In case of Overflow, press Emergency Stop!!!





Do the Filling Ink Procedure for the rest of colors, one by one.





Check that the Fire All function is working.





Check that the ink is fully cured in all modes.




After PHs Alignment/ Image Quality done, during the next days, check that there is no (overnight) ink leakage or sweating.




If required, assemble the Flatbed Tables, level them for the correct machine High and mark positions on the floor.





Remove irrelevant files and software from the Barak computer.

Check that the Ink in the SITs has reached the correct temperature and that it is stable within the allowed tolerance.

Print the Nozzle Test and other files and check that there are no missing nozzles.

Check the Image Quality/ Print Heads’ alignment and make the necessary adjustments if needed (Tilt, PHs, Y Encoder)

Make a BackUp of the BarakFE folder ant keep it on your USB memory key

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With the final adjustments and settings you made, take a screen capture of: Help  About Engineer Printer Parameters Engineer Servo Settings Voltage Calibration Plug Information (Plug Update) Preferences Print Modes UV Power Save all Capture Screen on the local Hard Drive and keep a copy on your USB memory Key




Take samples printed on BlueBack or WhiteBack of: Nozzle test PHs Alignment (Left/ Right Blocks) Tilt ATP (Express, Supreme, Swift)




If applicable- Send spare parts back to Matan. (Recommended only after the Application Training is completed.)





Prepare/Close Teodolite Box and inform Matan EU for PickUp Configure the Caldera PC. Establish physical and logical Connection the Barak PC with Caldera PC (see related Tech Document).

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2. Technical Training





Ink & media storage/ Handling (Spec, MSDS). Working environment (Temp, Humidity). Starter Kit. General overview:


System overview.
Ink System.
Pneumatic system.
UV system.
Data path.
Rollers system.
Carriage.
Barak PC.
Caldera PC.
Electrical system.
Motion system.
Ionizer feature.
Printer covers.
Emergency Stop buttons/cord.



Safety elements and guidelines (Buzzer etc’). Work procedure:


Start up procedure.
Shut down procedure.


Based on Barak Operation & Maintenance Guidelines- discuss the Ongoing maintenance procedure.

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Air filters replacement.
Ink filters replacement.
UV bulb replacement.
Carriage rail lubrication.
Critical screws.
Nozzle test.
Printer general cleaning.
Cleaning Ionizer Bars and UV HeatSink (underneath UV Lamps)


Material loading & unloading:


Roll to roll printing (5 and 3.2 meter media)
Multi roll.
Flatbed & multi Flatbed.
Mesh printing.
Freefall.


Barak GUI


Software overview.
S/W versions & Upgrades.
Control panel:
Media advance.
Measure media.
Left /Right calibration.
Noise.
UV Power.
One file workflow.
Queue workflow.
Quality tips and tricks Installation Guide

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3. Application Training


Caldera Registration and Dongle activation (recommended to be done in the first stage of the installation)






Network (Internet, External programs). File Formats and recommended spec. Caldera.


Caldera general overview.
Open a file, see parameters.
File preparation, copies, size, rotate.
RIP (Express, Swift, Supreme).
Spooler.
Copy/send file to the Barak, print, qualities.
Tips & Tricks.




How to open a service call. How to open an application call. How to order consumables.

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4. After Installation (once back home) Prepare End Of Installation Report Scan the signed COI/Acceptance Form Document (in this document, page 2) Scan Nozzle Test Scan PHs Alignment (Left/Right Block) Scan the this checklist Point 1 + 2 + 3 (from Page 1 till 12 ) Pass to Excel file the Table Adjustment parameters and PH Carriage

These documents should be sent (ASAP/ if possible in less than 48 hours ) by the FSE to the workgroup.

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