Ink Dispensing System IDS 10 User Manual - Vale
Contents
1. Main Controller Board 1014 Stepper Motor Controller Async Safety Piltz Relay Fuse Board 110 240 Switch 1015 Fuse 20mm 8 Amp Fuse 20mm 5 Amp Linear Power Supply LPS LPS Toroid Transformer LPS Capacitor LPS Rectifier Switch Mode Power Supply Air Control Box Complete Rex 3 Way Pilot Valve Manifold Rex Pot Pressure Regulator amp 1Bar Gauge Rex Air Input Pressure Switch Rex Incoming Air Regulator amp 5 Bar Gauge Rex Incoming Air Vent Valve Solenoid Rex Sounder PC inc Windows XP Exc Ink Manager Keyboard Mouse November 2007 SP Code SP 9127 SP 9128 SP 9006 SP 9004 SP 9005 SP 9881 SP 9036 SP 9038 SP 9110 SP 9868 SP 9861 SP 9873 SP 9399 SP 9215 SP 9376 SP 9238 SP 9416 SP 9200 SP 9119 SP 9421 42 SP 9141 SP 9385 SP 9410 SP 9412 SP 9011 SP 9022 SP 9007 SP 9023 SP 9125 SP 9124 SP 9120 SP 9077 SP 9078 SP 9079 SP 9129 SP 9801 SP 9802 SP 9803 SP 9804 SP 9805 SP 9806 SP 9003 SP 9891 49 Parts List cont IDS10 Series Machine User Parts List Page Item Description 4 1 Pot Sensor 4 2 Flexible Chain Assembly 4 3 Carriage Caster 4 4 Balance Lock Micro Switch 4 5 Balance Locking Handle 4 6 Scale assembly 10kg 280mm 4 7 Universal Pot Locater 4 8 Home Position Proximity Switch 4 9 Pot Sensor Reflector Tape 4 10 Dispense Valve Roller Switch 4 11 Roller Switch Actuator 4 12 Dispense Valve 4 13 Teflon Hose Specify Pot number 4 14 Motor Driv2. Ink Dispensing System IDS 10 User Manual VALE TECH LIMITED Unit 12 Depot Road Newmarket Suffolk CB8 OAL UK IDS10 Tel 44 0 1638 668583 668593 November 2007 Fax 44 0 1638 676720 E mail sales vale tech co uk valevtech Introduction This User Manual provides the user with a comprehensive guide to the machine The machine may be configured with 16 20 or 24 ink containers each with a maximum capacity of 10kg This comprises 16 containers within the main machine frame with an extension for each 4 additional containers The scale container range is up to 10kg accommodating 1kg 2 5kg and 5kg containers The User Manual identifies the requirements for the initial installation of the machine and continues to provide information for the effective operation of the machine on a day to day basis including maintenance to ensure a high standard of ink dispensing can be consistently achieved The Service section of this manual enables the user to identify any spare parts that may need to be ordered for the machine This product has been manufactured to the highest standards however should any difficulties arise before requesting technical support a speedier resolution can usually be reached by referring to the trouble shooting guide within this section A full set of drawings is also provided to assist in fault finding in the unlikely event of the product developing a fault Full Ink Manager Software training is provided
3. 7 2 Overweigh Protection Two photoelectric sensors are mounted in a position to scan across and through the locator plate and detect the following 1 That a container is present 2 The size of the container NG Ink container P sensors Batch size limits can be programmed into Ink Manager This ensures a batch cannot be dispensed if it is of greater size than the capacity of the container which has been detected on the balance Note The IDS10 will not perform a dispense operation if no container is detected on the locator plate If the IDS10 is required to dispense a quantity greater than the capacity of the container on the locator plate a warning will be shown on the screen giving the operator the following choice a Please reduce the batch size b Please increase the container size 7 3 Scale Calibration For the purpose of this example of the procedure a 10kg scale is to be calibrated using 9kg of test weights All Vale Tech scale systems calibrate at zero and then 90 of the full scale capacity For larger capacities using this principle a 30kg scale calibrates at zero and then 27kg and an 80kg scale calibrates at zero and then 72Kg IDS 10 31 November 2007 scale Calibration cont Always check the scale accuracy by selecting Show Scales from the drop down menu in Ink Manager and checking accuracy with a known weight before running the Scale Calibration option Always allow the scale
4. dispense and the machine operation will commence ea oe EEE Fn hots Diaper CELE ORARG As each component part of the formulation is dispensed the software will control the ink valve as described in 3 6 When the dispense is complete the dispense screen will clear and the container of blended ink can be removed from the scale unit If the software has been configured to allocate the ink to stock a box will appear and the allocation can be confirmed IDS 10 24 November 2007 4 Hardware Settings Ink Manager requires setting up to work with a particular machine and its requirements From the drop down menu select Options Settings General and the following screen will appear To configure the various fields refer to the Hardware Set Up in the Ink Manager Training Section tabase Users Weights and Measures Visual Preferences System Hardware Dispenser Type CAN l Manual Blending Hardware Manual Balance Port COM hd Manual Balance Type Vale MkII V1 11 and above Dispensing Hardware Balance Port ICOM Balance Type Vale Mkll Vi 1 1 and above Dispenser Port CO M2 Queuer Hardware Queuer Port CO M3 hd Bar code Hardware Default Label Printer Wee Ea _ Second Label Printer Not installed Label Scanner Port COMA To configure the ports which the various items of hardware are connected into and which type of balance
5. Inc AKD Assy SP 9116 Sub Assy Bellows SP 9115 Air Piston 8P 9114 ve Coarse DS Croescut Gasket Anti Drip Nozzle Fine Feed Spacer Assy SP 9111 Fina Feed Assy Comprising Teflon Retainer Ring PTFE Teflon m i j i Hing En RU 1 SP Insert Gasket and 4 SP 9117 SP Insert IA IDS 10 November 2007 47 DETH TAE 9 6 Level Sensor 1 Connector Block IDS 3P 8410 4 L vel Probe Assy MKII SP 8233 ET Ink Level Digitiser IDS SP 9410 3 F E Jack Plug amp Lead SP 9412 en IDS 10 November 2007 48 valente ch 9 7 Parts List IDS10 Series Machine User Parts List Page Item NN NDD NPNDDNDNDNDNRNND lt r gt gt a O OMAN OOH A A AON ml mm WWWWWWWWWWWWWWW WW W s NO Q3 14 IDS 10 Description Power on Indicator Power Indicator Bulb Emergency Stop Button Red Amber Green Colour Beacon Beacon Bulb Monitor 15 TFT Keyboard with Tracker ball PS2 Keyboard Cover Door Isolating Switch Reed amp Magnet Front Door Handle Levelling Foot Mains power Isolator Switch Quick Release Lid 1 Bar Lid Gasket Pot Vent Valve 8 mm Level Sensor Probe Hose Clip Dispense Valve 12 3DA BKT 1B 1 Htail Coarse Feed anti drip assembly Ink Delivery Hose Specify Pot Number Baffle Plate 25 Litre Ink Reservoir Ex Lid Ink Level Probe Digitiser Ink Level Probe Digitiser Lead
6. SLOWLY Place the correct locator plate on the balance The locator plate is required to ensure the container is positioned in the centre of the balance and secured firmly before the dispense process begins The balance and the locator plates are manufactured to suit customer specific container dimensions and weight requirements The locator assembles are keyed to only fit firmly in one position Ensure the locator plate is the correct size for the blend container to be used Adjustments can be made by re positioning the pins in the drilled slots in the upper locator plate All three must be positioned to keep the container central to the locator plate WARNING DO NOT USE THE DISPENSER WITHOUT THE CORRECT SIZE LOCATOR PLATE FOR THE CONTAINER Contact your supplier or Vale Tech Ltd direct if you do not have the correct size locator plate for the IDS10 Position the container to be used onto the locator plate and lift the handle Push the balance back towards the machine until it comes to a stop and then lower the handle into the lock position To ensure it is locked into the home position with the handle down gently try to pull it back out If it is correctly locked into position it will remain in place Note If the handle is not in the locked position the IDS10 will not dispense Locater plate adaptor for 1kg and 2 5kg containers Locater plate for 5kg container Balance assembl Balance i handle IDS 10 30 November 2007
7. and for diagnostic purposes Electrical Main Circuit Diagram Lead 1 Lead 2 Lead 3 Lead 4 Lead 5 Pneumatic Circuit Diagram 1 Circuit Diagram 2 Circuit Diagram 3 Dependant upon machine specification IDS 10 57 November 2007 TRAINING MANUAL 15 Ink Manager Software The Ink Manager Software Training Manual that follows will provide you with the information you need to use all the advanced functions and features along with basic instructions necessary for simple operation of the software It can also act as a complete package for structured onsite training IDS 10 59 November 2007 SERVICE LOE val te ch 16 Service Log This Service Log serves to provide contact information should additional assistance be required please refer to the contact details supplied below Forms available at the end of this section allow space for the service history of the machine to be recorded for future reference 16 1 Contact Information If you require any additional assistance or have any queries please contact Vale Tech Ltd Telephone 44 0 1638 668593 Fax 44 0 1638 676720 Email technical support vale tech co uk Website www vale tech co uk Address VALE TECH LIMITED Unit 12 Depot Road Newmarket Suffolk CB7 OAL UK IDS 10 61 November 2007 valdtech 17 Service History 17 1 Machine Fault Maintenance Log op Q Date Action Taken igne Ah IDS 10 November 2007 62 valeste
8. coarse feed for the bulk of the dispense down to approximately 100g before completion coarse pulsed feed giving coarse feed control down to approximately 20g before completion fine continuous feed down to approximately 10g before completion and finally fine pulsed feed down to completion of the dispense There can be up to 6 separate stages of dispense although they do not all have to be used For the purpose of this example 200g of ink is to be dispensed utilising only 4 of the stages Name field Folder tabs EEn Confane 2 Sippy Container 7 SCEE Supr Container 5 Supply Container 6 Supply C Name Ink il Valve Calibration Container Type Lis Pressunsed Active Coarse Pulsed Target Flow sei Completion Pees Stagel wv he a 100 Switched Pump Stage wf iw w 5 w 3 Level Sensor Stage3 w El a 10 Disable Level z Stage4 w a i 03 0 01 Capacitive Stage5 ra m Switch staget T Jr C 48 Calibrate Main Tank Levels Board ID Input Board ID Output Cylinder Up switch iy Cylinder Up relay hade Cylinder Down switch 1 Cylinder Down fela 1 Level Input lo no Dispense Valve n oO Header Tank Vent Valve Ts Enabled 5 ader zt Recirc Agitate Valve U oO io smilie Pump Control SA Drip Wipe Index lo The required speed of The length of time measured The weight remaining to dispense when the valve is in milliseconds that the valve is be dis
9. down to the new Completion Weight of 10g Total of 190g of Ink dispensed into the container Stage 4 Is Active or enabled Fine feed valve will pulse open for 60 milliseconds before closing and dispense at a target flow rate of 0 3grams second 2 Now down to the new Completion Rate of 0 3g This allows for the ink tail which may form at the outlet of the dispensing valve to be included For thicker inks this can be increased and for thin inks this can be zero 0g Total of 200g of Ink dispensed into the container WARNING IF STAGE 1 IS DISABLED THEN THE IDS10 WILL NOT DISPENSE ANY OTHER STAGES Note Container Type The IDS10 uses a pressurised container with the air pressure set at 0 8 1 0 bar Level Sensor Type The IDS10 uses capacitive sensing Optional header Tank The header tank is used to contain ink when a bulk container system and pump is used in conjunction with the IDS10 IDS 10 22 November 2007 Dupenpsint 3 6 What happens if the same ink is used in more than one of the ink Supply containers The IDS10 is designed to allow the operator to fill more than one of the supply containers with the same ink This is more commonly used for colors that are most frequently consumed In this case the same ink reference has to be given to both of the Folder Tabs when setting the Flow Rates See section Valve Configuration The IDS10 will dispense from the one of the containers until the empty point is
10. reached if this was to happen in the middle of a dispense sequence the IDS10 will automatically divert to the second ink container and continue to complete the mix warning message in Ink Manager will inform the operator that the first container is empty The IDS10 will now continue to use the second container until it is empty When the second container reaches the empty level the dispensing will automatically switch back to the first container By this time the first container requires re filling See Section Loading Ink Dispensing ink For instruction on entering recipes see Ink Manager Training section select the Ink Series to be used from the drop down menu and select the recipes tab at the bottom left of the screen In the recipes window locate and select the recipe to be dispensed place the curser over and highlight it using the right mouse button From the drop down list highlight dispense and select it using the left mouse button IDS 10 23 November 2007 val amp tech DH penrsing Sautons VOordsrde Dispensing ink cont Enter the dispense quantity and click OK Enter Dispense Quantity Enter Job Number Please Enter Required Quantity Enter Job Number E Kgs Cancel Enter the job number if required and click OK If the ink is not to be allocated to a job click ok The dispense screen shows details of the ink formulation to be dispensed Select
11. to stabilise for 30mins before checking the calibration Select Show Scales and allow the scale to tare If a small amount of fluctuation is seen this can be reset by clicking on Tare Scales If the scale value continues to climb or fall check for touch down of the scale and start again If there is no touch down and the scale will not stabilise contact Vale Tech for further advice Place known weights on to the scale weigh pan conformance weights supplied with the machine and verify the scale is within the allowed tolerance If it is calibration is not required If it is not follow the calibration procedure If it is determined that the scale requires re calibration log on to Ink Manger and ensure the scale calibration privileges are available by selecting Options Scale Calibration from the drop down menu If this option is not available see your system manager log in details The following screen will be displayed Calibrator scale Range Version I status FE range speed Full scale BO0240 zero 034049 Average Value Filter FFFF serial 4655 en average Hest Cancel This is the basic scale programming information stored on the scale board that Vale Tech service may ask for if there are problems calibrating the scale Check the scale range is correct The example above shows a 10Kg range Scale Board The average setting should be 02 on all scales IDS 10 32 November 2007
12. vibrations draughts and touching the scale during this time The blue progress bar indicates the stage of the procedure Calibrator Information Allowing balance to settle When the scale has finished recording the Zero value the folowing screen is displayed IDS 10 30 November 2007 scale Calibration cont Calibrator Information amp Calibration Place 9kg of conformance or calibration weights centrally on the scale with the balance locked in the home position as shown Click OK The scale will then allow time for the readings to settle before values are displayed and counting up to the calibration weight value This will overshoot up to three times reducing less each time as the calibration point is reached Calibrator Informations Calibrating full scale point Please wait 7775 8 Hest Cancel The final value in this example 9kg will be displayed as the value is stored During this stage it is again important that the scale is not exposed to vibrations draughts or being touched IDS 10 36 November 2007 valente ch Scale Calibration cont Callbratar Calbrsbrg full scale pont Please wail li After the full scale point is stored the following message will be displayed Calihratar Calibration eed band ee Test balance opm skier by pang vahis om the Click OK to return to the calibration window The final weight will be displayed Calibrator 1 Test b
13. 0 November 2007 40 8 3 Ink Supply Container amp Valve a Ensure container lid inside rim and gasket are clean and free from ink and contamination Check for air leaks around lid Check sensor connector cable Check level probe is not damaged Check air lines for leaks Check dispense valve is clean and leak free Check that coarse and fine dispense nozzles are clean Check hose is clean and leak free Ensure pipe clamp is secure 0 Check container seam is leak free OND OF WN IDS 10 41 November 2007 SERVICE MANUAL vald Fed 9 Spare Parts 9 1 External Parts 4 Beacon 6 YS SP 9004 Monitor 5 SP 9881 Beacon bulb 7 SP 9005 Keyboard SP 9036 3 8 Emergency st Keyboard en cover SP 9006 SP 9038 1 9 Power on Door cr indicator switc SP 9110 gt Power indicati bulb 10 SP 9128 Door handle SP 9868 12 Mains power isolator switch SP 9873 11 Leveling foot SP 9861 IDS 10 43 November 2007 val tech 9 2 Ink Supply Container and Valve 2 Quick release lid ae SP 9399 3 T ma a DE Pot vent valve l2 HH rk SP 9376 Ink level probe digitizer lead SP 9412 11 ed Z Ink level probe digitizer SP 9410 Level sensor probe SP 9238 10lt ink reservoir 10 er 9 SP 9385 4 id Hose clip Baffle plate SP 9416 SP 9141 8 Ink delivery hose SP 9421 42 6 Dispense valve SP 9200 Coarse feed anti drip assembly SP 9119 IDS 1
14. 0 44 November 2007 2 9 3 Pneumatics and Electronics 1 Main Controller Board PCB1014 13 SP9011 Sounder SP 9003 2 Stepper Motor Controller SP 9022 3 Safety Piltz Relay SP 9007 4 Fuse Board SP 9023 Fuse 20mm 8Amp SP 9125 5Amp 14 9 SP 9124 PC Linear Power Supply SP 9891 SP 9120 LPS Toroid Transformer SP 9077 8 LPS Capacitor 3 Way Rex SP 9078 Solenoid LPS Rectifier Manifold SP9079 SP 9802 12 Main Vent dump Solenoid Valve SP 9806 9 11 Pot Pressure hpa ila Air Regulator Upply 5 Bar po SP 9805 SP 9803 10 if Air Input Pressure Complete pneumatic pee my ER Switch box assembly pe SP 9804 SP 9801 3 IDS 10 November 2007 45 val amp tech 9 4 Carriage Assembly 13 12 Teflon hose Dispense valve Roller switch valve Stepper motor p actuator SP 9200 pp roller switcr SP 9635 i 14 SP 9260 pe Motor drive gearbox 5 SP 9261 Pot sensor 16 reflector tape pr P 94 ai coupling 8 SP 9262 Home position proximity switch 7 Universal 1 container locator Pot sensor SP 9310 SP 9411 2 Flexible chain a assembly lt SP 9076 En a 3 Carriage caster SP 9327 2 Carriage 4 re nd 9 A lock micro SP 9159 Balance locking switc handle 18 SP 9109 de Scale assembly comms power lead SP 9678 4 IDS 10 m November 2007 valet ech Gane MELINS Wet 9 5 Dispense Valve 1 BARB 5 BSP M Actuator x2 Assy
15. 1inch 25mm above the bottom of the level sensor probe in the container Level Sensor Full point Empty Point IDS 10 16 November 2007 valetech Dapersing Sautons Wiirde 3 3 Setting Ink Levels cont Select Set Empty button to set the empty level for this colour The numerical value for this will be recorded in the box above Set Empty button This ensures that the container will show the empty point BEFORE the ink reaches the bottom as previously explained Ink nnager fe Bepa ipaka oeh Mies bte Speco em Hei nn Snes IDS 10 17 November 2007 valetech Oe pensing Sauinas Wende Setting Ink Levels cont Continue to fill the container to a maximum level of 1 2 Inch 12mm below the bend at top of the probe When this is done click the Set Full button The numerical value for this will be recorded in the box above the Set Full button The value shown in the box for the full level should be smaller than the value of the empty point level Valve Configuration ca Iw vr Iw a gi E Calibrate Header Tank Levels Controller IE Level Sensor Irr Crarnrel S r Or Set Empty Indicatio Set Full Indication Note The live value in the boxes Set Empty Indication and Set Full Indication will be recorded into the selected container number into either the full or empty points depending on which button is clicked Therefore it is important to g
16. Pre Install Information IDS10 16 24 colour 10kg dispenser 350mm 1350mm 480mm 605mm 1220mm 500mm 480mm 1270mm IDS 10 November 2007 iuris Por 1 1 1 Services Connection Requirements 5 Bard 100 Litres minute 90 P amp 8122 Gallons minute minimum tee rn bur Supply n Electrical Supply 115 230VAC 50 60Hz 3 Uninterruptable 650 WA UK 2304 Supplied Power Supoly 1200 VA US 115 Recommended Air Supply to be Regulated and Filtered Electrical HM Airline i ere d onnecter ISAE B Bolte supplied by Vale Tec1 Air Supply Allow Hmm clearance at ihe rear of the machine 6 Bar for connections ond remma of the reor panal Minimum Adr Lipa G Ear Minicom iiach BSP Percale IDS 10 8 November 2007 val tech 1 2 Positioning of Machine The IDS10 comprises one primary module measuring 1 62m D x 1 4m W x 1 6m H It should be sited in its desired location by moving with a forklift or pallet truck remembering to ensure there is a requirement for a minimum of 300mm of clear space at the back of the machine for access to enable the connection of primary services and clearance at either side to gain access to the electrical and pneumatic supply cabinets After positioning the IDS10 ensure that all the feet are placed flat on the floor before leveling Correct leveling is achieved by placing a spirit level on all four corners and also across the frame Adjustment to the height of th
17. alance Assembly 7 2 Overweigh Protection 7 3 Scale Calibration Cleaning amp Maintenance 8 1 Dispense Valve Assembly 8 2 Carriage Assembly 8 3 Ink Supply Container amp Valve November 2007 20 26 26 26 2 2 28 28 29 30 30 31 31 39 39 39 41 valevtech Vale Tech IDS10 SERVIGE MANUAL 9 Spare Parts 9 1 External Parts 9 2 Ink Supply Container and Valve 9 3 Pneumatics and Electronics 9 4 Carriage Assembly 9 5 Dispense Valve 9 6 Ink Level Sensor 9 7 Parts List 10 Preventative Maintenance Programme 11 Trouble shooting Guide 11 1 Common Problems 12 PC Hardware Configuration 13 Ink Manager Hardware Configuration 14 Drawings TRAINING MANUAL 15 Ink Manager Software SERVICE LOG 16 Introduction 16 1 Contact Information 17 Service History 17 1 Machine Fault Maintenance Log IDS 10 November 2007 42 43 43 44 45 46 47 48 49 51 52 De 54 56 57 58 99 60 61 61 62 62 valevtech iri Declaration of Conformity amp Quality Vale Tech Limited Hereby Declares That Machine Project Is in conformity with the provisions of the machinery directives as listed below The Machinery Directive 98 37 EC Machinery is described in the Directive as an assembly of linked parts or components at least one of which moves with the appropriate actuators control and power circuits etc joined together fo
18. alance opersbon by plaong weights on the bala Cae dana hor fe 9000 2 The scale calibration can be tested using this window To do this remove all the weighs from the scale replace the weigh pan and 5kg Container Locator then click on Tare IDS 10 3 November 2007 scale Calibration cont ee me Place the calibration weights on the scale in 1kg increments and record the value displayed at each point again with the balance locked in the home position as shown If the scale is within specification at each of the calibration points click Done Calibration is complete If calibrator screen indicates the weight incorrectly click Done to close the current window and repeat the calibration procedure If repeating the procedure does not achieve the desired results please contact Vale Tech Technical Support IDS 10 38 November 2007 8 Cleaning amp Maintenance 8 1 Dispense Valve Assembly Check for damage to pipes Check for leaks between fittings and valve assembly 8 2 Carriage Assembly Check dispense valve air pipes are free from leaks Check ink container location sensors are clean Check carriage stop switch IS secure Check belt for damage and ink contamination IDS 10 39 November 2007 DH rey Silt Carriage Assembly cont Check flexi chain IS not damaged and track is clean Ensure castor Is clean and free running Ensure guide rail is clean IDS 1
19. ard Disk or Boot device Registry device files error message Hangs loading Windows no error message displayed PC still not getting into Windows Monitor appears to be broken or switched off No power to PC or machine Machine appears to be dead Press on button at front of PC If LED still not on check that Power Supply Switch at back of PC is on then press PC on button Check Power cable is secure press PC on button Check monitor is switched on press button on front of display Check Monitor cable at back of PC is secure plugged in turn monitor off then on again Display is stuck in power save mode turn monitor off then on again Ensure keyboard is secure plugged in then re boot Hard disk fault call Vale Tech Technical Support Call Vale Tech Technical Support Re boot with Ctrl Alt Del keys or switch PC off then on again Call Vale Tech Technical Support Check monitor power is switched on Check monitor is not in power save mode by pressing a mouse button or keyboard space bar Check mains power to machine Check Isolator switch is in ON position Check PC is switched ON 52 valevtech IDS Dispense Problems Low no air pressure Slow dispense IDS will not reset IDS 10 November 2007 Air pressure stays low after containers are turned on Air leaks at supply container Air leaks from lid fittings No air pressure
20. blem is not listed here what do I do now IDS 10 November 2007 The ink level sensors are not reading or are reading incorrectly They appear to be reading either full or empty when they appear to be neither There is no weight output or the weight shown is incorrect Machine resets ok but balance carriageway will not move Green Mains power is no longer lit on the front panel of the machine One or more of the beacon bulbs are not at all lit during the normal operating cycle of the machine Machine will not dispense ink from valves A Comprehensive list of Technical Bulletin Guides Have been produced to help you to resolve the problem These are available from Vale Tech Ensure Digitisers on containers are fully plugged in and working properly Check Min amp Max Levels have been set in Ink Manager Service personnel to ensure that the Ink Level sensor input PCB dip switch settings are correctly configured Check the calibration of the machine if necessary recalibrate Check settings in ink manager are the same as settings in the Hardware Configuration sheet Check side and front doors are all securely closed Service personnel to check 5 8 Stepper Motor Driver Board protection fuse located on Electrical Chassis service personnel to check the mains power supply bulb has not blown fit a replacement if necessary service personnel to check each of the beacon bulbs have
21. ch Machine Fault Maintenance Loa cont Date Action Taken Signed IDS 10 November 2007 63
22. e the emergency stop circuit within the electronics of the machine The machine will require resetting as detailed in Section 2 2 before any operations can be carried out and to stop the alarm sounding If the Emergency Stop button is depressed during a dispense operation this will be aborted To release the Emergency Stop the button must be turned anti clockwise ensuring that it is not depressed further preventing the button from releasing 5 4 Alarm Sounder The sounder is an alarm which alerts the user to any problems that occur with the machine It is located to the left of the Airbox assembly The alarm volume and tone can be adjusted via settings within the sounder For volume adjustment a screw can be found on the underside and by turning this either way the volume can be decreased or increased accordingly For tone adjustment a series of switches which can be placed in various position combinations alter the tone Note It is important that before any adjustment is made the user is reminded that the sounder is a safety feature that must be audible above the ambient noise of the workplace lam I Pi ee Tone av 7 E adjustment Sounder Sounder underside top Volume adjustment IDS 10 27 November 2007 DH ey esi lt 6 Ink Supply Container 6 1 Ink Supply Container Lids The supply container lid provides a pressure seal for the container via the gasket To remove a lid turn the blue air valve beside the containe
23. e Gearbox 4 1 4 15 Stepper Motor 4 16 Motor Drive Coupling Stepper Gearbox Assembly Complete Carriage Slides Pair 4 18 Scale Assembly Comms Power Lead IN oh N Actuator Bellows Air Piston Coarse Anti Drip Nozzle Assembly Fine Anti Drip Nozzle Assembly 1 2 SP Insert 0I OI O 1 0 A Hd TROND Connecter Block Ink Level Digitiser Jack Plug and Lead Level Probe Assembly O ODO RON IDS 10 November 2007 SP Code SP 9411 SP 9076 SP 9327 SP 9109 SP 9316 SP 9159 SP 9310 SP 9069 SP 9408 SP 9634 SP 9635 SP 9200 SP 9421 42 SP 9261 SP 9260 SP 9262 SP 9681 SP 9627 SP 9678 SP 9116 SP 9115 SP 9114 SP 9111 SP 9138 SP 9117 SP 9410 SP 9410 SP 9412 SP 9233 50 val te ch 10 Preventative Maintenance Programme Scale unit Check Comms and power lead are securely connected Scale feet are located correctly and balance is level Balance calibration WEEKLY Locator plates are clean amp undamaged Excessive ink on scale and scale support Container sensor and reflector are clean and functioning AS NECESSARY Carriage Check Drive belt carriage follower rollers and scale unit support castors are free from ink and dust contamination Check linear drive belt for alignment for wear and tear Carriage runs smoothly to its full extent at even speed Linear slide and scale unit support rail are free from ink and dust contamination Roller switch actuator shows no sign of damage and activates all of the rol
24. e IDS10 is done by adjusting each of the corner feet up or down as necessary 1 3 Connecting Electrical Supply Connect mains electrical power rated at either 115V or 230V 50 60 Hz to the UPS Uninterruptible Power Supply as illustrated or inlet power socket mains input if no UPS is fitted This is located inside the machine on the right side and indicated as POWER Removal of side panel is required for access to these connections Power to PC Main electrical power supply from UPS to machine UPS Mains electrical power supply to UPS IDS 10 9 November 2007 DApA rH 1 4 Connecting Air Supply Connect an airline from an external filtered clean dry regulated air supply to the air input connector This is located on the air manifold assembly within the left side of the IDS10 The air is connected via the quick fit air coupling supplied by Vale Tech and requires 8mm hard walled hose for the push fitting Alternatively the air supply can also be fitted using soft wall hose and a Jubilee Clip Use Imp bore or Met 12 70mm Imp 3 4 or Met 19 20mm o d air hose Air input connection gt ae Quick fit Air Coupling 1 5 Connecting the PC Connect the Keyboard and Monitor cables to the appropriate ports on the back of the PC refer to the configuration data in the service section Now connect network printer scanner and telephone modem connections to the PC if additionally required Note Befor
25. e powering on the PC Please ensure that its Power Supply Unit is set to the correct mains power voltage either 115V or 230V Full range PSU s are auto switching 115 230V IDS 10 10 November 2007 2 IDS 10 Start Up Procedure 2 1 Switching on the IDS 10 Before switching on the PC or IDS10 machine make sure that the Ink containers initially have their air valves turned OFF at the lids Now switch on the IDS10 by turning the mains ON OFF isolator switch on the lower right side of the machine CLOCKWISE to the ON position Now turn on the PC and the monitor The PC is located at the lower right side at the front of the machine and the power button is accessible through the open panel At this point the red light on the beacon will be illuminated and the alarm will be sounding 2 2 Log on and Dispenser Initialisation Once the PC has powered up launch the Ink Manager Software program and logon If there are no user accounts create these by logging on as administrator password supplied separately A Lt lnkM anager VaALE TECH rik amager IDS 10 T November 2007 val amp te ch DE persiag Sautoas Viordarde 2 2 Log on and Dispenser Initialisation cont When Ink Manager opens a formulation list will appear on screen The machine requires a reset to be carried out as follows Highlight Options Dispenser Reset After completing the reset process the sounder should stop and the beacon w
26. er Push button to open lid clamps IDS 10 15 November 2007 val amp tech 3 3 Setting Ink Levels Ink level sensing is achieved by monitoring the levels in the individual containers using a probe mounted on the inside of each container The probe comprises 2 insulated steel rods spaced 20mm apart One side is electrically isolated from the container The probe is mounted vertically inside the container with the end of the probe as close to the bottom of the container as possible The way in which the low level value is set ensures that the container empty point registers prior to the container actually becoming empty This eliminates air being drawn through to the dispense valve and ink spitting from the valve which may happen if the container was to actually become completely empty The high level value is set with the ink below the top of the level sensor probe keeping the ink away from the lid and its sealing gasket and well below the container air pressure inlet To set the ink levels select Options Dispenser Valve Configuration from the drop down menu in Ink Manager Once this page opens click on Calibrate Main Tank Levels to open the setting up option The diagram below shows the ink level probe and ink level indication within the ink container To begin setting the ink levels ensure the correct colour ink from the Setting Ink Names list in 3 1 is selected and pour in enough ink to cover approx
27. ill change from red to combined green and amber The balance will move to the home position at the front of the machine and the secondary air supply regulator will switch on If the dispenser does not reset check that the emergency stop button is released Note If the emergency stop button is depressed release it by turning the button clockwise and allowing it to spring out Ensure that the button is not depressed further whilst turning it or the button will not release After the initial IDS10 pressurisation turn the blue air valves located at the sides of the machine and feed the ink containers to the ON position one at a time Ensure the lids are secure and check for any minor air leaks IDS 10 12 November 2007 2 3 IDS Beacon Warning Indicator IDS 10 November 2007 RED Indicates Emergency Stop Switch activated or machine in initial Power ON state AMBER Indicates the balance dispenser is moving GREEN AND AMBER Indicates machine in RESET condition or ready to dispense GREEN Indicates machine is in the process of dispensing ink 3 IDS10 Ink Set Up 3 1 Setting Ink Names WARNING DO NOT FILL THE INK SUPPLY CONTAINERS WITH INK UNTIL THIS STAGE HAS BEEN COMPLETED The reference or description for each ink to be used must be allocated to each of the supply containers to be filled The corresponding ink will be put into the container later when filling commences Complete the Ink Reference names in the space pro
28. in container Containers not pressurising fast enough because low pressure is used No apparent air leaks Beacon light flashes from green to red Door switch active Emergency Stop activated All doors are closed Check air pressure regulators with containers turned off Valve 5 bar Container 1bar if low check air supply is good first then adjust gauges to specified pressures Check for air leaks Check and clean gaskets and lids all sealing surfaces must be clear of ink or contaminants Check lid is securely closed Check air in lines are secure push firmly into container vent finger valves Require engineer adjustment or replacement Check lid is closed and air is turned on Turn all containers off and then turn each container on individually allowing each container to pressurise before next is turned on Check flow rates set in dispenser Setup have not been set too low Call Vale Tech Technical Support Close any doors with sensor switches Release Emergency Stop switch Faulty switch call Support Call Vale Tech Technical Support 53 valevtech Ink Levels are wrong Balance errors Balance carriageway will not move Green Mains power indicator bulb is no longer lit on the front panel One or more of the beacon Red Amber Green bulbs are no longer lit Warning message Feed rate too slow always appears during a dispense My machine pro
29. is being used please refer to the Hardware Configuration information in the Service section of this manual for settings Note Hardware settings should only be changed by authorised personnel engineers IDS 10 25 November 2007 5 Safety Features The IDS10 dispensing machine incorporates safety features which work to prevent any potential injury or harm to the user or to the machine The safety features must not be tampered with When handling ink and lacquer products for use in conjunction with the IDS10 suitable protective equipment must be used Use latex or similar gloves eye protection suitable safety shoes and overalls to protect from splashes and spills 5 1 Isolator Switch The main power isolator switch is located on the right side of the machine When maintenance is being carried out the power must be isolated and the switch locked with a padlock 5 1 2 Door Switch The front door of the machine has a safety system which requires the door to be closed before a dispense operation can be started If the door is opened as a dispense is about to start or while the machine is in operation it will stop The operation will resume once the door is closed Magnetic interlock to disable machine if front door opened IDS 10 Warning 26 November 2007 notice Safety Features of the IDS10 cont 5 3 Emergency Stop Switch Pressing the red button labeled Emergency Stop at the front of the machine will activat
30. k valve will only dispense from the fine feed outlet Active Coarse this opens the valve to dispense to the Completion preset value of that stage from the coarse feed outlet Active Coarse Pulsed this Pulses the coarse feed to the Completion preset value of that stage at the preset Target Flow rate Active and Pulsed this Pulses the fine feed to the Completion preset value of that stage at the preset Target Flow rate IDS 10 21 November 2007 3 5 How does the Ink Valve function during a dispense cont The dispense example uses 4 stages to complete the process the break down of each dispense stage is as follows and for the example the dispense ink quantity is 200g Stage 1 Is Active or enabled Coarse feed valve continuous dispense From 200g down to the Completion Weight of 100g Total of 100g of ink dispensed into the supply container Stage 2 Is Active or enabled Coarse feed valve will pulse open for 100 milliseconds before closing and dispense at a target flow rate of 5grams second The target flow rate should be adjusted in increments of 10 if the target rate is difficult to achieve if the dispense time is taking too long for example 2 Now down to the new Completion Weight of 20g Total of 180g of Ink dispensed into the container Stage 3 Is Active or enabled Fine feed valve continuous dispense Now
31. ler switches WEEKLY Dispense alves Check Base of valves are clean Ink leakage from actuator fittings Check air lines to actuators are secure and not leaking EACH TIME CONTAINERS ARE CHANGED OR WEEKLY Flow rate configuration WEEKLY Air system Clean Filter and ensure air pressure is set to minimum 82psi 6 bar WEEKLY Ink containers Check Air settings to ink containers and valve actuators and adjust as required Ink supply container vent valves for damage or air leaks WEEKLY General Check machine for cleanliness and for mechanical integrity WEEKLY General Check main air pipes and fittings and electrical cables and fittings for signs of wear WEEKLY General Check safety switch to door and emergency stop buttons are functioning correctly DAILY General Check and report any mechanical damage or signs of misuse AS NECESSARY IF INANY DOUBT DO NOT USE THE MACHINE UNTIL A VALE TECH OR AN AUTHORISED SERVICE AGENT HAS CLARED THE MACHINE FOR USE IDS 10 51 November 2007 val amp tech 11 Trouble shooting Guide 11 1 Common Problems PC not coming on booting IDS power is on but no light on at front of PC PC LED is on but no display PC not getting Into windows Monitor screen has turned dark but PC is switched on Machine does not work at all IDS 10 November 2007 No Power No Display LED Display LED is on Display LED is amber or red Reports Keyboard error Error message H
32. not blown fit replacements if necessary Check main air supply is switched on Check the lid of the ink container is correctly fitted and the air tap is turned to the ON position service personnel to check air regulator settings are correct inside electrical chassis Contact your Authorised local Service Agent or contact Vale Tech Ltd direct on Office 44 0 1638 668593 Fax 44 0 1638 676720 Email technical support vale tech co uk 54 12 PC Hardware Configuration The following information is recorded during the final quality control checks and reflects the PC configuration prior to shipping Any changes made to the configuration after this may not be recorded This record may provide essential information in restoring system operation in the event of system failure Please do not remove it from this folder IDS 10 November 2007 55 13 Ink Manager Hardware Configuration The following information is recorded during the final quality control checks and reflects the Ink Manager Hardware configuration prior to shipping Any changes made to the configuration after this may not be recorded This record may provide essential information in restoring system operation in the event of system failure Please do not remove it from this folder IDS 10 56 November 2007 14 Drawings The following drawings are provided for use by plant engineers authorised service engineers to assist in the servicing of the IDS10
33. o through the filling of the ink containers and the setting of the low and high level procedure in the correct sequence If the Set Full button is clicked before the container is filled the value indicated will be stored as the full value If the Set Empty button is clicked when the ink container is full the machine will not dispense even though the container is full This is due to the software interpreting the signal sent from the Level Sensor Probe indicating that the container requires re filling IDS 10 18 November 2007 val amp tech setting Ink Levels cont The Weight field is optional This will allow a check of approximately how much ink by weight is in a particular container at any time To set this feature select Options Dispenser Ink Level Configuration and enter the quantity of ink by weight which was used to fill the container between the empty and full points into the weight box of the appropriate ink container Level Sensor Configuration Current Level Empty Pant Full Point Weight Disabled Current Level Empty Point Full Point Weight Disabled TT TT on on i TI TI Cc cc I N TI TI Ta TITT Co 4 1 0 2 0 3 FP 3 4 o of 5 of of o 6 0 7 0 EE 9 4 4 4 4 4 4 4 4 i dl Je II LL TI 4 a q m eee oo Jm x Set Empty F6 Set Ful F7 To view the levels of each of the inks within the s
34. pensed at which this pulsing in gms second open when it begins to pulse stage ends November 2007 3 5 How does the Ink Valve function during a dispense The ink valve is controlled by the Ink Manager Software to open allowing the flow of ink through the large outlet coarse feed and small outlet fine feed Both coarse and fine feeds can be set to complete the end of their dispense operations by pulsing the flow to reach the desired quantity The feed profiles are activated by setting parameters in the Ink Manager software causing the valve to achieve it s pre determined operation Coarse constant feed Fine constant feed Supply Container 1 Supply Container 2 Supply Container 3 Supply Container 4 Supply Container 5 Sfpply Container 6 Supply C_4 Name Ink 1 Valve Calibration Container Type Targets Pressunsed Crear Initial On Active Coarse Pulsed Target How Period Completion Pressout Stage W W 5 100 20 Level Sensor Stage J 10 Disable Level Stage4 l 0 3 60 0 1 Capacitive Stage IE Seach Stageb Calibrate Main Tank Levels ee TE sco CO Cylinder Up rey de bee Cylinder Down relay Level Input o i Dispense Valva 1 Vent Valve Recirc Agitate Valve V0 Pump Control Drip Wipe Index Coarse pulsed feed Fine pulsed feed By ticking Active this opens a dispense stage If the Coarse or Pulsed options are not selected the in
35. r a specific application in particular for the processing treatment moving or packaging of a material The manufacturer is responsible for verifying whether a particular product falls within the scope of the Machinery Directive The Pressure Equipment Directive 97 23 EC The directive provides control over equipment subject to pressure Pressure equipment being vessels piping safety accessories and pressure accessories A pressure assembly being several pieces of pressure equipment assembled to form an integrated functional whole The EMC Directive 89 336 EEC The Directive applies to most electrical and electronic apparatus that is finished products and systems that include electrical and electronic equipment The Low Voltage Directive 73 23 EEC Broadly the Regulations apply to most consumer commercial and industrial electrical equipment designed for use within the voltage ranges 50 V ac to 1 000 V ac and 75 V dc to 1 500 V dc Remarks amp restrictions for this declaration This declaration is no longer valid if any changes are made to the machine which is not corresponding to the abovementioned standards Place and date Newmarket G Adlem Mechanical Engineering C Stapleton Electrical Engineering M Hughes Director N Scott Director Representing Vale Tech Ltd 12 Depot Road Newmarket Suffolk CB8 OAL United Kingdom IDS 10 6 November 2007 val amp tech DEPA 1 Installation 1 1
36. r which is to be opened to the OFF position This allows the container to fully vent de pressurise When the hissing sound of escaping air ceases fully press the button on the side of the centre handle of the lid to release the side clamps allowing the lid to be lifted clear of the top of the ink supply container Ink Supply Container lid Top Ink Supply Container lid Underside with gasket removed Ink Supply Container lid Underside with gasket fitted To replace the lid ensure the gasket is clean and securely seated in position Place the lid on top of the ink container and press down the centre button to close the clamps Switch the air valve to the ON position and as it pressurises check for air leakage IDS 10 28 November 2007 Ds errsiri 6 2 Supply Container and Valve Air Regulator Adjustment The air supply enters the left side cabinet of the IDS10 through a filter The first air pressure regulator controls the air supply to the ink valve actuators with a pressure of 5 6 bar and the second air pressure regulator controls the air Supply to the ink containers with a pressure of 1 bar Air supply to ink Air supply to containers actuators Incoming air supply Regulator Set to 5 ML Ink Container air pressure valve set to 1bar IDS 10 29 November 2007 7 Balance assembly 7 1 The balance assembly Open the front door of the IDS10 and lift UP the handle Pull the balance out
37. scale Calibration cont Click OK and the following screen is displayed Calibrator Calibration Click OK and the following screen is displayed Calibrator 1 Press Tae 2 Place 10K g on the ee note the fral value 3 Remove 10Kg weight A Remove pot locator sits and tare plate fitted 5 Press Mest 183 5 Above is the Calibrator screen showing current weight and instructions on creating pre calibration figures which will be required for the purpose of completing a calibration certificate If it has been established that the scale is not out of calibration then recalibration is not required and cancellation of the procedure can be achieved at this point If calibration is required clicking on Next will start the calibration procedure which is irreversible Ensure the required conformance or calibration weights are available along with the Light Weigh Pan as shown IDS 10 33 November 2007 DAPAT Scale Calibration cont If the calibration is to take place now before clicking on Next remove the Universal Container Locator the 5kg Container Locator and the Weigh Pan as shown Place the Light Weigh Pan squarely on the Internal Weigh Pan with the balance locked in the home position as shown IDS 10 34 November 2007 scale Calibration cont Click Next and the calibration procedure begins The procedure allows the scale to settle before the reading is taken Avoid
38. upply containers select Options Dispenser Ink Levels Supply container Levels x 1 INK 0 Kgs 13 INK13 ME 2100 ko 2 INK2 0 Kas 14 INKi4 HE 0 60 kgs 3 INKS 450 Kgs 15 INKI5 AE ku 4 IMKA 480 Kos 16 INKIE EE ka 5 INKS 0 ka 17 INK17 en oe 6 INKE 900 Kos 18 INKIS EE ko 7 INK I Kgs 19 Contanet8 00 Kas o INES Kas 20 Cantainel3 00 Kas 3 INKS 470 Kos 21 Containerz0 O10 Kas 10 INK1O D Kgs 22 Contaimer2t OO Kas 11 INK11 460 Kgs 23 Contamer22 00 Kags 12 INK12 480 Kos 24 Contaner23 Kgs IDS 10 19 November 2007 val te ch 3 4 Valve Configuration To allocate settings to each ink container open the Valve Configuration settings Select Options Dispenser Valve Configuration from the drop down menu in Ink Manager Each container has its own Folder tab and must be allocated the correct colour reference in the Name field before the valves can be configured for their flow rates For this information please refer to the list in Setting Ink Names in 3 1 Before starting to dispense ink the flow rate for each ink valve needs to be set in order to provide swift but controlled dispensing It is necessary to understand that the viscosity and flow attributes of the ink will affect its actual dispense rate The ink container regulator has been set at 16psi 1bar There is a facility to split the dispense process into stages for ease of control These are
39. vided below Some machines may have a pre determined list setting out which ink should be placed in which supply container In this case this information will be supplied in conjunction with this manual or obtained from the distribution agent Container Series Reference Colour Fl 22 23 ra Pat 21 3 i a 24 Extern PO NTa de 1 ON ara 1 7 I hy 3 i 20 Exienaon Se ee ST SS 14 48 ao om ke um kh h A h ek ll LE Pat Har Line ha Go ek ek ek ok Se eS Frank NN NNN See Se IDS 10 14 November 2007 3 2 Loading Ink WARNING NEVER TRY TO REMOVE A SUPPLY CONTAINER LID WHILST UNDER PRESSURE Turn the blue air valve on the side of the machine relating to the container which is to be refilled to the OFF position This allows the container to fully vent de pressurise When the hissing sound of escaping air ceases fully press the button on the side of the centre handle of the lid to release the side clamps allowing the lid to be lifted clear of the top of the ink supply container Each IDS10 ink container is pressure tested using water prior to shipment and so any residual moisture should be fully removed before each container is filled with ink Before loading ink it may be advisable to clean out the containers with an alcohol isopropranol solution taking care not to move or damage the level sensor probes attached to the side of the contain
40. within the Training Manual to ensure that the user can feel confident with the machine operation The Service Log at the back of this manual serves to provide contact information Should additional assistance be required please refer to the contact details supplied within this section Forms available in this section allow the service history of the machine to be recorded for future reference IDS 10 2 November 2007 Vale Tech IDS10 Introduction Contents Certificate of Conformity 1 Installation 1 1 Pre Install Information 1 1 1 Services Connection Requirements 1 2 Connection of Services 1 3 Connecting Electrical Supply 1 4 Connecting Air Supply 1 5 Connecting the PC 2 IDS Start Up Procedure 2 1 Switching On IDS 2 2 Log on and Dispenser Initialisation 2 3 IDS Beacon Warning Indicator 3 IDS Ink Set Up 3 1 Setting Ink Names 3 2 Loading Ink 3 3 Setting Ink Levels 3 4 Valve Configuration 3 5 How does the ink valve function during a dispense 3 6 What happens if the same Ink is used in more than one of the ink supply containers 3 7 Ink dispensing IDS 10 November 2007 10 10 11 11 11 12 13 13 14 15 19 20 22 22 IDS 10 Vale Tech IDS10 Hardware Settings Safety Features 5 1 Isolator Switch 5 2 Door Switch 53 Emergency Stop Switch 5 4 Alarm Sounder Ink Supply Container 6 1 Ink Supply Container Lids 6 2 Supply Container and Valve Air Regulator Adjustment Using the Balance 7 1 B
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