alien-100 2/tt pad printer machine operation manual · 2012. 3. 20. · ink cup setup unit...

ALIEN-100 2/TT Pad Printer

Machine Operation Manual

Serial No.:

ContentSection Page

Introduction --------------------------------------------------------------------

Installation ----------------------------------------------------------------------

Machine Setup:

Ink Cup Installation ------------------------------------------------------

Ink Cup Removal --------------------------------------------------------

Printing Pad Setup ------------------------------------------------------

Pad Clean Tape Setup -------------------------------------------------

Print Head Adjustment -------------------------------------------------

Worktable Adjustment --------------------------------------------------

Control Feature:

Front Control Panel -----------------------------------------------------

Pneumatic Control Panel ----------------------------------------------

Pad Clean Tape Platform Speed Adjustment ------------------

Control Sequence -----------------------------------------------------------

Sensor Layout ----------------------------------------------------------------

Electrical Circuit Diagram -------------------------------------------------

Pneumatic Circuit Diagram -----------------------------------------------

Maintenance -------------------------------------------------------------------

Spare Parts List:

Electrical Spare Parts List --------------------------------------------

Mechanical Spare Parts List -----------------------------------------

Pneumatic Spare Parts List ------------------------------------------

1

2.1-2.2

3.1-3.2

3.3

3.4

3.5

3.6

3.7

4.1

4.2

4.3

5.1-5.8

6

7.1-7.5

8.1-8.2

9

10

11

12.1-12.2

Industrial Pad Printing Supplies, S. de R. L. MI.

WARNING

INTRODUCTION

The following manual will familiarize you with the setup,use and maintenance of

your printer.Please note that the diagrams shown within this manual are not toscale,and may not show all details.

We would like to draw your special attention to the following notes:

It is the operator’s responsibility to comply with the following safety instructionsto prevent any personal injury.1) Please disconnect the main power supply before attempting any machine

maintenance.Foot-switch or side doors is to stop machine for adjustment only.2) The air pressure must be released before attending to any service inside the

machine or any moving accessories.

Page 1Industrial Pad Printing Supplies, S. de R. L. MI.

Ground

Page 2.1

Installation

Mechanical Part:

Machine Standing Horizontal Adjustment:

Place machine on flat place. If not, you need to adjust machine foot levers to adjust machine level.

Adjusting steps is shown below:

Steps:

1. Place level ruler on ink cup platform of machine to survey machine horizontal.

2. Release upper screw nut of foot lever.

3. Turning foot lever supporter up or down to adjust supporting level.

4. Tighten upper screw nut to fix supporter position.

(Test Result: Adjust horizontal level until the level ruler on platform indicating desirable outcome.)

Foot Lever

Supporter

Upper Screw Nut


Installation

Electrical Part:

Page 2.2

Pneumatic Part:

- Connect the compressed air line to machine service unit.

Please use only clean and dry air.

- Set pressure of main service unit for machine operation to 5-6 bar.

- Connect air hose of turntable to connector AUX. AIR.

0

4

AUX. AI R

AUX.AIR for connect

pneumatic accessory

compressed air inletservice unit

Service Unit of Alien Printer

(at the rear of machine body)

adjust knob

1. 15-way D-connector - for turntable cable connection

2. 9-way D-connector - spare

3. 8-way round connector - spare

4. Foot switch connector - connect to foot control switch

5. Main power connector - connect to main power cable with correct

power plug. Machine is suitable for 110V - 230VAC 50/60Hz.

Note: The ground lead of power plug must be wired correctly.

Printer Rear Control Panel

(at the rear of machine body)

Power cable

Fuse

Power On / Off Switch

15 WayD-connector

Foot switch connector

9 WayD-connector

8 Way round connector


Machine Setup

Ink Cup lnstallation:

1.Set platform in/out manual key to extend platform to the front.

2. Cover ink cup by thin steel plate upside down as right diagram.

Remark: The image side of plate cover faces ink cup.

3. Insert ink cup setup unit into thin steel plate with ink cup into ink cup setup and then turn it upside

down.

ink cup setup unit insert setup unit into thin steel plate turn upside down

4. Release ink cup holder swing arm lock and lift up ink cup holder.

ink cup holder

swing arm lock

5. Place ink cup setup unit with ink cup and steel plate on ink cup

platform. Buckle rear hole of steel plate with rear registration pin

of platform.

rear registration pin

Page 3.1Industrial Pad Printing Supplies, S. de R. L. MI.

Machine Setup

Ink Cup lnstallation:

6. While slide ink cup setup unit out, put hand on ink cup top to

stay it on plate. Buckle front hole of steel plate with fornt

registration pin of ink cup platform.

front registrationpin

7. Push ink cup against the internal back side of the ink cup holder.

Then pull down the swing arm and tighten swing arm lock.

swing arm lock

8. Release bleeding screw of ink cup.

bleeding screw

9. Use allen key to adjust ink cup holder pad position.

(This step apply for first setup of new inkcup holder)

ink cup holder pad


1.Set platform in/out manual key to extend platform to the front.

Machine Setup

Ink Cup Removal:

2. Tighten ink cup bleeding screw.

bleeding screw

swing arm lock

3. Release lock of ink cup holder and lift up swing arm.

4. Lift up the front side of thin steel plate.

Insert ink cup setup unit between ink

cup platform and thin steel plate. Push

it forward to against rear registration

pin. Remove the thin steel plate and

ink cup with ink cup setup unit.

5. Hold the ink cup, turn ink cup over and then remove ink cup

setup unit and thin steel plate.

6. Clean the ink cup ring and then cover it well.

7. Use thinner to clean the thin steel plate. Apply grease on its

surface and store it in plastic bag for prevent oxidation.


Machine Setup

Printing Pad Setup:

1. Fasten printing pad to pad mounting by 4 screws.

2. Mount printing pad with mounting to pad holder assembly. Then

tighten pad locking screws to hold oad securely.

pad locking screws

Y-axis locking screw X-axis locking screw

Pad Holder Assembly

pad locking screws

pad X-slide

Page 3.4

pad mounting

3. Loosen X-axis locking screw of pad holer assemby.

Insert assembly onto pad X-slide of printer. Tighten

X-axis locking screw to fix the position.

Completed Setup


Machine Setup

Pad Clean Tape Setup:

Page 3.5

1. Insert a roll of tape to tape mounting without cylinder driving.

2. Insert a roll of tape core to tape mounting with cylinder driving.

3. Pull the tape along the tape platform to another tape mounting side.

(Sticky face of tape faces upward)

4. Roll up the tape from core outside.

cylinder

platform with tape

(sticky face face upward)tape mounting

tape coretape


Print Head Adjustment

Adjustment knob

locking screws

1. Loosen two locking screws.

2. Turn adjustment knob to move print head up or down.

- turn knob clockwise to move up

- tunr knob anti-clockwise to move down

3. Tighten locking screws to fix print head position.

Page 3.6

Machine Setup


7

Worktable Adjustment:

Y-Axis Screw

Knob

X-Axis Screw

Knob

Handwheel

X-Axis Lock

Handle

Y-Axis Lock

Handle

Angle Lock

ScrewUp/Down Lock

Handle

Angle Screw Knobs

Angle Lock

Screw

X-Axis Adjustment:

1. Release X-axis lock handle.

2. Screw X-axis screw knob to adjust X-axis position.

3. Lock X-axis lock handle to fix X-axis position.

Angle Adjustment:

1. Release two angle lock screws and two angle screw knobs.

2.a. Turn Left: Release left angle screw knob and screw right angle

screw knob tighty.

b. Turn Right: Release right angle screw knob and screw left angle

screw knob tighty.

3. After adjustment, tighten two angle screw knobs and two angle lock

screws to lock the position.

Y-Axis Adjustment:

1. Release Y-axis lock handle.

2. Screw Y-axis screw knob to adjust Y-axis position.

3. Lock Y-axis lock handle to lock Y-axis position.

Up / Down Adjustment:

1. Release two Up/Dn lock handles.

2. Turn the handwheel to adjust up/down position.

3. Lock 2 Up/Dn lock handles to lock up/down position.

Machine Setup


Control Feature

Front Control Panel:

G

E

D

C

B

F

C

A. Display Window

- to show printer status

B. Mode Selector Key

- to select printing functions

C. Plus (+) & Minus (-) Key

- to increase or reduce setting value (e.g. pad stroke depth)

D. Manual Key - Pad Up/Down

- to move pad up and down in manual mode

E. Manual Key - Platform In/Out

- to move platform in and out in manual mode

F. Start Key

- to start printing modes or confirm settings

G. Emergency Stop Switch

- to cut printer main electrical power in emergency

A


Control Feature

Pneumatic Contol Panel:

1 2 3 4

1. Carriage forward speed control knob.

- a flow regulator to control forward speed of pad carriage.

2. Carriage backward speed control knob.

- a flow regulator to control backward speed of pad carriage.

3. Pad stroke downward speed control knob.

- a flow regulator to control downward speed of pad stroke.

4. Pad stroke upward speed control knob.

- a flow regulator to control upward speed of pad stroke.

Note:4 speed control knobs are turning clockwise to decrease speed or anti-clockwise to increase.


Control Feature

Pad Clean Tape Platform Speed Adjustment

Right hand side of printer

21

Page 4.3

1. Pad clean platform backward speed control knob.

- a flow regulator to control backward speed of pad clean platform.

2. Pad clean platform forward speed control knob.

- a flow regulator to control forward speed of pad clean platform.

Note: speed control knobs are turning clockwise to decrease speed or anti-clockwise to increase.


Control Sequence

Fig.1

3. Press “ ” to select APS or DPS.

APS - Automatic pad stroke

Machine will automatically sense inking, printing and pad

clean depth that are normally at different level of height.

DPS - Digital pad stroke

Inking, printing and pad clean depth must be pre-set

before operations.

Page 5.1

Start Machine:

1. Switch on ON/OFF switch at rear machine.

2. Release panic switch. Then display window shows as Fig.1.

4. Press “ ” to confirm and enter manual printing mode

APS

PRESS TO DPS

DPS

PRESS TO APS

DSP

: START :SETUP

1

2

3

4


Control Sequence

Manual Printing Mode:

- Press any manual control keys. Its corresponding LED will be

lighted.

- Press “ ” key once to enter manual printing mode. The

selected manual printing function will be run.

Auto Printing Mode:

1.Select “AUTO” in Print Config Mode of Mode Setting .

(Please see part “Mode Setting” for details)

2.Turn all manual control keys off.

3. Press “ ”once to enter auto printing mode. Printer will

run continuously.

4. Press any manual control key or foot switch to stop

printing mode.

- Pad Up/Down : Press once to move pad up and down

once.

- Platform In/Out: Press key once to move ink cup

platform in ond out continuously.

Press once again to stop movement.

Single Cycle Printing Mode:

1.Select “One Cycle” or “Two Cycle” in Print Config Mode

of Mode Setting . (Please see part “Mode Setting” for details)

2.Turn all manual control keys off.

3. Press “ ”once to enter printing mode.

4. Press foot switch once to start one printing cycle.

Fig.2

- Index : in “Manual Index” of program mode as fig. 2 shown, press “ “

key once to turn turntable one station. Press once more to return.

MANUAL INDEX

PRESS ON

MANUAL INDEX

WAIT....

manual control keys

manual control keys

34

2

Page 5.2

manual control keys

32

Foot Switch

2


Control Sequence

Pad Stroke Depth Setting:

1. Press “ ” to set platform at inking or printing position.

- platform extended for inking.

- platform retrieved for printing.

2. Press “ ” and “ ” to adjust pad stroke depth.

Remark:

- Maximum print stroke range is = 008-150mm

- Maximum ink stroke range is = 001-150mm

- Each increment or decrement is 1mm

- Please see part “ Pad Clean Stroke Depth” for pad

clean stroke depth setting in details.

AUTO START DELAY

PAD CLEAN BUZZER

RESET COUNTER

PAD CLEAN DEPTH

PAD CLEAN CYCLE

MANUAL INDEX

PRT DWELL DELAY

PRINT MODE

REMOTE START

Various mode selections:

LARGER PRINT

DR BLADE DELAY

DELAY BEFORE PRT

Page 5.3

ink stroke depth

Mode Setting:

1.Press “ ” to enter mode setting display.

2. Press “ ”and “ ”to change mode selections

3. Press “ ” key once to exit mode setting.

MANUAL DPS

:036 :005

print stroke depth

1

22


Control Sequence

Mode Setting:

Print Mode:

This mode allows selection between one-cycle and

automatic cycle, and single or double printing.

1. Press “ ” to select Print Mode Setting.

AUTO DPS

Page 5.4

current print mode

2. Press “ ” and “ ” to scroll through available print modes.

3. Press “ ” to select desire print mode and return to mode setting display.

Reset Counter:

- Press “ “ to reset counter to 00000000.

LARGER PRINT

01 TO EDIT

LARGER PRINT

01

Larger Print:

This feature provides deeper pad stroke depth when printing and

inking resulting in a larger print inAPS printing m ode.

1. Press “ ” to select Larger Print Setting.

2. Press “ ” and “ ” to increase or reduce the value.

Remark:

- Setting range : 00-09 (1 = 2mm)

3. Press “ ” to confirm setting value and return to mode

setting display.

00000100

RESET COUNTER

Print Mode Sequence

Auto : ink once --> print once --> repeat cycleAUTO

Single Cycle : ink once --> print onceONE CYCLE

Single Cycle : ink once --> print once --> ink once --> print onceONE CYCLE

AUTO DPS

TO ONE CYCLE


Control Sequence

Mode Setting:

Page 5.5

PAD CLEAN DEPTH

030 TO EDIT

PAD CLEAN DEPTH

030

Pad Clean Depth:

To set pad stroke on pad clean platform surface.

1. Press “ ” to select Pad Clean Depth Setting.


Remark:

- Maximum stroke = 130mm

- Each increment or decrement is 1mm

3. Press “ ” to confirm setting value and return to mode setting display.

PAD CLEAN CYCLE

01 TO EDIT

PAD CLEAN CYCLE

01

Pad Clean Cycle:

To set frequency of pad cleaning.

1. Press “ ” to select Pad Clean Cycle Setting.


Remark:

- Setting range = 00 - 99

- If setting is 00, pad clean function is disable.


PRT DWELL DELAY

01 TO EDIT

PRT DWELL DELAY

01

PRT Dwell Delay:

To set delay time for pad pressing on the product before pad

moves up.

1. Press “ ” to select PRT Dwell Delay Setting.


Remark:

- Setting range = 00 - 40 (1 = 0.1 second)



Control Sequence

Mode Setting:

DR BLADE DELAY

01 TO EDIT

DR BLADE DELAY

01

Page 5.6

Dr Blade Delay:

To set delay time to raise Dr. blade up when ink tray is moving forward.

1. Press “ ” to select Dr Blade Delay Setting.


Remark:


3. Press “ ” to confirm setting value and return to mode

setting display.

Pad Clean Buzzer:

To enable or disable buzzer alert sound for pad cleaning.

- Press “ ” to turn on and off buzzer function alternatively.

AUTO START DELAY

01 TO EDIT

AUTO START DELAY

01

Auto Start Delay:

To set delay time before starting next printing cycle inAuto Printing Mode.



Remark:


- Each increment and decrement is 0.5 second.


PAD CLEAN BUZZER

PRESS OFF

PAD CLEAN BUZZER

PRESS ON


Control Sequence

Mode Setting:

Page 5.7

Remote Start:

To enable or disable remote control function. When function is enable,

outside control can start print cycle through the remote start input.

- Press “ ” to turn on and off remote control function alternatively.

DELAY BEFORE PPT

01 TO EDIT

DELAY BEFORE PPT

01

Delay Before PRT:

To set delay time before pad goes down to print inAuto Printing Mode.



Remark:



REMOTE START ON

PRESS ON -> OFF

REMOTE START OFF

PRESS OFF -> ON

Reset Eeprom:

1. Power off machine.

2. Press and hold “ ” key and power on machine at the

same time. LCD dispaly will be shown as follows.

3. press “ ” to reset Eeprom data as factory default.

4. Or press “ ” key to quit the function.

** RESET EEPROM **

YES = NO =

42

3


Stopping and Resuming:

There are many ways of stopping printing. Press ONE of:

1. Mode Selector Key

2. Manual Control Key

3. Foot Switch

4. Emergency Stop Switch

Resume:

- For 1, 2 & 3, press “ ” to resume printing.

- For 4, to turn emergency switch clockwise to release the switch,

and then follow the sequence as part “Machine Startup” to resume.

Control Sequence

Switch off the machine:

1.Stop printing cycle.

2.Turn machine power off.

Page 5.8

manual control keys

4

Emergency Stop Switch

Foot Switch

2

1

1

2

3


Sensor Layout

Page 6

B

A

D

C

F

E

A : PS1 PAD Stroke Home Sensor.

B : PS2 Optical Sensor.

C : PS3 Ink Cup Home Switch.

D : PS5 Ink Cup Actuate Switch.

E : PS6 PAD Clean Home Sensor.

F : PS7 PAD Clean Actuate Sensor.

G : MS1 Sensor.

H : MS2 Sensor.

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b

Page 9

There are some regular maintenance works to keep printer in smooth operation.

1. LUBRICATION:

Please weekly do lubrication:

Inject lubricant into elbow grease injection by lubrication injector:

a. Grease nipples on runner blocks of pad stroke.

b. Grease nipples on runner blocks of ink cup platform.

c. Grease nipples on pad clean mounting blocks.

d. Apply lubricant to gear and rack of furntale.

3. Compressed Air Service Unit Checking:

Daily Checking:

- Alway discharge liquid inside tube of service unit. Release tube

bottom screw to discharge liquid.

- The operation pressure always keep at 6 bar.

discharge screw

2.System Cleaning:

Please weekly check:

-Please clean-up the scale rule. scale rule

a

a

0

4

d

Electrical Spare Parts List

15-EC-131

Proximity sensor TL-Q5MC1(Omron)

15-EC-A974

Foot switch

35-EC-170

Proximity sensor (TL-W3MC1)

AN10-EC-000

Emergency stop switch

AN10-EC-521

Proximity sensor (SMC D-C73L)

AN10-EC-611.01

Power socket

AN10-EC-620

Optical sensor (EE-SX 672)

AN10-EC-910.03

Eprom AN10-IO1.31

AN10-EC-921

Eprom AN10-DS1.5

AN10-EC-930

Eprom AN10-TTC01

AN10-EC-A009

AK-004 complete panel PCB(without IC)

AN10-EC-A015

AN-2T PCB Assembly

AN10-MEC-070

Panel sheet

DRE70-EC-050

Slow blow fuse 4A

KP100-EC-A100

KP100 PCB assebbly without eprom

MPOS-EC-060

Switching power supply

Page 10

Mechanical Spare Parts List

15-PA-A004.01

Pad holder ass'y FOR(76MM Pad mounting plate )

AN10-PC-111

Runner block

AN12-PC-051

Pad stroke guide rail L 390MM(HIWIN)

ICH-A015.03

90mm Swing arm ink cup holderass'y

NIC-A050

90mm AMC ceramic magnetic inkcup +protective plate

Page 11

Pneumatic Spare Parts List

10-PFR-010

Flow control valve supply side(GRL-M5-PU4-S)

10-PFT-021

Fitting (elbow connector )(GCK1/4-4)

15-PAH-010.01

Tube (PUN-8)I.D.5.7mm O.D.8mm

15-PAH-020.01

Tube (PUN-6)I.D.4mm O.D.6mm

15-PFR-030.01

Flow Regulator (AM 5062)

15-PFT-031

Fitting (straight connector )(CK1/8-4)

15-PFT-050

Fitting (elbow connector )(GCK-1/8-PK-4-KU)

15-PFT-151

Fitting (GCK1/4-6)

15-PFT-281

PUN8-6-8 T Q uick connectorcoupling (AIRTC APEG8-6)

15-PSL-021

Silencer PT 1/4" (AN-200-02)

15-PVA-120

3/2 Single solenoid valve PT 1/4(VT-307-5G-02)

30-PSA-020

Hydraulic shock absorber(RBC-1412S)

AN10-PCY-040

Double acting cyl(For pad clean)DSNU-25-80-PPV-A

AN10-PSU-020

Filter-regulator

AN12-PCY-010

Pad carriage cylinder(L-CG1BN-50-150)

AN12-PCY-030

Pad carriage cylinder(CG1BN63-150)

C16-PCY-020

Registration Cylinder(AVL-20-10)

DR11L-PVA-011

3 Ports plunger valve (V-3-M5)

Page 12.1

Pneumatic Spare Parts List

EX-PFR-011

Flow control valve(JSC6-01AT)

KP150-PFR-011

Flow regulator for pad stroke(ASC-08)

KP200-PVA-010

Solenoid valve(VQZ3121-5GB-02F)

KP90-PCY-010

Cylinder ( L-CDGIBA-32-75 )

PW4-PVA-010

Double Pilot Valve

Page 12.2

alien-100 2/tt pad printer machine operation manual · 2012. 3. 20. · ink cup setup unit...

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