AGFA Printer, Operator'S Manual

Page 1: ... ANAPURNA L XL OPERATOR MANUAL Version 1 0 AB ...

Page 2: ...Curing setup and sequences 16 6 3 Uni and Bi directional printing 17 7 Printing Table 18 7 1 General information 18 7 2 Belt Tension control 18 7 3 Maintenance 19 7 4 Replacement 19 8 Maintenance 20 8 1 General information 20 8 2 Daily Maintenance Nozzle check purge 20 8 3 Weekly Maintenance 23 8 4 Long Stand Still 24 9 Media Setup 26 9 1 Roll to Roll 26 9 2 Rigid Media 28 9 3 Media Roller Bars 29...

Page 3: ...o look at the direction of the light wear protective glasses or look through the front cover glas WARNING UV ink contains chemicals when handling the ink wear protective gloves to protect your skin and protective glasses Should the ink come in contact with your skin wash with water immediately IMPORTANT The Anapurna engines are equipped with an exhaust system to extract the heat and the ozone gas ...

Page 4: ...ANAPURNA L XL OPERATOR MANUAL AB 4 8 09 2006 2 Printer Overview and Features System Dimensions ANAPURNA XL Max media width 2 5m printable width 2 48m ANAPURNA L Max media width 1 6m printable width 1 58m ...

Page 5: ... ANAPURNA L XL OPERATOR MANUAL AB 5 8 09 2006 2 1 Front view parts locations 2 2 Rear view parts locations ...

Page 6: ...ront and Rear cover Carrige movement and printing can only be done with covers closed 1 When carriage is waiting Purge or Home When a cover is open you will see the door open error on the screen and the carriage will not move to Home or Purge if requested 2 During printing When you open the cover at this stage the PRINT will be CANCELLED and the UV lamp shutter will be closed automatically COVER O...

Page 7: ... ANAPURNA L XL OPERATOR MANUAL AB 7 8 09 2006 2 3 Head Carriage view parts 2 4 Signal tower ...

Page 8: ...ing Assembly Calibrated Drop Size 75 pl 256 addressable jetting nozzles single line Nozzle spacing 279 microns 0 011 Intrinsic resolution 91 dpi 8 JA mounted in head base plate 7 heads in line 1 head mounted in front of the other heads used for Pre White Supported Color mode fixed Color Sequence ...

Page 9: ...ion by using Light Cyan and Light Magenta Results in smooth highlights Ink usage 10ml m all colors together 6 4 2 Color gamut Agfa Inks tuned towards the ISO Standard 12647 2004 Calculated nr of colors Volume calculated within Monaco CMS ISO Standard 12647 770 000 colors Anapurna Ink on Anapurna printing in 6 pass 830 000 colors 8 pass 850 000 colors 12 pass 1 080 000 colors 16 pass 4 3 Packing 1L...

Page 10: ...ring rod inside Tanks WARNING ONLY refill with the 1liter bottle when the low level alarm goes off At that point you can pour in a complete 1L bottle and you won t have any left over ink remaining in the bottle 5 2 Auto ink supply From the ink tank ink is pumped into the Sub ink tank which is positioned on the Head Carriage The Sub ink tank is temperature controlled and has a content of 35ml per c...

Page 11: ... ANAPURNA L XL OPERATOR MANUAL AB 11 8 09 2006 At this stage you also need to Press the AT button to close the procedure Read out How to make changes ...

Page 12: ...es or misfiring nozzles Push the Purge button at very short intervals this will cause ink flowing through the heads this will un clog the missing nozzles make sure the Grid is pushed to the back Cleaning the heads with Cleaning solution The color valves must be closed set them to the S direction Now the ink flow to the heads is closed Open the Cleaning Solution control valve on the right When you ...

Page 13: ...n the pressure is too low the ink will leak out of the heads The Neg Pressure should be set to 0 34 The system will adjust the setting when the temperature on the Head Base plate is getting too high This is an automatic function the customer will never see a change on the display When using White ink It is possible that the Neg Pressure needs to be tuned towards 036 to get a stable nozzle behavior...

Page 14: ...perature the lower value is only an indication The actual temperature will not change if you change that lower value The actual temperature needs to be 32 C when engine is not in use cold engine When printing the temperature indication should not exceed 38 C Make sure you print with closed engine doors all the time especially when room temperatures are 25 C and above This will give you the best co...

Page 15: ...s out of top cap Close top cap tighten by hand Observed during printing The customer needs to call the Service Engineer Empty and Feeding led stay lighted ON Operator Check the ink level in the tank visually Push the Manual Feed button If the problem persists Push emergency stop and restart the system If the problem persists Call the Service Engineer 5 7 Waste Tank When the waste tank is full the ...

Page 16: ...half strength Air cooled lamp house Quick and easy replacement of the UV bulbs Always change both the lamps Expected lifetime 1000 hours Use of an automated shutter system 6 2 Curing setup and sequences Settings in software Lamps continous ON lamp stays ON for next print longest lifetime WarmUp Time when turning back on the UV lamps before ready state Cooling Time after turning off the UV lamps La...

Page 17: ...Off 6 3 Uni and Bi directional printing For Bi directional printing both UV lamps need to be used curing is done on the fly in both printing directions For Uni directional printing only the right UV lamp will be used curing is only done when the shuttle is moving from right to left Depending on the heat resistance thickness of your media you can set the UV lamp power to Half or Full power By defau...

Page 18: ...tched on in that order When printing on a banner paper type of roll media only the right 1 vacuum side should be used Even when the media width is almost the engine width When printing on two rigid media both vacuum tables must be used 7 2 Belt Tension control 1 if the belt is touching the left or right guide on the underside of the table 2 remove the metal covers on the backside both left and rig...

Page 19: ...is masked so printing on the belt is reduced to a minimum When you have printed onto the Conveyor belt try to remove the ink with a cleaning solution 7 4 Replacement of Conveyor belt Vacuum can become insufficient when the belt is completely printed The Conveyor belt therefore is a Spare Part and can be ordered as such ...

Page 20: ...rid this will help to keep the area clean it s advisable to replace them weekly The Purge Grid must be placed forward again when you start to print It prevents the ink in the underneath waste box from getting cured by the UV lamps during the printing stage It also prevents the UV lamps from curing the ink onto the heads 8 2 Daily Maintenance Nozzle check purge Check the state of the Purge and Home...

Page 21: ...t are OK switch them to the S position Push the Purge button frequent at very short intervals Open all heads again switch them back to the I position Clean the heads with a fiber free cloth Check on weeping Large purge With all the heads open switch them all to the I position Push and hold the Purge button for a longer time 2 sec end the procedure by pushing the Purge button again but now frequent...

Page 22: ...ing pressure CLEANING the failing heads Set the valves of the failing heads to the S position Set the Solution valve to S Push the Solution Purge button on the back of the carriage Keep pushing until you see a CLEAR Solution Curtain under the heads then stop pushing Leave the heads in this condition for at least 5 minutes Set the valves back to I Set the Neg Pressure to 0 leave the system for 1 mi...

Page 23: ...econd stage purge the remaining 4 left heads K C M Y Finally open the 4 right heads again and purge all 8 heads together now By doing so you ll have the most optimal cleaning pressure Switch all heads and the Solution valve back to I Set the Neg Vacuum Pressure to 0 leave the system for 1 minute Ink will now start dripping out the heads Empty the sub airtank by opening the tap use a tube into a PE...

Page 24: ...all ink valves in the S position set the Solution valve to I On the Engine s Control Panel perform a Head Lift Up the carriage will go to the highest position Clean the Head Base Plate with a cloth Set the Vacuum Pressure to 0 Negative Pressure Mount the Capping Plate underneath the Head Base Plate use a plastic foil to wrap around the capping plate new foil every time place a support between the ...

Page 25: ...wards Startup the engine and switch the engine s PC back on ATTN carriage will move slowly to the Home position Move the carriage back to the Purge position Switch all ink valves back to I Perform a long purge until you see ink appearing out of the heads Let the ink drip for 1 minute Set the vacuum pressure back to 034 Negative Pressure Clean the heads and base plate Perform a nozzle check and pur...

Page 26: ...ension and height controlling These are acquired from the signal sensors The Front roll bar will wind the printed media holding a constant tension to reduce distortion Wind direction can be reversed Make sure you always insert the Tension Roll Bar at a correct way The ball bearing must be inside the guide When inserting make sure both side s are positioned as high as possible into the left and rig...

Page 27: ...elect motor direction CW or CCW In Manual Mode select motor Back or Front 4 Select Mode Manual or Auto 9 1 3 Roll Alignment When the roll media is loaded measure the distance from the right side A to the point where you want to start printing Enter this value on the engine s Control Program as a Left Margin 9 1 4 Vacuum For roll media even at full engine width you should only use vacuum table 1 fo...

Page 28: ...wing you to load one rigid This rigid can be small or at full engine width When you turn the button once more the nr 2 pin will also come down allowing you to load two rigid media While performing those actions the blue light will lighten up on the tower 9 2 2 2 Top and Left Margin Setup The A and B positions the o point at the corner of your media are known distances The A point has a Top margin ...

Page 29: ...rding the covered area on the conveyor belt When printing on two rigid media activate both the vacuum tables 1 2 more info see chapter 7 1 9 3 Media Roller Bars The engine has got one roller bar on the front and one on the back They are located underneath the front and back covers These bars will help to keep the media flat while it s been transported on the conveyor belt It can be used on Roll me...

Page 30: ...you want the Head Base to be above the media surface Recommended values 1 5mm for Rigid media and 2mm for Roll media Check Distance Enter the Distance from the Home position where the Set Gap must be executed This must be the HIGHEST point on your media Reference This is the point where the Head Base will wait for an on screen confirmation before going down to set the desired Gap Important Always ...

Page 31: ...ion Shuttle will move 800mm to the left and come down to set the Gap A sensor plate will become visible underneath the Head Base to make contact with the media surface The Head Base will lower to his Reference point and you ll have to confirm on screen Ready to Set Gap to make the last fine tuning This is lowering from the Reference point to the desired Head Base Height 2 mm Gap When this is done ...

Page 32: ...etup Menu to Change Parameters 10 Press to Open TEST menu 11 Select PASS mode 12 Push to start Printing 13 Open image file rtl to be printed 14 Lift head to highest position 50mm 15 Select to Uni Directional printing When you open an image file rtl which is sent from the Rip station you ll get an on screen preview and it will also show the image size and nr of passes the image is ripped for if an ...

Page 33: ...t Step size etc The dat files are best named after the Carriage Speed and head height e g s 1250_2mm_flex dat It s best to make a new dat file for every different head height also make a different for flexible and rigid media 11 2 1 Bi Dir Alignment This only applies to Bi directional printing You can change the value when you see that the drops are deviated from their correct position When printi...

Page 34: ...ng this you ll have a print with unfinished passes at the end helping you to evaluate the alignment The Bi Dir can be out of focus left or right Look at the end of the interrupted print A Too much left B GOOD C Too much right Change the Bi Dir Value Change the Bi Dir Value from e g 4965 to 4980 from e g 4965 to 4950 After changing use Save as and make a new dat file e g s 1250_2mm_flex dat In the ...

Page 35: ...se the Step Size value from e g 51660 to 51640 After changing the value use Save as and overwrite the existing dat file In the TEST menu select Parameter Download click on TEST Now the new value will be active 11 2 3 Carriage Speed The engine has got 3 pre defined Carriage speeds 900 1250 and 1525 These speeds are continuously variable We consider 1250 as the default speed When printing Uni direct...

Page 36: ... the carriage already started to print the next pass 11 2 5 UV Options See chapter 6 2 Curing setup and sequences for detailed info 11 2 6 Head Gap Control See chapter 10 1 Automatic Head Base Height Setup for detailed info 11 2 7 Factory Set This button is password protected It can only be used by an Agfa trained technician 11 2 8 Head Offset These are the Head alignment settings for each head in...

Page 37: ...8 09 2006 11 3 Test Menu 11 3 1 Jet Test See chapter 8 2 Daily Maintenance Nozzle check purge 11 3 2 Feed Step Test 11 3 3 Nozzle Test This allows you to test 1 nozzle of a particular head The requested nozzle is printed in a straight line ...

Page 38: ...r you ve changed a parameter in the Setup file which was marked with an use this feature to validate those new values 11 3 6 Carriage Release Test This feature is mainly intended for a Service engineer it allows the release of the Carriage motor which is normally anchored on both side s After executing it s possible to move the Carriage by hand from right to left IMPORTANT To end this test select ...

Page 39: ...led printout 12 2 Preparing the Anapurna 1 The carriage must be moved to the home position first Always make sure there is NO media or obstructions on the conveyor belt when you move the carriage to the home position 2 Place load the media rigid flexible onto the front side of the belt turn on the vacuum white lamp on tower vacuum is on 3 Load the correct setup file e g s 1250_2mm_flex dat 4 Perfo...

Page 40: ... and set the Print Mode to the correct passes check Status Message e g 8 pass Ready 3 Set the Top and Left Margin according your desired placement See chapter 9 1 3 and 9 2 2 2 4 Choose between Uni or Bi directional printing 5 Switch on the UV lamps See chapter 6 6 As soon as the green lamp comes up on the tower you can press the PRINT button green lamp on tower UV lamps are ready ...

Page 41: ...nt While printing press S and Y the print is then cancelled 12 5 Purge function on the printing While printing press S and N at Purge Request select Y the carriage will move to the Purge position After the Purge intervention press the OK button to continue printing ...

Page 42: ...uces 1 2 of your UV lamp heat Place the media at the 2nd register pins left side so you ll allow more surface cooling down time On very small media mask the conveyor belt area around the media ensuring a stronger local vacuum Use sheets of paper 13 2 Media corners lift a bit up rigid media Place another piece of rigid media in front of the loaded rigid This will ensure a stronger vacuum on the fro...