Instruction Manual Z4500 Rel 1.01 ENG

Z4500
Instruction
Manual
Rel: 1.01
Z4500
CHAPTER
FOREWORD
USE AND MAINTENANCE MANUAL 0
0 Foreword
Table of Changes
Revision Performer Date Description of changes
1.00 M.R. 19/07/2010
1.01 M.R. 08/10/2010 Added bracket for sensor
PAGE 0.1
Z4500
CHAPTER
0 FOREWORD
USE AND MAINTENANCE MANUAL
Table of contents
0 FOREWORD ..................................................................................................................................7
0.1 HOW TO KEEP THE MANUAL ..........................................................................................7
0.2 HOW TO READ THE MANUAL ..........................................................................................7
0.2.1 Key to each page ...................................................................................................9
0.3 PICTOGRAMS CONCERNING “OPERATORS” ................................................................9
0.4 OTHER PICTOGRAMS ......................................................................................................9
1 START UP ...................................................................................................................................13
1.1 LIFTING AND HANDLING ................................................................................................13
1.1.1 Unpacking ............................................................................................................13
1.1.2 Storage .................................................................................................................15
1.1.3 Disposal of packaging .........................................................................................15
1.2 SYSTEM INSTALLATION .................................................................................................17
1.2.1 Preparation of the area by the user ....................................................................17
1.2.2 Operational and Maintenance areas ...................................................................17
1.2.3 System placement ...............................................................................................17
1.2.4 Photocell and Print head placement ..................................................................19
1.2.5 Electrical connection ...........................................................................................21
1.3 ADJUSTMENTS BEFORE ACTIVATION .........................................................................23
1.3.1 Print head preparation.........................................................................................23
1.3.2 Ink and Make-Up fill .............................................................................................23
1.4 SYSTEM START UP .........................................................................................................25
1.4.1 Print head cleaning ..............................................................................................27
1.5 SYSTEM SET UP .............................................................................................................29
1.5.1 Product sensor programming.............................................................................29
1.5.2 Print speed ..........................................................................................................29
1.5.3 Print delay with sensor product .........................................................................31
1.5.4 Automatic print repeater .....................................................................................31
1.6 SYSTEM SWITCHING OFF ..............................................................................................33
1.7 ENCODER .......................................................................................................................35
1.8 VAPOUR RECOVERY ......................................................................................................37
1.9 PRINT HEAD PRESSURIZATION ....................................................................................37
2 PROGRAMMING .........................................................................................................................41
2.1 USER INTERFACE ...........................................................................................................41
2.2 PROGRAMS AND FUNCTIONS .......................................................................................43
2.2.1 Main page .............................................................................................................43
2.2.2 Texts and hypertexts: general remarks .............................................................43
2.2.3 Message selection ...............................................................................................43
2.2.4 Pre-Edit (to modify the archieve) ........................................................................45
2.2.5 Edit ........................................................................................................................45
2.2.5.1 Main properties of the text..................................................................................45
2.2.5.2 Secondary properties of texts ............................................................................47
2.2.5.3 Key shortcuts (simplified editing) ......................................................................49
2.2.5.4 Special characters ...............................................................................................49
2.2.6 Text .......................................................................................................................49
0.2 PAGE
Z4500
CHAPTER
FOREWORD
2.2.7 Date .......................................................................................................................51
2.2.8 Expiry date ...........................................................................................................53
2.2.9 Hour ......................................................................................................................53
2.2.10 Expiry hour ...........................................................................................................55
2.2.11 Counters ...............................................................................................................55
2.2.11.1 Incremental counter ..........................................................................................57
2.2.11.2 Decremental counter .......................................................................................57
2.2.12 Batch.....................................................................................................................57
2.2.13 Shift ......................................................................................................................59
2.2.14 Barcode ................................................................................................................61
2.2.15 Logo ......................................................................................................................65
2.2.16 Logo editor ...........................................................................................................65
2.2.17 DataMatrix ............................................................................................................67
2.3 ENCODER .......................................................................................................................69
2.4 PRINT MODE ...................................................................................................................69
2.5 SETTINGS .......................................................................................................................69
2.5.1 Load rod amplitude .............................................................................................69
2.5.2 H.V. value (high voltage on deflection plates) ...................................................69
2.5.3 Pressure ...............................................................................................................71
2.5.4 Suction .................................................................................................................71
2.5.5 Flight Time and Phase Peak ................................................................................71
2.6 SYSTEM PARAMETER ....................................................................................................71
2.6.1 Ink Type ................................................................................................................71
2.6.2 Viscosity ...............................................................................................................71
2.6.3 Ink Temperature ...................................................................................................71
2.6.4 Board Temperature ..............................................................................................71
2.7 SYSTEM CONFIGURATION.............................................................................................73
2.7.1 Serial address, Baudrate and Serial Type ..........................................................73
2.7.2 Coding type ..........................................................................................................73
2.7.3 Language ..............................................................................................................73
2.8 ENABLE PAGE ................................................................................................................75
2.9 TIME AND LEVELS SETTINGS .......................................................................................77
2.10 REPORT MANAGING AND DISPLAYING........................................................................77
2.11 SYSTEM PROTECTION ..................................................................................................79
2.11.1 Password insertion procedure ...........................................................................79
2.11.2 Protection management ......................................................................................79
2.12 HOW TO USE BARCODES UCC/EAN-128 AND CODE 128 ...........................................80
2.13 BARCODE EAN-128 CHARACTERS TABLE ..................................................................82
3 SYSTEM DESCRIPTION AND MAINTENANCE .........................................................................85

3.1 PRELIMINARY INFORMATION ON THE PRINTING SYSTEM ........................................85
3.1.1 Main components ................................................................................................85
3.2 WORKING ........................................................................................................................87
3.3 CHARACTER COMPOSITION .........................................................................................89
3.4 PRINTING FEATURES .....................................................................................................89
3.5 TECNICAL SPECIFICATIONS .........................................................................................91
3.6 MAINTENANCE ...............................................................................................................92
3.6.1 Maintenance safety conditions ...........................................................................92
3.6.2 Technical instructions for correct maintenance ...............................................92
PAGE 0.3
Z4500
CHAPTER
0 FOREWORD
3.7 MAINTENANCE SCHEDULE ...........................................................................................93

3.8 FILTERS ...........................................................................................................................95
3.8.1 Tubular filters ........................................................................................................95
3.8.2 Main filter..............................................................................................................95
3.8.3 Damper .................................................................................................................95
3.9 ELECTRO-VALVE ............................................................................................................97
3.9.1 Valve cleaning ......................................................................................................97
3.9.2 Valve replacing ....................................................................................................97
3.10 VISCOMETER ..................................................................................................................99
3.10.1 Viscosimeter cleaning ........................................................................................99
3.10.2 Viscometer replacement .....................................................................................99
3.11 PRINT HEAD ..................................................................................................................101
3.11.1 Ink stream alignment .........................................................................................101
3.11.2 Nozzle cleaning ..................................................................................................101
3.11.3 Nozzle replacement ...........................................................................................103
3.11.4 Tubus replacement ............................................................................................103
3.11.5 Gutter cleaning ..................................................................................................103
3.12 PUMPS ...........................................................................................................................105
3.12.1 Force Pump replacement ..................................................................................105
3.12.2 Suction Pump replacement ...............................................................................105
3.13 HYDRAULIC CIRCUIT CLEANING ................................................................................105
3.14 POWER SUPPLY ...........................................................................................................107
3.14.1 Switching power supply ....................................................................................107
3.14.2 Fuses ..................................................................................................................107
3.15 SHIPPING PACKAGING ................................................................................................107
3.16 SYSTEM ALARM ...........................................................................................................109
3.16.1 *Low priority alarm* ...........................................................................................109
3.16.2 **High priority alarm** ....................................................................................... 111
3.16.3 Other warnings .................................................................................................. 111
3.16.3.1 Maintenance Warning ..................................................................................... 111
3.16.3.2 No Flush Warning ........................................................................................... 111
3.16.3.3 Low Ink Temperature Warning ....................................................................... 111
4 HYDRAULIC AND ELECTRONIC DIAGRAMS ......................................................................... 114

4.1 CHAPTER OVERVIEW .................................................................................................. 114
4.2 SYSTEM COMPONENTS ............................................................................................... 115
4.3 HYDRAULIC MANIFOLD ............................................................................................... 116
4.4 PUMP-MOTOR GROUP ................................................................................................. 117
4.5 VISCOMETER ................................................................................................................ 118
4.6 PRINT-HEAD .................................................................................................................. 119
4.7 ELECTRONIC COMPARTMENT ....................................................................................120
4.8 HYDRAULIC COMPARTMENT ......................................................................................121
4.9 TANKS GROUP ..............................................................................................................122
4.10 USER INTERFACE: KEYBOARD ..................................................................................123
4.11 PHOTOCELL CONNECTION .........................................................................................124
4.12 ENCODER CONNECTION .............................................................................................125
4.13 BCD INPUT CONNECTION ............................................................................................126
4.14 ALARM OUTPUT CONNECTION ...................................................................................127
4.15 CONNECTION TO A PC OR OTHER DEVICES .............................................................128
0.4 PAGE
Z4500
CHAPTER
FOREWORD
4.16 HYDRAULIC CIRCUIT ...................................................................................................129
5 GENERAL INFORMATION ........................................................................................................133

5.1 GENERAL REMARKS....................................................................................................133
5.2 HOW TO USE THE MANUAL ........................................................................................134
5.3 WARRANTY ...................................................................................................................134
5.4 UNALLOWED USES AND CONTRA-INDICATIONS......................................................135
5.4.1 Electric safety ....................................................................................................135
5.5 RESIDUAL RISKS ..........................................................................................................136
5.6 RAEE DIRECTIVE ..........................................................................................................137
5.7 CE DECLARATION OF CONFORMITY ..........................................................................138
5.8 GLOSSARY ....................................................................................................................139
5.9 SOFTWARE RELEASE UPDATES ................................................................................140
PAGE 0.5
Z4500
CHAPTER
0 FOREWORD
B C
0.6 PAGE
Z4500
FOREWORD CHAPTER

0 FOREWORD
IMPORTANT NOTICE
Before carrying out any operation on the machinery, operators and

technicians must carefully read the instructions contained in this
publication and comply with them while carrying out interventions.
In case of doubs about the correct interpretation of the instructions,
please make enquiries with the after sales service in order to obtain
the necessary details.
This manual in an integral part to the machinery and is designed to provide all the neces-
sary information for:
• the operators’ awareness of safety issues; handling of the machinery, both packed and
unpacked, under safety conditions;
• the correct set up of the machinery;
• detailed knowledge of its operating and of its limits;
• its proper use under safety conditions;
0.1 HOW TO KEEP THE MANUAL
The manual must be carefully kept and must accompany the machinery throughout its life
cycle.
0.2 HOW TO READ THE MANUAL
The manual is divided into separate chapters and/or paragraphs, each of which addresses a
specific operator (INSTALLER and/or MAINTAINANCE ENGINEER) for whom the necessary
skills have been identified in order to operate the machinery under safety conditions.
In order to make understanding of the text easier, abbreviations, symbols and pictograms
have been used whose meaning is explained in paragraphs 0.3 and 0.4.
Chapters are structured as follows:
A Introductory page.
B Pages with figures referring to the text on “C”-type pages, sometimes used as de
scriptive pages.
C Descriptive pages containing the different paragraphs.
PAGE 0.7
Z4500
CHAPTER
0 FOREWORD
C D E
F G
I M
L N
0.8 PAGE
Z4500
FOREWORD CHAPTER

0.2.1 Key to each page
Every page of the manual displays different kinds of information whose meaning is the
following:
A Logo of the manufacturer

B Name and/or type of machinery
C Title of the chapter
D Title of the publication (where publication indicates the whole manual)
E Number of the corresponding Chapter
F Space for description
G Space for pictograms on safety standards to be complied with
H Page number (the first digit indicates the number of the chapter, the second the ove-
rall pages of the Manual)
0.3 PICTOGRAMS CONCERNING “OPERATORS”
I Operator:
Personnel trained and skilled to operate the machinery. In order to understand the
instructions (text and figures) the operator must have (or obtain by means of ade-
quate training) the following characteristics:
• general and technical culture enabling him to read and understand the
contents of the parts of the manual referring to the operator, and to correctly
interpret pictures and drawings;
• ability to understand and interpret symbols, pictograms, and video messages;
• his tasks are: machinery start-up, use of machinery, machinery stop.
L Electrical maintenance engineer:

At this level, the operator must be able to carry out electrical operations including
the set up and the ordinary maintenance.
0.4 OTHER PICTOGRAMS
M Warning!
The texts accompanied by this symbol contain important information about safety
N Note
Texts accompanied by this symbol contain further information.
O Respect of the environment

Texts accompanied by this symbol contain notices about the environment.
PAGE 0.9
Z4500
CHAPTER
START UP
1 Start up
PAGE 1.11
Z4500
CHAPTER START UP
1 USE AND MAINTENANCE MANUAL
E
A1
A2
1.12 PAGE
Z4500
START UP CHAPTER

1 START UP
1.1 LIFTING AND HANDLING
Lift and handle the machinery with great care so as to prevent it from falling or tilting.
THE SYSTEM IS DISPATCHED IN A RIGID BOX PLACED ONTO A PALLET
During transport, the ink tank is empty. The system can be handled even if the ink tank is
full. In any case take care not to overturn the cabinet.
Be careful, with smooth and linear movements, during transport and handling of the sy-
stem.
1.1.1 Unpacking
Take great care in not accidentally damage the system while unpacking it.
The material contained in the packing comprises:
A) 1 console complete of 1 cabinet (A1) with print head (A2)

(Keep the printhead in its protections to the moment of installation)
B) 1 power cable
C) 1 cabled photocell (with bracket and screwdriver for adjustment)
D) 1 instruction manual
E) 1 maintenance kit including:
• 1 backer 500 ml
• 1 wash bottle
PAGE 1.13
Z4500
CHAPTER START UP
1.14 PAGE
Z4500
START UP CHAPTER

1.1.2 Storage
The system is in its original packaging with the empty tank; follow the techinical instruction
for the storage.
When the system is already used with the tank full, follow the preventive maintenance
described in chapter 3.
WARNING:
the system must NEVER be stored with ink or solvent in the hydraulic circuit or in
the tank; in such case the hydraulic system would be surely damaged.
In dusty environments and for long periods of inactivity, protect the system by covering
it.
CONSOLE PROTECTION DEGREE: IP55
1.1.3 Disposal of packaging

Respect rules and regulations in force in the country of use of the system.
Keep the packaging for a further use of a transport.
PAGE 1.15
Z4500
CHAPTER START UP
1 meter
1.16 PAGE
Z4500
START UP CHAPTER

1.2 SYSTEM INSTALLATION
1.2.1 Preparation of the area by the user

It is task of the user to prepare:
• rooms for installation as provided for by local rules and regulations about health and
safety at the workplace.
• power supply in compliance with the rules and regulations in force in the place of in-
stallation.
• a properly working grounding.
In dusty environments, the filters must be replaced every six months.
1.2.2 Operational and Maintenance areas
WARNING:
The system placement must allow an easy access for the maintenance or possible
replacement of spare-parts.
1.2.3 System placement

• Place the control cabinet on a steady support with the keyboard at about 1 meter from
the floor.
WARNING:
be sure that the support do not obstruct the vapors exit fitting placed on the floor
of the cabinet.
WARNING:
The cabinet must be free of vibrations, must be kept horizontally and be electrically
isolated from any other equipment.
The support of the cabinet can be provided by the Manufacturer or the Supplier.
WARNING:
The print head must be mounted onto a fixed support free of vibrations.
Be sure that the ground connection is properly working. An ordinary grounding

has an alternating voltage between 0.6 and 1.5 Vac (as measured by means
of a tester) between the neutral and the ground. A proper grounding ensures
proper safety and the proper operating of the system. The absence of a properly
working connection makes the warranty null.
PAGE 1.17
Z4500
CHAPTER START UP
SENSOR CONNECTOR
1.18 PAGE
Z4500
START UP CHAPTER

If the supply line has frequent black outs and/or voltage peaks and disturban-
ces, a sinusoidal wave UPS should be inserted on the line in order to avoid
damages to the system and/or difficulties in managing it.
The UPS must absorb at least 300VA.
The UPS will help and “filter”, and therefore to optimize, supply as well as to
support supply in the event of a black out, allowing the operator to properly
shut down the system in compliance with the standard procedure.
A dedicated supply line should be used to supply the system. AVOID to connect
with machinary powered with 380V.
IMPORTANT!
Maintenance and repairs on the system must be carried out by trained personnel ei-
ther approved of by the manufacturer or authorized to carry out such operations.
1.2.4 Photocell and Print head placement

The system works with the photocell. It must be connected to the 5 pin connector (SEN-
SOR) placed on the side of the console.
Use the special bracket (supplied) in order to fix the sensor to the printhead; in case it’s
not possible (or for different needs), be sure to place the sensor NOT to get dirty with ink
during the use of the system.
Different sensors may be used:

• Direct reflection photocell (standard)
• Photocell with reflector
• Optical fiber photocell
• Inductive/capacitive sensor
The sensor used must feature either a N.P.N. or P.N.P. 24 VDC open COL-
LECTOR output or it must be a voltage free contact.
The sensor (photocell) provided along with the printer is cabled for NPN
logic.
Refer to paragraph 4.11 for other types of cabling.
The print head must be easily accessible for cleaning and maintenance.
The system can print either on the side, the top or the bottom of a product.
The distance from the print head to the surface to print must be set from 5mm to
20mm.
WARNING:
The print head must be free of vibrations.
PAGE 1.19
Z4500
CHAPTER START UP
BA
TC
5 4 .J H
41
BA
TC
5 4 .J H E
41 2 2 .1 X P IR
2 .0 Y
9
2 2 .1
BA
TC
54.J H
41
BA
TC
54.J H
41
BA
TC
54.J H
41
E
22.1 X P IR
2.09 Y
22.
E
22.1 X P IR
2.09 Y
22.1
A B C
1 2
1.20 PAGE
Z4500
START UP CHAPTER

A) PRINTING ON THE SIDE
The product passes in front of the print head, from right to left or vice versa.
B) PRINITNG ON THE TOP SURFACE

The product passes under the print head, from right to left or vice versa.
C) PRINITNG ON THE BOTTOM SURFACE

The product passes over the print head, from right to left or vice versa.
In the three cases, set the eventual printing delay so the product can get the right position
in front of the print head. The printing delay can be set like descibed in paragraph 1.5.3.
1.2.5 Electrical connection

The system features the following connections:
1. main button
2. socket
3. 18 pin male: alarms / bcd inlets
4. 9 pin male: serial line
5. 5 pin female: encoder (speed sensor)
6. 5 pin female connector: photocell (product sensor)
Before connecting the system to the electrical supply, make sure supply voltage and fre-
quency are compatible with the system.
The power supply must be:
85-240 VAC, 50-60 HZ SINGLE PHASE WITH GROUNDING.

(Refer to the lable with the serial number)
The power supply must be free of any voltage interruptions or variations. In case of a large
number of voltage variations, the use of a 300 VA Uninterruptible Power System (UPS) is
recommended.
• AVOID sudden interruptions in the power supply.

• AVOID voltage variations exceeding 10%.
• AVOID to surrounding devices to cause damages or disturbances to the system.
• AVOID to connect the system power supply to a panel supplying other
equipment.
• VERIFY the condition of socket and plug.
PAGE 1.21
Z4500
CHAPTER START UP
2 A
C E
D F
1.22 PAGE
Z4500
START UP CHAPTER

1.3 ADJUSTMENTS BEFORE ACTIVATION
1.3.1 Print head preparation

The print head is equipped with covers in order to avoid damages to its components during
transport. Such covers must be removed when the print head is activated for the first
time:
• Remove the white protection from the print head
• Remove the casing to get inside the print head (use the knob 1)
• Remove nozzle protection panel (2)
• Remove gutter heat shrink cover (3)
• Place the carter on the print-head and fix it with the knob (1)
1.3.2 Ink and Make-Up fill

Ink and make-up tanks are located in the front of the cabinet and can be accessed by
opening the keyboard door.
When delivered, the system is ready to print with a reserve of ink inside the tank. Remove
the two empty cartridges placed onto the tank cap (by rotating them anticlockwise and pulling
them upwards (A)), and add a further ink and make-up cartridge, as descrbed below:
- Ink fill
• Energicatelly shake the new ink cartridge for some seconds (B).
• Remove the plastic seal from the cover of the ink cartridge using a cutter.
• Get wet the sealing lip washer on the ink tank cap using the correct solvent (C)
• Place the cartridge in the left slot (D).
• Push resolutely the cartridge inside the slot, being sure that the black cover is com-
pletely inserted.
WARNING:
the INK cartridge must be inserted in the LEFT slot.
- Make-up fill
After the ink fill operation, insert a make-up cartridge:
• Remove the plastic seal from the cover of a ink cartridge using a cutter.
• Get wet the sealing lip washer on the make-up tank cap using the correct solvent (E)
• Place the cartridge in the right slot (F).
• Push resolutely the cartridge inside the slot, being sure that the black cover is com-
pletely inserted.
WARNING:
the MAKE-UP cartridge must be inserted in the RIGHT slot.
WARNING:
THE USE OF INK OR MAKE-UP NOT APPROVED BY THE MANUFACTURER
MAKES THE WARRANTY NULL.
PAGE 1.23
Z4500
CHAPTER START UP
INT
A B
C D
1.24 PAGE
Z4500
START UP CHAPTER

1.4 SYSTEM START UP
Switch on the system by pressing the main button (INT).

The main page will appear on the display (A).
From main page, press “START / STOP” (1): motors start and the system initialize its
star-up procedure (B).
After 10 seconds, the system enable automatically the ink stream (C).
After 50 seconds more, the system enable automatically the High Voltage (D).
At the end of the procedure, the system is ready to print (E) and the greeen leds on the
“START / STOP“ and “PRINT“ keys are lighted up.
PAGE 1.25
Z4500
CHAPTER START UP
a
b
c
1.26 PAGE
Z4500
START UP CHAPTER

1.4.1 Print head cleaning
If the print head is dirty of ink, it must be cleaned before use.
Clean:
• nozzle (a)
• charge electrode (b) and phase electrode (c)
• deflection plates (d)
• gutter (e)
1. If the ink stream is present, it must be turned off by pressing “SCREWDRIVER” fol-
lowed by “F4”.
2. Use the wash bottle and the solvent provided with the system to clean the print head
3. The solvent evaporate; the surplus quantity must be wiped off with a clean lint-free
cloth.
WARNING:
The inside of the print head must be perfectly dry. The presence of moisture con-
ditions the system function.
When operating on the print head, be careful to avoid any damage and to avoid
misaligning the ink stream.
PAGE 1.27
Z4500
CHAPTER START UP
1
2
1.28 PAGE
Z4500
START UP CHAPTER

1.5 SYSTEM SET UP
Once the print head has been cleaned, the system can be prepared for printing.
Make sure that the protection cover (f) is fixed on the print head.
Press “START/STOP” to start printing process from the main page.
Automatically, the printer is ready to print the current message according the settings.
The system has already been set up by the Manufacturer with a TEST message
to use during the first start up in order to check it has been properly installed.
WARNING:
enable the H.V. and Gutter alarm which have been disabled during the test (see
par. 2.8)
WARNING:
the system must be not operating when the cover is removed.
The system must be set up in order to operate under the requested conditions and with the
necessary external devices. From the main page (shown when switching on the system),
press “SPANNER” to enter all the maintenance and configuration pages of the system.
1.5.1 Product sensor programming

Install the product sensor (photocell) as shown in par. 1.2.4.
The product sensor can be used to detect a continuous product (a hose) or the presence
of a single product (a bottle).
Single product: the sensor detects the edge of the product and activates the printing.
Continuous product:: while the sensor detects the presence of the product, the system
prints with a repeater frequency previously set up. This funcion is called “print repea-
ter”.
Press SPANNER to enter the PRINTING PARAMETERS page (A) from which the product
sensor (1) can be enabled (PHOTOCELL: Y) or disabled (PHOTOCELL: N).
1.5.2 Print speed

From the PRINTING PARAMETERS page set up the PRINT SPEED value (2).
To establish the SPEED value, initially insert the value 200. Change this value decreasing
it if the printing is too wide or increasing it in the opposite case.
PAGE 1.29
Z4500
CHAPTER START UP
3
4
NO
OK NO
1.30 PAGE
Z4500
START UP CHAPTER

1.5.3 Print delay with sensor product
From the PRINTING PARAMETERS page set up the PRINT DELAY value (3).
This value defines the time between the moment the product sensor is excited (when the
product to be printed is detected) and the moment the system starts to print.
In order to set up the print delay on the system, its value between 0 and 65535 must be
found; the unit corresponds to 100 μs.
The value to set up can be obtained tentatively or by the following calculation:
PRINT DELAY = (Distance [m] / Speed [m/min]) x 60 x 10000

where:
• Distance: distance from the product edge, expressed in metres
• Speed: conveyor speed, expressed in metres per minute
Example: Distance = 0.003 m, Speed = 30 m/min

PRINTING DELAY = (0.003 / 30) x 60 x 10000 = 60
These calculations allow to find a PRINT DELAY value close to the required one
1.5.4 Automatic print repeater

This function is used to print with constant frequency on a continuous product.
The automatic repeater is enabled from the PRINTING PARAMETERS page by setting
up the REPEATER = Y (4) parameter.
When the automatic repeater is enabled, printing is continuous and occurs at intervals
determined by the REPEATER TIME field. The values of this field range from 0 to 32767
(each unit corresponds to 222 μs).
The value to set up can be obtained tentatively or by the following calculation:
REPEATER TIME = (Distance [m] / Speed [m/min]) x 60 x 4505

where:
• Distance: space between two printings, expressed in metres
• Speed: conveyor speed, expressed in metres per minute
Example: Distance = 0.2 m, Speed = 30 m/min

REPEATER TIME = (0.2 / 30) x 60 x 4505 = 1802
The way the repeater operates depends on the product sensor set up:
PHOTOCELL = Y, the print repeater is activated only when the photocell is excited;
PHOTOCELL = N, the print repeater is always active.
PAGE 1.31
Z4500
CHAPTER START UP
INT
1.32 PAGE
Z4500
START UP CHAPTER

1.6 SYSTEM SWITCHING OFF
In order to switch off the system:
- Press “START / STOP”. The switching off page will appear (A).
- Press “F2” to enable the switching off procedure (B), and the hydraulic circuit is
flushed automatically.
- At the of the procedure (C), press the main button (INT), to switch off the system.
PAGE 1.33
Z4500
CHAPTER START UP
1.34 PAGE
Z4500
START UP CHAPTER

1.7 ENCODER
When the product line speed is not constant, the use of an encoder is necessary.
The encoder is a speed sensor used to syncronize printing according to the product
speed.
The figure shows an encoder installed on a production line and its corresponding compo-
nents.
Refer to par. 2.3 for encoder set up.
PAGE 1.35
Z4500
CHAPTER START UP
C
ATTENTION:
DO NOT OBSTRUCT
FILTER - PRESSURE REDUCER
Ingresso ARIA
(max 0.6 bar)
1.36 PAGE
Z4500
START UP CHAPTER

1.8 VAPOUR RECOVERY
The system produces solvent vapours that are condensed and reused in the system. A
small quantity is expelled through the condeser outlet placed on the floor of the cabinet
WARNING:
Be sure not to obstruct the vapor exit connector by closing the fitting shown in
position C.
This would increase the pressure inside the system thus causing damage to the
system.
1.9 PRINT HEAD PRESSURIZATION
When the system is installed in a dusty and moist room, the print head must be pressurized
with cleaned compressed air.
Connect the filter-pressure reducer (provided separately by Zanasi or by the distributor)

to the air inlet as shown in figure, by using a pipe diameter 4 and regulate the manometer
to 0.6 bar.
PAGE 1.37
Z4500
PROGRAMMING CHAPTER
2 Programming
PAGE 2.39
Z4500
CHAPTER PROGRAMMING
3 2 4
6 7
2.40 PAGE
Z4500
PROGRAMMING CHAPTER

2 PROGRAMMING
2.1 USER INTERFACE
The user interface comprises the following devices and corresponding functions:
1. Main switch:
Provides power supply to the printer.
2. Liquid cristal display:

Shows the pages
3. Program selection keys:
PENCIL KEY: gives access to the EDIT page where you can insert, read,
change or delete the messages.
SCREWDRIVER KEY: gives access to the page showing manual commands

for ordinary maintenance.
TRAFFIC LIGHT KEY: gives access to the alarms page showing the causes
generating alarms.
WRENCH KEY: gives access to all system maintenance and configuration

pages.
4. Arrow keys:
To browse the pages and select fields.
5. Function keys:
Press these keys to retrieve previously programmed functions which vary according
to the page shown.
6. Start / Stop button:
Switches on and off the system.
7. Print button:
Enables printing.
8. Number, characters, and special characters buttons:
To edit text messages, messages or modify parameters.
PAGE 2.41
Z4500
CHAPTER PROGRAMMING
a Reference
Text
Code
0 TEST
1 PRINTING TEST 1
... ...
148 PRINTING TEST 148
149 149 THE LAST PRINTING TEST
2.42 PAGE
Z4500
PROGRAMMING CHAPTER

2.2 PROGRAMS AND FUNCTIONS
This paragraph explains how to insert texts and includes a description of the printing
possibilities and functions.
2.2.1 Main page

When the system is switched on, the display shows the main page (A).
The upper part of the display shows the message to be printed (e.g. “TEST”), whereas the
lower part shows:
• N: 0 (TEST)
Shows the number of the selected message (e.g. “ZERO”) and the name associated
to the message (between parenthesis).
• DATE AND TIME
Values from the system internal calendar and clock. The calendar is set in the DAY/MON-
TH/YEAR mode, while the clock is set in the HH:MM mode.
2.2.2 Texts and hypertexts: general remarks

The system allows to create an archive (database) of 150 different messages of up to
300 characters and of 50 images (logo) of 32rowsx90columns. The message or the
logo en inserted and stored into the system archive can be used at any time. The messages
can be modified and deleted even when the system is operating.
WARNING:
The system only prints one message at a time. This message is the one previously
selected and printed (on page A the message is 0).
Each message has been given a reference code. The code number ranges from 0 to 149
and refers to one message only (see table a).
The system will not print if no messages are selected alongside the printing
code.
2.2.3 Message selection
In order to use a message, first select it on the main page (page A).
Messages can be selected in two ways:
1) type in a number between 0 and 149 in the N° in the lower left-hand part of the main
page, then press “ENTER” to confirm.
2) use “ARROW UP” or “ARROW DOWN” to browse the messages shown in the N°
field on the main page.
Be sure that the selected message is not empty.
PAGE 2.43
Z4500
CHAPTER PROGRAMMING
2.44 PAGE
Z4500
PROGRAMMING CHAPTER

2.2.4 Pre-Edit (to modify the archieve)
From the main page, press “PENCIL” to enter into the PRE-EDIT page (B) to select the
message to modify or to create a new one.
2.2.5 Edit
From the PRE-EDIT page, press “F1” or “F4” to enter into the EDIT page (C) to insert,
read, modify or delete the selected message.
• The upper part of the display limited by a rectangle is reserved for the showing and
insertion of the message.
• The central part is used to select the different texts which may be inserted in a mes-
sage and their properties.
By texts we mean the following functions:
1) NUMBERS AND LETTERS (TEXT)

2) DATES (CURRENT AND/OR EXPIRY DATE)
3) HOURS (CURRENT AND/OR EXPIRY HOUR)
4) INCREMENTAL COUNTERS
5) DECREMENTAL COUNTERS
6) BATCHES
7) WORKING SHIFTS
8) BARCODE
9) LOGOS
10) DATAMATRIX
WARNING:
every message, besides text and logos, allows to insert up to 10 functions exposed
above.
To select and browse among these texts you first need to place the cursor on the field
“TEXT TYPE” by using “ARROW UP” and “ARROW DOWN” then press “ARROW
RIGHT” and “ARROW LEFT”.
2.2.5.1 Main properties of the text

All texts have common properties:
1) FONT is the format of the character which depends on the selected matrix. The ma-
trix values refers to the vertical and horizontal distribution of the dots of every single
character. For instance, FONT 7x5 refers to a character made up of 7 vertical dots
(columns) and 5 horizontal dots (rows).
The values avaliable in the FONT property depend on the CODING value set up in the
EDIT page (C).
In the example shown using the most advanced coding type, the matrixes available
are: 5x5, 7x5, 9x7, 10x8, 16x10, 24x16.
Use “ARROW RIGHT” or “ARROW LEFT” to browse the FONTS.
PAGE 2.45
Z4500
CHAPTER PROGRAMMING
2.46 PAGE
Z4500
PROGRAMMING CHAPTER

2) BOLD regulates the thickness of the character (columns) and may vary from 0 to 8.
For instance: a 7x5 character prints 5 vertical lines of dots. By setting BOLD to 3, you
will get 3x5=15 vertical lines of dots.
Use “ARROW RIGHT” or “ARROW LEFT” to browse the available BOLD value.
3) CODING: allows the selection of obtainable rows.
4) NAME: associates a name up to 8 characters to the message. When inserted, it will

be shown in the main page (A) when the message is selected.
2.2.5.2 Secondary properties of texts

From the main EDIT page, enter to the OPTIONS page (D) by pressing “FUNCTION
ARROW RIGHT”.
Use “ARROW UP” and “ARROW DOWN” to select and browse these properties. use
“ARROW RIGHT” and “ARROW LEFT” to enable or disable the properties.
REVERSE PRINT = Y
the message becomes
INVERTED PRINT = Y
the message becomes
Parameters REVERSE PRINT and INVERTED PRINT assume as default settings

the ones set in the PRINTING PARAMETERS page (E).
NEGATIVE PRINT = Y
the message becomes
TOWER PRINT = Y
the message becomes
For the INTERLINE, property (i.e. the space between the text lines) insert a value from
0 to 9.
WARNING:
the SPEED and DELAY in this page (if set), prevails over the main ones of the
system. This means that the message will be printed at a PRINT SPEED and with
a PRINT DELAY independent of all the others.
PAGE 2.47
Z4500
CHAPTER PROGRAMMING
2.48 PAGE
Z4500
PROGRAMMING CHAPTER

2.2.5.3 Key shortcuts (simplified editing)
In the EDIT PAGE (C), press sequentially two keys (one after the other), to obtain:
• “CTRL” + “BACK SPACE” delete the message.
• “CTRL” + “C” copy all the content of the message.
• “CTRL” + “V” paste all the content in another message:
• “CTRL” + “ARROW LEFT” place the pointer at the beginning of message
• “CTRL” + “ARROW RIGHT” place the pointer at the end of message
2.2.5.4 Special characters

The spacial characters are usable in the EDIT page.
1) Red special characters (!, “, ‘, %, .....). Placed in the upper-left side of every key,
they can be selected by pressing first the “RED fn” key, then the key with the desired
character.
Example: to edit the character “€”, press “RED fn” followed by “D”.
2) Green special characters (É, È, À,....). Placed in the upper-right side of every key, they
can be selected by pressing first the “GREEN fn” key, then the key with the desired
character.
Example: to edit the character “(“, press “GREEN fn” followed by “,”.
3) Wrap next line with the selectd font by pressing ENTER, (if the font allows it), to write
part of a message on the next line.
4) Delete last character inserted by pressing BACK SPACE.
5) Enable/disable UPPERCASE characters by pressing CAPS LOCK (red led on/off).
6) Enable/disable the insertion/overwriting function by pressing INS.
2.2.6 Text
In the EDIT page (C) the default TEXT TYPE selected is TEXT. Start inserting the mes-
sage, just pressing the keys on the keyboard.
The pointer must be placed at the end of the message in superior rectangle and it shows
the insertion position of new characters.
To save an edited message, press “PENCIL”. The display will show the save message
page (F).
• Press “F1” to save the message and exit from the EDIT page.
• Press “F4” to exit from the EDIT page without saving.
PAGE 2.49
Z4500
CHAPTER PROGRAMMING
G1
2.50 PAGE
Z4500
PROGRAMMING CHAPTER

2.2.7 Date
WARNING:
the printed dates refer to the inner clock of the system, shown in the main page
(A). To modify the actual date and hour, refer to parag.2.9
To insert a DATE in a message, press “ARROW DOWN” in the EDIT page (C) and with
“ARROW RIGHT” select TEXT TYPE: DATE (G)
To change the date settings press “FUCTION ARROW RIGHT”. The date settings page
will appear (G1).
Repeatedly press “ARROW RIGHT” to select the date format.

The available formats are:
1) DMY = Day Month Year

2) MDY = Month Day Year
3) MY = Month Year
4) DM = Day Month
5) MD = Month Day
6) D = Day
7) M = Month
8) Y = Year
9) JULIAN = Julian day
10) JUL. Y = Julian day/Year
11) SEQ.WK. = Sequential week
12) DAY WK. = Day of the week
Julian Day: it’s the day expressed by a sequential numerical format from 001 to 365.
Example: on February 3rd, the system prints “034”
Week Number: it’s the week expressed by sequential numerical format from 01 to
52. Example: on January 10th, the system prints “02”.
Day of the week : it’s the day of the week from 1 to 7, where 1=Monday.
Press “ARROW DOWN” to place the cursor on the TEXTUAL MONTH field. Press “ARROW
RIGHT” to enable or disable the print of the month in letters instead of in numbers.
Example: the date expressed by the numerical format 26/12/2010 becomes 26/DEC/2010 by using
the textual format.
With the textual month field selected, use “ARROW DOWN” and “ARROW RIGHT” to
select the month language.
Press “ARROW DOWN” and “ARROW RIGHT” to select the year format.
PAGE 2.51
Z4500
CHAPTER PROGRAMMING
I-1
2.52 PAGE
Z4500
PROGRAMMING CHAPTER

Three formats are available which represent the number of digits of the year.
Example: year 2009
• YEAR FORMAT : YYYY will be printed 2009
• YEAR FORMAT : YY will be printed 09
• YEAR FORMAT : Y will be printed 9
Press “ARROW DOWN” to move the pointer to the SEPARATOR field. Dates have “ / “
as separator by default.
To change such value, type in a different character then press “ENTER”.
Example:
• date with “/” as separator: 26/DIC/2010
• date with “-”: as separator: 26-DIC-2010
2.2.8 Expiry date

Add to the actual date the time to estabilish the precise expiry moment of the product.
In the date options page (“G1”) press “ARROW DOWN” to move the cursor to the “EXPIRY
DATE FORM MODE” fields.
Modify HOURS, MONTHS, DAYS, and YEARS and press ENTER to confirm.
When such values are modificied, the display will show the EXPIRY DATE updated.
2.2.9 Hour
WARNING:
the printed hours refer to the inner clock of the system, shown in the main page
(A). To modify the actual date and hour, refer to parag.2.9
To insert an HOUR in a message, press “ARROW DOWN” in the EDIT page (C) and with
“ARROW RIGHT” select TEXT TYPE: HOUR (I)
To change the hour settings press “FUCTION ARROW RIGHT”. The hour settings page
will appear (I-1).
Repeatedly press “ARROW RIGHT” to select the hour format.

The available formats are:
1) HH MM SS = Hour Minutes Seconds

2) HH MM = Hour Minutes
3) HH = Hour
4) MM = Minutes
5) SS = Seconds
6) QH = Quarter of an hour
PAGE 2.53
Z4500
CHAPTER PROGRAMMING
L1
2.54 PAGE
Z4500
PROGRAMMING CHAPTER

By QH we mean the quarter of the current hour as of midnight. The value ranges
between 1 and 96.
Example: from 00:00 to 00:14 = QH = 1
from 00:15 to 00:29 = QH = 2
from 00:30 to 00:44 = QH = 3
.... .... .... .... .... .... ....
from 23:45 to 23:59 = QH = 96
Press “ARROW DOWN” to place the cursor on the TEXTUAL FORMAT field. Press
“ARROW RIGHT” to enable or disable it (the hour is printed in letters instead of in num-
bers, where 0=A, 1=B, 2=C, 3=D, and so on.).
Example: the hour expressed in numbers 10:33:16 becomes BA:DD:BG in letters.
Press “ARROW DOWN” to move the pointer to the separator field. Hours have “ : “ as
separator by default.
To change such value, type in a different character then press “ENTER”.
Example:
• hour with “ : “ as separator: 10:33:16
• hour with “ - “ as separator: 10-33-16
2.2.10 Expiry hour

Add to the actual Hour the time to estabilish the precise expiry moment of the product.
Repeatly press “ARROW DOWN” to move the cursor to the “EXPIRY DATE FORM MODE”
fields.
Indicate the expiry moment in HOURS and/or MINUTES and press ENTER to confirm.
When such values are modificied, the display will show the EXPIRY HOUR updated.
2.2.11 Counters
The system features 16 independent counters (0 to 15) which may be individually inserted
in any message (one or more messages at a time) to count the number of products which
have been printed. They may be of either numerical or textual type.
Press “ARROW DOWN” on the EDIT page (C) to insert a COUNTER. Use “ARROW
RIGHT” to move the cursor to the TEXT TYPE: INCREMENTAL COUNTER or DECRE-
MENTAL COUNTER (L) field.
Set up the counter properties, by pressing “FUCTION ARROW RIGHT”
The counter properties page (L1) featuers the following characteristics:
PAGE 2.55
Z4500
CHAPTER PROGRAMMING
M1
2.56 PAGE
Z4500
PROGRAMMING CHAPTER

Counter selection: the number identifying the counter to insert in the message. You
can select a number between 0 and 15.
Start counter value: it is the starting value of the counter.
Stop counter value: it is the final value of the counter.
Counter present value: it is the value of the counter. To change it, insert a value between
the starting and the final values.
Counter step: the value of the step of incremental and decremental counters
can range between 1 and 99.
Counter digits: it is the maximum number of digits with which the counter can
be represented. You can select a value between 1 and 9.
Show zeros: enable or disable the showing of not significant zeroes.
Textual form: enable or disable the textual counter instead of a numerical
one: every digit (0-9) will be converted in letter (A-J).
Example: 3 corresponds to D, and 21 corresponds to CB.
Use “ARROW UP” and “ARROW DOWN” to browse properties.

Use “ARROW RIGHT” and “ARROW LEFT” to modify the last two properties.
2.2.11.1 Incremental counter

Use “ARROW DOWN” to insert an INCREMENTAL COUNTER in a message on the
EDIT page (C). Use “ARROW RIGHT” to move the cursor to the “TEXT TYPE: INCRE-
MENTAL COUNTER” (L) field.
The counter ranges between the START and STOP COUNTER VALUES, increasing by
steps of the value set in the COUNTER STEP properties.
Once the STOP COUNTER VALUE has been reached, the counter restart from its START
COUNTER VALUE again.
Every moment it’s possible check/modify the actual VALUE.
2.2.11.2 Decremental counter

Use “ARROW DOWN” to insert an DECREMENTAL COUNTER in a message on the
EDIT page (C). Use “ARROW RIGHT” to move the cursor to the “TEXT TYPE: DE-
CREMENTAL COUNTER” field.
The counter ranges between the STOP and START COUNTER VALUES, decreasing by
steps of the value set in the COUNTER STEP properties.
Once the START COUNTER VALUE has been reached, the counter restart from its STOP
COUNTER VALUE again.
Every moment it’s possible check/modify the actual VALUE.
2.2.12 Batch
Use “ARROW DOWN” on the EDIT page (C) to insert a BATCH in a message. Use
“ARROW RIGHT” to move the cursor to the “TEXT TYPE: BATCH” (M) field.
Use “FUNTION ARROW RIGHT” to set up batch properties. The BATCH PROPERTIES
page (M1) will be shown:
PAGE 2.57
Z4500
CHAPTER PROGRAMMING
N1
2.58 PAGE
Z4500
PROGRAMMING CHAPTER

Description:
Batch number: it is the number of the batch being printed.

Quantity per batch: it is the number of items per production batch.
Current quantity value: it is the current value of the quantity per batch.
Counter digits: it is the maximum number of digits with which the batch can be
represented. The value ranges from 1 to 9.
Use “ARROW UP” and “ARROW DOWN” to browse the properties.

Use “ARROW RIGHT” and “ARROW LEFT” to modify the last two.
Batch operating: as the QUANTITY PER BATCH has been set to 1000, BATCH NUM-
BER to 1, COUNTER DIGITS to 4 and SHOW ZEROS to Y, 0001 will be printed for the
first 1000 items, then 0002 for the following 1000 items and so forth, until 9999 is printed
for the last 1000 items.
The maximum value is determined by the maximum number the COUNTER DIGITS field
can show.
Example: if the number of digits selected is 4, you can print 9999 as maximum batch number.
If the number of digits selected is 7, you can print 9999999 as maximum batch number.
When the BATCH NUMBER has reached its maximum allowed number, counter starts
from 0 again.
The CURRENT QUANTITY VALUE counts how many items have already been printed.,
and can be modified by the operator.
2.2.13 Shift
Use “ARROW DOWN” on the EDIT page (C) to insert a SHIFT in a message. Use
“ARROW RIGHT” to move the cursor to the TEXT TYPE: SHIFT field (N).
Use “FUNCTION ARROW RIGHT” to set shift properties.

The SHIFT PROPERTIES page (N1) will be shown.
Repeatedly press “ARROW RIGHT” to select shift format. Shift can be NUMERICAL,
TEXTUAL or CUSTOM.
To modify the starting time of the four shiftes, move the pointer on the hour and insert the
new value. Press ENTER to confirm.
• NUMERICAL: the number corresponding to the actual shift is inserted in the messa-
ge.
Example: START S1 HOUR: 6 MIN:0
START S2 HOUR: 12 MIN:0
At 13:25, the system prints 2
PAGE 2.59
Z4500
CHAPTER PROGRAMMING
2.60 PAGE
Z4500
PROGRAMMING CHAPTER

• TEXTUAL: the letter corresponding to the actual shift is inserted in the message.
Example: START S1 HOUR: 6 MIN:0

At 13:25, the system prints B
• CUSTOM: an alphanumerical string corresponding to the actual shift is inserted in the

message. The string can be edited by the user.
By default, shift 1 (S1) = “TURNO 1”,
shift 2 (S2) = “TURNO 2”,
shift 3 (S3) = “TURNO 3”
shift 4 (S4) = “TURNO 4”.
Example: at 13:25, the system prints TURNO 2.
• a new shift always begins whent the previous one ends

• if less than 4 shifts are requested, the starting time of the last one must overlap
with the starting time of the previous shift, ans so on.
2.2.14 Barcode
Use “ARROW DOWN” on the EDIT page (C) to insert a BARCODE in a message. Use
“ARROW RIGHT” to move the cursor to the TEXT TYPE: BARCODE field (O).
Use “FUNCTION ARROW RIGHT” to enter in the BARCODE OPTIONS page (O1) and
set barcode properties.
Barcode Type: to select the barcode type

Text visual.: enable/disable the alphanumeric text under the barcode
B.code size: indicates the height of the barcode in dots
Extra text: when enabled, it shows the barcode both under and right of the
barcode.
Use “ARROW UP” and “ARROW DOWN” to browse properties.

Use “ARROW RIGHT” and “ARROW LEFT” to modify them.
The available barcodes are:
1) EAN 13
2) UCC/EAN 128 (A-B-C)
3) 2/5 INTERLEAVED (A-B-C)
4) 2/5 INDUSTRIAL
5) UPC-A
6) CODE 39
PAGE 2.61
Z4500
CHAPTER PROGRAMMING
O1
2.62 PAGE
Z4500
PROGRAMMING CHAPTER

EAN-13
EAN = European Articles Numbering, now International Article Numbering Association. It is
the most used code in Europe, and its use is increasing throughout the world. Bidirectional
numerical code made of 13 digits. The first 2 digits identify the country. The following 5
digits identify the manufacturer and the manufacturing sector. The following 5 digits identify
the product code. The last digit is the control digit.
UCC/EAN-128, CODICE 128 (UCC = Uniform Code Council)

Alphanumeric barcode of variable length used to identify information concerning the
product (batch, expiry date...). It is becoming the standard code for handing over infor-
mation and goods within a company and among companies.
REFER TO PARAG. 2.12 AND 2.13 FOR PROPER INSERTION OF BARCO

DES UCC/EAN 128.
2/5 INTERLEAVED (ITF A-B-C)

Bidirectional numeric barcode of variable length. Being bidirectional, this code can be
read both from left to right and from right to left.
This barcode may be printed in three different formats according to the user’s needs.
ITF-A is the standard barcode
ITF-B has horizontal bearer bars
ITF-C features a framed barcode.
It must also be entered a number between 1 and 9 defining the width of the quiet zones
before and after the barcode.
Important
Only numbers in even quantities can be inserted..
2/5 INDUSTRIAL
Bidirectional numeric barcode of variable length.
Quiet zones are non significant and it can contain any number of digits.
UPC-A
UPC = Universal Product Code. It is the most used code in the United States, Canada
and Great Britain and it’s made of 12 digits. The first digit identifies the code application
field (Number System). The following 5 digits identify the manufacturer and the following
5 identify the product code. The last one is a control digit.
CODE 39
It is bidirectional and of variable length barcode.
It comprising 10 digits (0-9), 26 letters and 7 special characters (-, *, space, $, /, +, %).
The star (*) is conventionally used to indicate start and stop functions (beginning and end
of the code).
PAGE 2.63
Z4500
CHAPTER PROGRAMMING
2.64 PAGE
Z4500
PROGRAMMING CHAPTER

2.2.15 Logo
The system allows the storage of 50 logos with sizes (up to) 32 lines per (up to) 90
columns.
Use “ARROW DOWN” on the EDIT page (C) to insert a LOGO inside a message. Use
“ARROW RIGHT” to move the cursor to the TEXT TYPE: LOGO field (P).
Use “FUNCTION ARROW RIGHT” to enter in the LOGO OPTIONS page (Q) and set
logos properties.
The cursor automatically moves to the number of logo to select. Enter a number between
0 and 49 to insert in the message one of the logos stored in the memory of the console,
then press “ENTER” to confirm your choice.
The NEGATIVE property allows to insert a logo with inverted pixels.
Example: the logo when negative becomes
2.2.16 Logo editor

Logos can be realized or by the logo editor present on the system, or by the managment
software GIS4 (sold separately)
Logos are identified by a two-digit number (0-49) and may be inserted at any point within
a message.
Use “CTRL” followed by “F3” to access the logo editor page (R) from the main page
(A).
The field NUMBER represent the logo to edit and fields HEIGHT and WIDTH define its
dimension.
F1 to select the use way:

EDIT: to move in the drawing area
DRAW: to trace the logo pixels
DELETE: to cancel the logo pixels
F2 to dalete the selected logo.
F3 to store the selected logo.
F4 to exit from the Logo editor page.
PAGE 2.65
Z4500
CHAPTER PROGRAMMING
R1
R2
2.66 PAGE
Z4500
PROGRAMMING CHAPTER

2.2.17 DataMatrix
To insert in a message a bidimensional DATAMATRIX barcode, preload it in the system by
the GIS4 software. A demo barcode of size 16x16 dots containing the string:
“www.zanasi.it” is already inserted in the system.
The GIS4 software is separately available from the local distributor or from ZANASI.
Use “ARROW DOWN” on the EDIT page (C) to insert a BARCODE inside a message.
Use “ARROW RIGHT” to move the cursor to the TEXT TYPE: DATAMATRIX field (R1).
The graphic view of a DATAMATRIX barcode is a matrix of dots like the one just below:
Use “FUNCTION ARROW RIGHT” to enter into the DATAMATRIX OPTIONS page (R2)
where to browse the present DATAMATRIX (max 50) and check the FORMAT and DATA
properties.
FORMAT correspond to the barcode matrix size.

DATA correspond to the alphanumeric string of the barcode content.
PAGE 2.67
Z4500
CHAPTER PROGRAMMING
2
3
4
5
6
7
8
9
2.68 PAGE
Z4500
PROGRAMMING CHAPTER

2.3 ENCODER
Install the encoder as explained in parag.1.7.
Press “WRENCH“ on the main page to enter into the PRINTING PARAMETERS page
(S).
Set ENCODER = Y to enable it (1).
To determine the SPEED value, insert the value 10 at first. Modify increasing or decreasing
it to extend or reduce the printing width.
2.4 PRINT MODE
Press “WRENCH“ on the main page to enter into the PRINTING PARAMETERS page
(S).
• REVERSE TEXT = Y sets each character print reversed way (2).

• INVERTED TEXT = Y sets each character print upside down way (3).
2.5 SETTINGS
From PRINTING PARAMATERS page (S), press “FUNCTION RIGHT ARROW” to enter
into the SETTING PAGE (T) where it’s possible to check the following parameters:
2.5.1 Load rod amplitude

The parameter LOAD ROD AMPLITUDE (4) refers to the sinusoid width value driving
oscillator.
WARNING:
Modify the value by steps of 5 units to the attainment of the best printing quality.
2.5.2 H.V. value (high voltage on deflection plates)

The H.V. VALUE (5) refers to the high voltage value read by the system according to the
SET parameter (0-15).
WARNING:
The value must be modified only by authorized technicians, or under their check.
PAGE 2.69
Z4500
CHAPTER PROGRAMMING
10
11
12
13
2.70 PAGE
Z4500
PROGRAMMING CHAPTER

2.5.3 Pressure
The PRESSURE parameter (6) refers to the ink pressure inside the hydraulic circuit.
2.5.4 Suction
The SUCTION parameter (7) refers to the suction power of the suction pump.
2.5.5 Flight Time and Phase Peak

Parameters FLIGHT TIME (8) and PHASE PEAK (9) are used for the service procedu-
re.
2.6 SYSTEM PARAMETER
From the SETTING PAGE (T), press “FUNCTION RIGHT ARROW” to enter into the SY-
STEM PARAMETERS page (U) where it’s possible to check the following parameters:
2.6.1 Ink Type

Parameter TIPO INK (10) correspond to the name of the used ink.
2.6.2 Viscosity
Parameter VISCOSITY (11) shows the actual value of the ink viscosity (READ) and the
reference value (REF).
2.6.3 Ink Temperature

Parameter INK TEMPERATURE (12) shows the actual value of the ink temperature.
2.6.4 Board Temperature

Parameter BOARD TEMPERATURE (13) shows the actual value of the electronic
compartment.
PAGE 2.71
Z4500
CHAPTER PROGRAMMING
U1
14
15
16
17
18
2.72 PAGE
Z4500
PROGRAMMING CHAPTER

2.7 SYSTEM CONFIGURATION
From the MAIN PAGE (A), press “SCREWDRIVER” to enter into the MANUAL COM-
MANDS page (U1):
F1: to execute a purge of 30 seconds

F2: to enable a viscometer reading cycle
F3: to call make-up for 5 seconds
F4: to enable/disable the ink stream
FLUSH VALVE: to check the flushing state.
Press “FUNCTION RIGHT ARROW” to enter in CONFIGURATION page (V) where it’s
possible to check and modify the following settings:
SERIAL ADDRESS
BAUDRATE
SERIAL TYPE
CODING TYPE
LANGUAGE
Press “ARROW UP” and “ARROW DOWN” to browse fields.
2.7.1 Serial address, Baudrate and Serial Type

SERIAL ADDRESS (14): it’s the serial address of the system. The value cannot be changed
by keyboard and follows the setting of the SW2 switch on the logic board (4 minidip - 16
combos). The defalt is “0” (zero).
BAUDRATE (15): it’s the speed of data transmission. The available values are: 4800, 9600
or 19200 bps.
SERIAL TYPE (16): it’s the protocol handshaking used for data transmission. The available
values are: RS232 o RS485.
2.7.2 Coding type

Parameter CODING TYPE (17) refers the possible way to print allowed with the system.
The available coding types are:
17-S 17-STANDARD: it’s the most used; it allows to use font from 5x5 to 16x10
up to 17 dots.
16-HS 16-HIGH SPEED: it allows to use font from 5x5 to 16x10 up to 16 dots;
ideal for quick lines.
3L-9X7 3 LINES 9X7: ideal for messages on three lines with font 5x5, 7x5 e 9x7
(with con interline respectively 5, 3 and 1).
24-HQ 24-HIGH QUALITY: it allows to use font from 5x5 to 24x16 up to 24 dot.
1L-7x5 1 LINE 7x5: ideal for messages on one line with font 5x5 and 7x5.
2L-7x5 2 LINES 7x5: ideal for messages on two lines with font 5x5 and 7x5 (with
interline respectively 3 and 1).
2.7.3 Language
Parameter LANGUAGE (18) set the language for the menu pages. To modify it, use “AR-
ROW LEFT” and “ARROW RIGHT”.
PAGE 2.73
Z4500
CHAPTER PROGRAMMING
19
20
21
22
23
24
2.74 PAGE
Z4500
PROGRAMMING CHAPTER

2.8 ENABLE PAGE
From the CONFIGURATION page (V), press “FUNCTION RIGHT ARROW” to enter in to
the ENABLE PAGE (Z) where to enable/disable the alarms on the system.
To enable every parameter, set the field (Y/N)=Y
H.V. ALARM (19): notices the electrostatic charge between the deflection plates. The ink
stream automatically stops and the system shows an alarm message on the display.
GUTTER ALARM (20): notices the absence of ink into the gutter. The ink stream automa-
tically stops and the system shows an alarm message on the display.
PRESSURE ALARM (21): notices a not conforming pressure in the hydraulic circuit. The
ink stream and the motors automatically stop and the system shows an alarm message
on the display.
START UP FLUSHING (22): enable the tubus flushing for 10 seconds during the system
start up procedure.
WARNING:
Disable the start up flushing during the maintenance procedure to avoid to modify
the viscosity during the numerous system start up procedures.
ENABLE BCD (23): the system prints the message about the configuration of the BDC
entries (parag. 4.13).
BCD STROBE (24): the system reads the configuration lof the BDC entries at every BCD
STROBE segnal (parag. 4.13).
PAGE 2.75
Z4500
CHAPTER PROGRAMMING
2.76 PAGE
Z4500
PROGRAMMING CHAPTER

2.9 TIME AND LEVELS SETTINGS
From the ENABLE PAGE (Z), press twice “FUNCTION RIGHT ARROW” to enter into
the DATE AND TIME SETUP PAGE (X), where to modify the date and the time of the
system:
Use “ARROW UP” and “ARROW DOWN” to browse the fields

Insert new values and confirm with ENTER.
Fields INK LEVEL, MAKE-UP LEVEL, TANK FULL LEVELLI and GUTTER SENSITIVITY
are parameter that can be only displayed, not changed.
In the left column there are the values “read“ by the system; in the right column there are
the reference values automatically set.
The HOUR COUNTER field refers to the system working hours. It can be read only, not
changed.
2.10 REPORT MANAGING AND DISPLAYING
From the MAIN page (A) press “SPANNER“ to enter into the PRINTING PARAME-
TERS page (S).
Press “FUNCTION LEFT ARROW” to enter in REPORT page (Y) where to check and
reset the printing report.
The REPORT value shows how many times the message selected in the field MESSA-
GE NUMBER has been printed.
To reset just a report, press CTRL and F1.

To reset the reports of all the messages, presse CTRL and F2.
PAGE 2.77
Z4500
CHAPTER PROGRAMMING
W1
W2
W3
2.78 PAGE
Z4500
PROGRAMMING CHAPTER

2.11 SYSTEM PROTECTION
It’s possible to protect the messages modification and the printing parameters by inserting
a PASSWORD.
To see the system situation, a “padlock“ icon was inserted in the system that appears on
the main page when the system is protected by password (closed padlock) or not (opened
padlock).
2.11.1 Password insertion procedure
From the MAIN page (A) press “CTRL” and “F2” to enter into the “PASSWORD” page
(W1):
• insert a password and press “ENTER”.
• confirm the password and press ”ENTER”.
The message “CORRECT PASSWORD” confirm the insertion, otherwise the message
“INCORRECT PASSWORD” will appear.
The system returns in the main page still not protected (opened padlock).
2.11.2 Protection management
Press “CTRL” and “F2” to enter into the PROTECTION MANAGEMENT page (W2).
The system shows three options:
• < F1 > RETURN PROTECTED VERSION: the message ACTIVATED PROTECTION

VERSION confirm the protection of the system (closed padlock).
• < F2 > CHANGE PASSWORD: to modify the actual password.
• < F3 > EXIT.
To remove the protection, press “CTRL” and “F2” and insert the password (W3).
WARNING:
When the system is protected, it’s possible only to turn on/off the ink stream ot the
system (“START/STOP” and “PRINT” keys) and check settings and alarms pages
(“SPANNER“ and “TRAFFIC LIGHT“ menu).
PAGE 2.79
Z4500
CHAPTER PROGRAMMING
2.12 HOW TO USE BARCODES UCC/EAN-128 AND CODE 128
The barcodes 128 e EAN-128 have many rules established by different authorities: INDI-
COD, EAN International, etc. that allow their large flexibility.
The barcode UCC/EAN-128 (UCC = Uniform Code Council) is a variable length alpha-
numeric code for encoding information concerning products (batch, expiration, etc.). It
is becoming a standard for goods and information transfer inside companies or among
them. A detailed list of the printable characters, refer to the chart in parag. 2.13
There are three series:
UCC/EAN-128A. The A series consists of all numeric characters, the alphabetic capital
letters, special and command characters.
UCC/EAN-128B. The B series consists of all numerical characters, the alphabetic capital
and lower case letters, special characters.
UCC/EAN-128C. The C series consists of the hundred couples of digits from 00 to

99, as well as special characters. This series allows to encode numeric data only and
features a very compact code since digits have been encoded coupled. It must be used
with four or more numeric charcaters, with even digits always.
The code EAN-128 differs from Code 128 since it presents a specific character (function
code 1, FNC1) positioned after the initial character showing which series being used (A,
B, C).
This barcode features a lot of possibilities. The using rules are in the documents pro-
vided from national and international regulatory authorities.
It’s possible to insert the alphanumeric data inside the barcode as preferred.
To comply with the UCC rules, the different data must go after an identifier device (AI =
Application Identifier) in order to define the following field.
The Application Identifier are numbers in brackets. The fields coming after AI are subject
to well defined rules. The most used are:
(00) Item sequential number

Made of 18 numbers. 8 numbers must be inserted representing the packaging
(1 number) and the EAN manufacturer code (7 numbers). These will be added
to the 9 incremental counter numbers of the system (see page CONT.). The last
is automatically calculated (checksum).
(01) Code numberEAN/Unit-packaging code

Made of 14 numbers, the last is automatically calculated (checksum).
If less than 13 numbers are inserted (7 for EAN-8, 11 for UPC-A, 12
for EAN-13, 13 for ITF14), initial “0” are automatically added.
(02) Code number EAN for products inside another packaging unit.
See the previous one.
2.80 PAGE
Z4500
PROGRAMMING CHAPTER

(10) Manufacturing batch number
Insert up to 20 numbers and/or letters. Comply with the selected series rules (for
instance, the C series is required to have even numbers only).
(11) Manufacturing date

Inside the barcode the today’s date is printed following the format yymmdd
(year, month, day).
13) Packaging date

Inside the barcode the today’s date is printed following the format yymmdd (year,
month, day).
(15) Minimum expiration date

month, day).
It is required to indicate how many days are to go before the expiration date
(000-999).
(17) Maximum expiration date

month, day).
It is required to indicate how many days are to go before the expiration date
(000-999).
The other usable AI have no automatic managment (like date or incremental numbers).
It is possibile to change series inside the same barcode by using specific auxiliary
characters (Code A, Code B, Code C). This allows, for instance, to carry out encoding
procedure in the same barcode with letters A series and numbers C series, getting a
barcode more compact than using the A serie only.
To insert auxiliary characters in a barcode, use:

A Start A Character starting A series
B Start B Character starting B series
C Start C Character starting C series
# FNC1 Character showing a EAN-128 code or the end af a variable leght

field not positioned at the end of the barcode
! Code A Character showing characters encoded according to the A series.
& Code B Character showing characters encoded according to the B series.
? Code C Character showing characters encoded according to the C series.
PAGE 2.81
Z4500
CHAPTER PROGRAMMING
2.13 BARCODE EAN-128 CHARACTERS TABLE
2.82 PAGE
Z4500
SYSTEM DESCRIPTION AND MAINTENANCE CHAPTER
3 System description
and maintenance
PAGE 3.83
Z4500
CHAPTER SYSTEM DESCRIPTION AND MAINTENANCE
1
A
2
3
4
5
B1
B3
B2
3.84 PAGE
Z4500

3 SYSTEM DESCRIPTION AND MAINTENANCE
3.1 PRELIMINARY INFORMATION ON THE PRINTING SYSTEM
Z4500 is a continuous ink jet printing system, suitable for printing on various types of pro-
ducts and substrates.
The system is composed of two main parts: the print head (A) and the control cabinet
(B), connected by an umbilical cord.
The control cabinet is built in stainless steel to offer maximum resistance to external agents
in every industrial environment. It is divided into three main parts:
• (B1) electronic section: it contains the control system (logic board, power supply and
motors).
• (B2) hydraulic section: it contains the hydraulic circuit (tanks, pumps, hydraulic block,
viscometer and filters).
• (B3) operator’s interface: it is composed of keyboard, graphic display, LED alarm .
3.1.1 Main components
PrintHead:
1) Cover sensor
2) Tubus (emitting microdrops)
3) Nozzle (removable)
4) Charge electrode
5) Phase electrode
6) Deflection plates
7) Gutter (charging drops)
PAGE 3.85
Z4500
14
13
12
10
11
15
25
16
17
18
24
19
21
20
21
22 23
3.86 PAGE
Z4500

Electronic compartment:
8) Logic board
9) Power supply
10) Fans
11) Power filter: it eliminates all the possible inconveniences from the power supply
entering
12) Motors
13) “IO-INT 5000” interface board:it is the system interface with the field connecting the
product sensor, encoder, BCD signals, alarms and serial lines
14) Idra board: it controls the electronic components placed in the hydraulic compart-
ment, as the electro-valves, the pressure transducer, the viscometer and the probes
for the alarms in the tanks
Hydraulic compartment:
15) Main filter: it filters the ink circulating into the system
16) Manifold: complete of electro-valves and pressure transducer
17) Damper: it keeps the ink pressure in the hydraulic manifold constant
18) Suction pump: it sucks the ink from gutter, tubus, viscosimeter and make-up
19) Ink Cartridge
20) Force pump: it supplies the pressure to the hydraulic manifold
21) Tubolar filters
22) Ink tank: it contains the mixture ink-solvent
23) Make-Up tank: it contains the solvent (make-up)
24) Make-up Cartridge
25) Viscometer: check the viscosity of the ink
3.2 WORKING
The system Z4500 prints on the side, on the top or on the bottom of the product.
The product to be printed must pass in front of the print head to a distance from 2 to 90
mm.
The product passes in front of the print head indifferently from left to right or from right to
left. The product passing is detected by a photocell (product sensor).
If the product motion is discontinuous, an encoder must be wired to the line to detect the
speed changes to get always the same width.
PAGE 3.87
Z4500
Row 7
Row 6
Row 5
1 Row 4
Row 3
Row 2
Row 1
Column 1 2 3 4 5 6
C D
F G
3.88 PAGE
Z4500

3.3 CHARACTER COMPOSITION
Characters are formed by columns of dots, made up of a number of rows.

For example: the 7x5 font matrix is shown in figure (1), and it’s composed of 7 rows and
5 columns of dots.
An empty column (the sixth), separate a character from the following. To print more
lines, they are separated by one, two or three empty rows. The space between the prin-
ted lines is called interline.
3.4 PRINTING FEATURES
The following font matrix are available:

5x5 7x5 9x7 15x10 16x10 24x16
24 dots per column are printable, getting from 1 to 4 rows
The system prints upper cases (A) and lower cases (B).
The height (C) and the width (D) of the character are adjustable as preferred.
Characters are printable with bold (E) up to 8 times.
Counters allow printing incremental numbers (F) or decremental (G).
Date and/or time (H) are printable using the internal clock of the system.
The system prints logos (I) and barcodes shown below, with or without the correspondent
text:
• Interleaved 2/5 (ITF) / with or without bearer bars / with or without frame (L)
• Industrial 2/5 (M)
• UPC-A (N)
• Code 39 (O)
• EAN-13 (P)
• UCC/EAN-128 (Q)
• DATAMATRIX (R)
The text is printable upside down (reversed print) or backwards (inverted print) to allowdif-
ferent product orientations or motions.
PAGE 3.89
Z4500
A
370
435
325
227
49
42
3.90 PAGE
Z4500

3.5 TECNICAL SPECIFICATIONS
Electrical specifications:
Power supply # 85-240 Vac, 50-60 Hz, single phase
Power rating # 100 VA
IMPORTANT:
The system must be grounded like expressed in par. 1.2.3
System specifications:
CABINET IP55 PROTECTION LEVEL

System Weight: 20 kg
Cabinet (A) Height: 435 mm (17.1inches)
Width: 370 mm (14.6 inches)
Length: 325 mm (12.5 inches)
Print Head (B) Height: 49 mm (1.9 inches)
Width: 42 mm (1.6 inches)
Length: 227 mm (8.9 inches)
Umbilical cord length (print head - cabinet): 4m (13 feet)
Power cable length: 2.0 m (6.6 feet)
Environmental specifications:
Optimum operating temperature 20 °C (68 °F)
Operating temperature range 5-40 °C (41-104 °F)
Storage temperatures 5-50 °C (41-122 °F)
Humidity range 10-90 % relative without condensation
Inputs:
Product sensor (photocell) 24 Vdc N.P.N./P.N.P. or
Normally Open contact (NO)
Encoder 24 Vdc N.P.N./P.N.P.
From a BCD device 6 bit + STROBE pulse
Data input:
From a Host Computer serial line RS232-RS485
Alarm output:
Outputs (relay free contact) max 500mA
Print specifications:
Number of lines: up to 4
Character height 0,8-12 mm
Character width adjustable
Minimum printing distance 2 mm
Maximum printing distance 90 mm
Recommended printing distance 7-10 mm
Other specifications:
Battery duration: 10 years
Message store: 150 messages with a maximum length of 300 characters
(INCLUDING THE CHECK MESSAGES).
PAGE 3.91
Z4500
3.6 MAINTENANCE
As concerns safety, refer to chapter 1.
Maintenance personnel qualifications

To carry the hydraulic and eletrical maintenace the operator needs to be qualified and
trained through an approved practical and theorical training course consisting of:
• theoretical and functional training concerning the system main parts
• manufacturer’s engineers helping for the starting-up.
3.6.1 Maintenance safety conditions
Qualified personnel is required to service the system.

Every maintenance on the system not described on the manual affects the warranty and
relieves the manufacturer of any responsability.
Carry out periodical checks and maintenance procedures on the system to keep it in good
working order and safety working conditions.
If the system operates in a harsh environment, the maintenance operations must be sche-
duled more frequently.
Before any maintenance, cleaning or repair procedure has been carried out by operators,
it is recommended to wear safety devices.
If any doubt concerning the correct way of maintenance carrying out arises (in spite of
the instructions in the current handbook), operators must ask the manufacturer or Service
Assistance for needed information.
3.6.2 Technical instructions for correct maintenance
In order to obtain an optimal maintenance:

• use always original spare parts, equipment suitable and in good working order.
• comply with the handbook instructions in order to carry out preventive and scheduled
maintenance. (see par. 3.7)
• in order to carry out efficient maintenance, pay constant attention and closely watch
the system.
If the system has not being used for long periods of time you are strongly advised
to operate the system for at least 2 hours every 7 days. This is important to prevent
the ink from drying up in the hoses and pumps.
For this purpose you need to:
1. Turn on the main power switch of the unit.

2. Check for alarms or warnings.
3. Press the button “START/STOP”. This procedure activates the pumps and sends ink
to the print head.
4. Press the button “PRINT” to disable high voltage between the deflection plates.
5. Let the ink flow 2 hours minimum in the hydraulic manifold..
6. After that, press “START/STOP” and then “F2” to start the system switching off.
7. Switch off the system and properly clean the print head using the solvent.
3.92 PAGE
Z4500

3.7 MAINTENANCE SCHEDULE
Daily maintenance
1. Check for alarms or warnings.
2. Switch off the system and properly clean the print head using the solvent.
Yearly ordinary maintenance or every 4000 hours

(the first occurring)
The service consists of:

1. filters and damper replacement
2. ink stream alignment checkup
3. system cleaning (internal and external)
4. ink tank drainage and cleaning using the cleaning solven
5. ink tank filling with new cartridges
6. setting and system parameters checkup
In case of larger utilization (more than 4000 hours) the yearly ordinary maintenance
must be defined with the Manufacturer considering the real use.
The services have to be carried in workshops in Sassuolo (MO) or Pero (MI) or in other
official Zanasi service workshops.
PAGE 3.93
Z4500
1 2
m
5m
m
5m
OUT
IN
MAIN FILTER
B
IN
OUT
DAMPER
3.94 PAGE
Z4500

3.8 FILTERS
The system features a main filter and four tubular secondary filters.
The filters must be replaced following the preventive maintenance schedule (see para-
graph 3.7).
3.8.1 Tubular filters
They are black, grey (two) and white according to their filtering capacity. In order to re-
place them, please comply with the following instructions:
1. Cut pipes at the ends of the locknuts, removing the filter to be replaced.
2. Loosen the new filter locknuts, put hoses into the locknuts, make them stick out 5 mm
of the locknut exit.
3. Tighten the locknuts to its filter by using hands only. The system has one main filter
and three tubolar filters.
WARNING:
In replacing filters, make sure the ink flows properly. The arrow on the filter indica-
tes the direction of the ink flow. Replace the filters by using new filters of the same
colour.
3.8.2 Main filter
It has a nominal filtering capacity of 5μm (15μm for pigmented inks). It is located inside the
hydraulic section (A) left-upper corner.
To replace the main filter observe the following procedure:

1. Remove the filter from the cabinet.
2. Place an absorbent piece of paper under the filter.
3. Unscrew both the nuts and remove hoses.
4. Wrap the filter with absorbent paper and dismantle it.
5. Insert the new filter and screw the nuts again, being sure to close very well. The arrow
indicates the direction of the ink flow.
6. Reinsert filter in its seat, make sure it has been properly set by putting the two hoses
next to the manifold.
7. When the system is ON, check the absence of ink leakage.
3.8.3 Damper
For the damper replacement (B):

1. Unscrew both the nuts.
2. Remove hoses.
3. Empty it from the ink inside
4. Wrap the filter with absorbent paper and dismantle it.
5. Insert the new damper and screw the nuts again, being sure to close very well. The
arrow indicates the direction of the ink flow.
6. Reinsert filter in its seat.
7. When the system is ON, check the absence of ink leakage.
PAGE 3.95
Z4500
fixing screws
lock nut
bobbin
A
C
EV. MAKE-UP
EV. GUTTER
EV. VISCO
EV. PURGE
electro-valve sliding box

body solenoid
with spring
3.96 PAGE
Z4500

3.9 ELECTRO-VALVE
On the manifold there are three electro-valve (C).
From left to right, they check:

• Ink suction from tubus (purge).
• Make-Up adding in the ink tank and tubus purging.
• Ink suction from viscosimeter.
3.9.1 Valve cleaning
1. Open the electronics and hydraulic compartments.

2. Unscrew the lock nuts and remove the bobbins (B).
3. Remove the manifold from the hydraulic compartment.
4. Unscrew the fixing screws and remove the electro-valve. Pay attention not to lose
the O-rings under the valve.
5. Open the electro-valve with a screwdriver and extract the sliding box and the solenoid with
the spring (C). Pay attention not to lose the spring.
6. Clean every component of the electro-valve using the solvent (D).
7. Dry every part with compressed air.
8. Clean the valve seat on the manifold using the solvent (E).
9. Riassemble the spare-parts, paying attention to respect the right insertion order (so-
lenoid with spring and sliding box).
10. Screw the 2 fixing screws without forcing. Pay attention to place correctly the O-
Rings
3.9.2 Valve replacing
After cleaning, if the valve still does not work, must be replaced.
A new valve is available from the manufacturer or supplier.
PAGE 3.97
Z4500
A B
3.98 PAGE
Z4500

3.10 VISCOMETER
This paragraph decribes the viscometer spare-parts, theur cleaning and replacing.
3.10.1 Viscosimeter cleaning
The viscosimeter is connected to pipes (a) by the fixing ring-nuts (b). Clean the viscometer
following the procedure:
1)
- Remove from the cabinet.
- Loosen the ring-nuts fixing the pipes.
- Operate like fig. B.
- Riassemble the viscomenter in the right way and place it again in the seat.
WARNING:
Don’t open the viscometer and don’t disconnect the promixity sensor. Maintenance
to be executed only by trained technicians.
2)
- Remove the hose connected to the make-up cap from the cap side.
- Put it into a beaker with a clean solvent (cleaner M).
- Switch on the system and press the button “START/STOP”. The system will enable
the button “PRINT” automatically.
- Press this button to disable high voltage between the deflection plates. Press the button
“START/STOP” again. By means of this procedure, the ink stream is disabled and the
motors still work.
- Press the button “SCREWDRIVER”. The MANUAL COMMAND page will appear
(C).
From the MANUAL COMMANDS page, press “F2” to enable the viscometer reading
and wait 20 seconds.
- Repeat the operation described above 3 times. After any selection operation, the sof-
tware gets back to the starting display.
- Press “START/STOP” and then “F2” to enable the system switching off
- Reconnect the hose to the solvent cap tightening it properly.
3.10.2 Viscometer replacement
After cleaning, if the viscometer does not work, it is needed to replace it. Remove hoses and
switch off the system. These operations can be carried out only by trained technicians.
PAGE 3.99
Z4500
3
2
a deflexion axle
b
gutter axle
NO OK
WHITE WHITE
PAPER PAPER
3.100 PAGE
Z4500

3.11 PRINT HEAD
The print head maintenance includes:

• Print head cleaning: see paragraph 1.4.1
• Ink stream alignment
• Nozzle cleaning
• Tubus replacement
• Gutter cleaning
3.11.1 Ink stream alignment
WARNING:
The ink stream must be adjusted with the system ON and the key “PRINT” ena-
bled.
Remove the carter from the print head and place a coin on the sensor (fix it using a piece
of scotch). Press “PRINT”.
Check and adjust the alignment as follows:

• Be sure that screw (1) has been tightened.
• Loosen the screw (2) and through the screw (4) adjust the ink stream in the
middle of the suction hole along the gutter axle (b). When the ink stream is cen
tered, block the screw (2)
• Loosen the screw (1) and through the screw (3), adjust the ink stream to 4/5 of
the deflection axle (a).
• Place a piece of white paper next to the gutter.
• Rotate the screw (3) clockwise until droplets apper on the white paper
• Rotate the screw (3) anticlockwise until the drop spots disappear.
• Tighten the screw (1).
Remove the coin from the sensor and put the carter on the print head.
3.11.2 Nozzle cleaning
When the system works, press the “PRINT” to disable H.V. (high voltage).
Then press “START-STOP” and stop streaming by pressing F1.
Sprinkle nozzle with solvent, closing the gutter hole with a finger at the same time.
PAGE 3.101
Z4500
B
2 1
2 1
D
3.102 PAGE
Z4500

3.11.3 Nozzle replacement
1. Switch off the system.

2. Unscrew the 2 lateral screws (fig. A).
3. Lift the tubus (fig. B).
4. By using the special wrench unscrew the nozzle anticlockwise (B).
5. Remove the O-Ring between nozzle and tubus body and put it into the new nozzle.
7. Reassemble the new nozzle inside the tubus and tighten the tubus properly by
screws.
8. Align the ink stream (see parag. 3.11.1)
The special wrench to remove the nozzle can be provided by the Manufacturer or
the Supplier.
3.11.4 Tubus replacement
Phase 1 - broken tubus removal

1. Switch off the system.
2. Unscrew the 2 fixing screws (fig C).
3. Remove from the print head the two piece of pipe connected to the tubus.
4. Dissolder the black wire by using a tin welder (fig.D).
5. Remove the tubus.
Fase 2 - new tubus insertion

1. Connect the two pipes to the print head.
2. Fix the tubus to the support with the two screws.
3. Solder the black wire.
4. Adjust the ink stream (see parag. 3.11.1)
3.11.5 Gutter cleaning
When the ink is not sucked by the gutter:

1. Press “PRINT” to disable the high voltage.
Then press “START/STOP” and then F1 to turn off the ink jet.
2. Remove the carter from the printhead, place it in vertical position with the becker
under it (fig. E).
3. Sprinkle nozzle with solvent on the gutter hole.
After cleaning operation, if the gutter still does not suck ink from the tubus, the suction
problem could be probably caused to the broken suction pump. Please call the manufac-
turer assistance service.
PAGE 3.103
Z4500
3.104 PAGE
Z4500

3.12 PUMPS
In the hydraulic compartment there are two pumps: - suction pump (a)
- force pump (b)
3.12.1 Force Pump replacement
When there is no pressure in the hydraulic circuit, replace the force pump (b) as described
below. Switch of the system and:
1) Loosen the fittings and disconnect the pipes (fig.A).
2) Unscrew the three fixing screws on the cabinet (fig.B) and remove the group motor-
pump from the electronic compartment.
3) Insert the new pump and fix it with the 3 screws, paying attention to its position, like in
origin.
4) Reconnect pipes and screw the ring-nut.
When the system is ON, check the absence of ink leakage on the fittings.
3.12.2 Suction Pump replacement
When there is no suction from the gutter, replace the suction pump (a) as described below.
Switch of the system and:
1) Loosen the fittings and disconnect the pipes (fig.A).
2) Unscrew the three fixing screws on the cabinet (fig.B) and remove the group motor-
pump from the electronic compartment.
3) Insert the new pump and fix it with the 3 screws, paying attention to its position, like in
origin.
4) Reconnect pipes and screw the ring-nut.
When the system is ON, check the absence of ink leakage on the fittings.
After the pumps have been replaced, if pressure or suction still do not work in the hydraulic
manifold, please call the assistance service.
3.13 HYDRAULIC CIRCUIT CLEANING
It must be operated by the assistance service when a stop of at least 30 days is sched-
uled.
PAGE 3.105
Z4500
-+ 5
+ 24
+ 12
- 12
3.106 PAGE
Z4500

3.14 POWER SUPPLY
3.14.1 Switching power supply
The system switching power supply generates and supplies constant voltages for circuits
and electrical components. They are verifiable by the active leds on the main board.
3.14.2 Fuses
The alternating voltage in input is filtered by fuses in order to damp all electrical noises in
the circuit.
When there is no voltage, check the fuse in the electronic compartment. If they are broken,
replace them with new equivalent fuses: 1.6A 220V retarded or 3.15A 110V retarded.
3.15 SHIPPING PACKAGING
It is needed to pack the system carefully using the appropriate protection cover to ship or
carry it. Follow the procedure below:
1. Stop the ink stream and clean the gutter with solvent for about 15-20 seconds.
2. Switch off the system and disconnect it from the supply power voltage.
3. Remove ink from the tank and wash it with solvent.
4. Clean the print head and protect it with its original packaging.
5. Place the cabinet in the packaging cardboard with its original protections. Roll up um-
bilical cord inside the packaging.
6. Seal packaging with adhesive rubberized tape for shipping.
7. Place the packed system on pallet and anchor it to the pallet with strapping band.
PAGE 3.107
Z4500
A B
D E
F G
3.108 PAGE
Z4500

3.16 SYSTEM ALARM
Alarms are visualized by LEDS on the MAIN PAGE (A).
Press “TRAFFIC LIGHT“ to enter into the ALARM PAGE (B) to check the active
alarms.
In the system are present 2 different level of alarm:

* LOW PRIORITY ALARMS * : The system is able to print
** HIGH PRIORITY ALARMS** : The system is not able to print
Press “FUNCTION RIGHT ARROW“ to check the genaral state of the alarms (C).
Press “TRAFFIC LIGHT“ to exit and come back to the MAN PAGE (A).
3.16.1 *Low priority alarm*
MAKE-UP MISSING: the make-up cartridge in the hydraulic tank has run out. Replace
the used cartridge with a new one (refer to parag. 1.3.2). The system may be refilled
when it is normally operating.
After one working hour without Make-Up, the system will show the warning message
(D).
If the alarm is ignored for one hour more, the system will switch off automatically and
will show the warning message (E).
INK LEVEL LOW: the ink level in the tank is below the minimum admitted for the cor-
rect operation of the printer. Replace the used cartridge with a new one (refer to parag.
1.3.2). The system may be refilled when it is normally operating.
After three working hours with low ink, the system will switch off automatically and will
show the warning message (F).
If the alarm is ignored for one hour more, the system will switch off automatically and
will show the warning message (G).
TANK TOO FULL: the ink level in the level is above the maximum admitted for the cor-
rect operation of the printer. In order to remove the surplus ink, remove the main filter
from the cabinet, disconnect the inlet pipe, insert it in a becker and turn on the system
until the alarm disappear
Connect again the pipe to the main filter and place it again inside the cabinet. When the
system is ON, check the absence of ink leakage on the fittings.
VISCOMETER FAULT: the viscometer does not work correctly. Restore its right opera-
tions (parag. 3.10)
PAGE 3.109
Z4500
H I
L M
N O
P Q
3.110 PAGE
Z4500

3.16.2 **High priority alarm**
HIGH VOLTAGE ALARM: a spark between the high voltage plates has occurred.
The system shows the message with the instruction to execute (H).
GUTTER ALARM: the ink is not draining into the gutter. The system shows the mes-
sage with the instruction to execute (I).
TRANSDUCER ALARM: the transducer does not work in a good way for a problem in
the pressure reading (L) or in the ink temperature reading (M).
PRINT-HEAD COVER MISSING: the print head cover on the print-head has been re-
moved. Place it again on the head and check it’s fixed correctly.
PRESSURE ALARM: the pressure in the hydraulic compartment is not stable.
3.16.3 Other warnings
3.16.3.1 Maintenance Warning
When the message (N) during the system start-upn and the logo SERVICE in the main
page (O) appear, contact the assistance service.
3.16.3.2 No Flush Warning
During the system start-up, a message (P) advises that the cleaning procedure during
the last system turning off was not completed.
3.16.3.3 Low Ink Temperature Warning
If, during the system start-up, the ink temperature is lower than 10°, the system waits 5
minutes before turning on the ink stream. During this time, the system brings the ink to
the right temperature. A logo with a thermometer appears in the main page (Q) .
PAGE 3.111
Z4500
CHAPTER
HYDRAULIC AND ELECTRONIC DIAGRAMS
4 Hydraulic and
electronic diagrams
PAGE 4.113
Z4500
CHAPTER
4 HYDRAULIC AND ELECTRONIC DIAGRAMS

4.1 CHAPTER OVERVIEW
This chapter contains hydraulic diagrams and assembly drawings to help the mainte-
nance technicians in their operations.
Attached drawings are listed below:
Assembly drawings: System components

Ink distribution group (hydraulic manifold)
Motor-pump group
Viscometer
Print head
Electronics section
Hydraulics section
Tank group
User Interface: keyboard
Circuit diagrams: Photocell connection

Encoder connection
BCD input connection
Alarm output connection
Connection to PC or other devices
Hydraulic Scheme
NOTE: refer to the assembly drawings to get the description for each component.
4.114 PAGE
Z4500
CHAPTER
4.2 SYSTEM COMPONENTS
1 3
01. USER INTERFACE COMPARTMENT (KEYBOARD)

02. HYDRAULIC COMPARTMENT
03. ELECTRONIC COMPARTMENT
PAGE 4.115
Z4500
CHAPTER

4.3 HYDRAULIC MANIFOLD
12 11 10 9
14
1 13
2 3 4 5 6 7 8
01. MANIFOLD
02. INLET FITTING FROM MAIN FILTER
03. OUTLET FITTING TO DAMPER
04. OUTLET FITTING TO SUCTION PUMP
05. INLET FITTING FROM PURGE
06. INLET FITTING FROM MAKE-UP TANK
07. INLET FITTING FROM GUTTER
08. INLET FITTING FROM VISCOMETER
09. VISCO VALVE
10. GUTTER VALVE
11. MAKE-UP VALVE
12. PURGE VALVE
13. BY-PASS
14. PRESSURE TRANSDUCER
4.116 PAGE
Z4500
CHAPTER
4.4 PUMP-MOTOR GROUP
01. INLET FITTING

02. ELECTRONIC CONTROL
03. MOTOR
04. SUCTION OR FORCE PUMP
05. OUTLET FITTING
PAGE 4.117
Z4500
CHAPTER

4.5 VISCOMETER
4
5
01. OUTLET FITTING TO MANIFOLD

02. BODY OF VISCOMETER
03. LABLE WITH SET POINT
04. SENSOR
05. INLET FITTING FROM INK TANK
4.118 PAGE
Z4500
CHAPTER
4.6 PRINT-HEAD
13
12
11
10
1 9
7
2
6
3
4
01. COVER SENSOR

02. SUPPORT BRACKET
03. TUBUS SUPPORT
04. CHARGE ELECTRODE
05. DEFLECTION PLATES
06. GUTTER
07. PHASE ELECTRODE
08. NOZZLE
09. BODY OF TUBUS
10. PURGE PIPE
11. INK PIPE
12. HEAD CLOSING BOX
13. CARTER CLOSING KNOB
PAGE 4.119
Z4500
CHAPTER

4.7 ELECTRONIC COMPARTMENT
10
2 9
8
3
4 5 6
01. LOGIC BOARD

02. H.V. BLOCK
03. POWER SUPPLY
04. FANS
05. GROUND
06. POWER FILTER
07. FORCE PUMP
08. SUCTION PUMP
09. IO-INT BOARD
10. IDRA BOARD
4.120 PAGE
Z4500
CHAPTER
4.8 HYDRAULIC COMPARTMENT
13 12
11
2
4
10
5
7
6
7 9
8
01. MAIN FILTER

02. MANIFOLD
03. DAMPER
04. SUCTION PUMP
05. INK CARTRIDGE
06. FORCE PUMP
07. TUBOLAR FILTERS
08. INK TANK
09. MAKE-UP TANK
10. MAKE-UP CARTRIDGE
11. VISCOMETER
12. ELECTRO-VALVE
13. PRESSURE TRANSDUCER
PAGE 4.121
Z4500
CHAPTER

4.9 TANKS GROUP
13 12 11
14 8 7
6
10 9 5
3 4
1 2
01. INK TANK

02. MAKE-UP TANK
03. TOOTHED CROWN
04. CARTRIDGE BREAKER
05. OUTLET FITTING TO THE PRINT-HEAD
06. FITTING CONNECTING TO THE INK TANK
07. PROBES FOR MAKE-UP ALARMS
08. VAPORS EXIT FITTING
09. OUTLET FITTING TO MANIFOLD
10. OUTLET FITTING TO VISCOMETER
11. FITTING CONNECTING TO THE MAKE-UP TANK
12. PROBES FOR INK ALARMS
13. INLET FITTING FROM SUCTION PUMP
14. OUTLET FITTING TO FORCE PUMP
4.122 PAGE
Z4500
CHAPTER
4.10 USER INTERFACE: KEYBOARD
1 4
01. KEYBOARD DOOR

02. DOOR HANDLE
03. KEYBOARD
04. DISPLAY
PAGE 4.123
Z4500
CHAPTER

4.11 PHOTOCELL CONNECTION
5 pin female connector pinout (front view):
1. +24 VDC
2. Product signal
3.
4. Common
5. GND
Connections for the product sensor are: Female connector
4.124 PAGE
Z4500
CHAPTER
4.12 ENCODER CONNECTION
5 pin female connector pinout (front view):
1. +24 VDC
2. Product signal
3.
4. Common
5. GND
Connections for the encoder are: Female connector
PAGE 4.125
Z4500
CHAPTER

4.13 BCD INPUT CONNECTION
3 pin of the alarm connector are used as BCD input.

18 pin male connector pinout (front view):
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11. GND
12.
13.
14. +24 VDC Male connector
15.
16. BCD 0
17. BCD STROBE
18. Common
Connections for the external devices are:
4.126 PAGE
Z4500
CHAPTER
4.14 ALARM OUTPUT CONNECTION
1. CONTACT 1 COMMON (CM1)

2. CONTACT 1 NORMALLY CLOSED (NC1)
3. GND
4. CONTACT 2 NORMALLY OPENED (NO2)
6. +24 VDC
8. CONTACT 3 COMMON (CM3)
10. GND
11. GND
12. CONTACT 2 COMMON (CM2) Male connector
13. +24 VDC
14. +24 VDC
16.
17.
18.
Connections for the alarms are:

Contatto n° 1 Contatto n° 2 Contatto n° 3
(NC1) (NC2) (NC3)
(NO1) (NO2) (NO3)
(CM1) (CM2) (CM3)
Note:
- Contact n°1 (pin 1-2-9) opens or closes only when a “high priority alarm“ occurs.
- Contact n°2 (pin 12-5-4) opens or closes only when a “low priority alarm“ occurs.
- Contact n°3 (pin 8-7-15) opens or closes when the system can or cannot print (SYS
TEM READY).
PAGE 4.127
Z4500
CHAPTER

4.15 CONNECTION TO A PC OR OTHER DEVICES
A serial line allows the connection of PC or other devices to the system.

It can be set by keyboard, by means of the following electrical standards:
RS232C allows point-point connection up to 15 metres.
RS485 allows a multi-drop connection (up to 32 systems on the same cable) up

to 1,300 metres.
1 6 TX- (422)
2 RX232 7 TX+ (422)
3 TX232 8 RX- (422/485)
4 9 RX+ (422/485)
5 GND
Connection to a PC through serial line RS232
Male connector
4.128 PAGE
4.129
4
PAGE
CHAPTER
MAIN VISCOMETER
FILTER MANIFOLD
OUT
IN
MAKE-UP
VISCO
PURGE
GUTTER
OUT
OUT
IN
INK FILTER IN
DAMPER
GUTTER FILTER
SUCTION P.
IN
MAKE-UP FILTER INK PURGE GUTTER FLUSH
Z4500
OUT
FORCE P.
IN
4.16 HYDRAULIC CIRCUIT
OUT
VISCO FILTER
2 3 2 3
1 4 1 4 VAPORS
PIPE 6 x 4
PIPE 4 x 1.5
PIPE 4 x 2.5
INK TANK CAP MAKE-UP TANK CAP PIPE 4 x 2
(black) (grey)
Z4500
CHAPTER
GENERAL INFORMATION
5 Generaral information
PAGE 5.131
Z4500
CHAPTER
5 GENERAL INFORMATION
5.132 PAGE
Z4500
CHAPTER
GENERAL INFORMATION
5.1 GENERAL REMARKS
Serial number (1): it is on CE lable on the outer side of the console.

The external lable comprises:
Model Z4500
Serial number univolcal code for the system identification
Year year of production
In the hydraulic compartment inside the cabinet a second label is present (2) with a code
for the Manufacturer’s use.
THE MANUFACTURER’S OFFICIAL LANGUAGE IS ITALIAN.
The manual refers to the state of the system when delivered.

ZANASI reserves the right to update manuals without being obliged to update the
previouses.
ZANASI is not responsable in case of incorrect use of the system, such as:
a) improper use of the machinery by untrained personnel;
b) use not conform to the specific standards;
c) improper installation;
d) supply errors;
e) maintenance faults;
f) unauthorized changes or interventions;
g) use of not original or unsuitable spare parts;
h) failure to comply with the instructions provided;
i) use of not originals inks and solvents;
l) use of the machinery with covers removed or disabled;
PAGE 5.133
Z4500
CHAPTER
5.2 HOW TO USE THE MANUAL
• This manual has been devised in order to provide the user with a detailed knowledge
of the machinery and with the instructions to use it in a proper way.
• Before moving to installation, maintenance and repair procedures, please read carefully
this manual
• Controls and maintenance should be carried out as scheduled in this manual in order to
make sure the printer is properly functioning throughout its life cycle and under normal
operating conditions.
WARNING:
Any change to the machinery unauthorized by the manufacturer will make the
warranty null and void.
The following instructions are part of the standard behaviour operators must comply with
when operating the printing system.
5.3 WARRANTY
During the period of warranty, the user must carry out all the preventive maintenance
procedures described in this manual. In case of failure to comply with such procedures,
the manufacturer is not responsable for any faults affecting the proper functioning of the
system, making the warranty null.
5.134 PAGE
Z4500
CHAPTER
GENERAL INFORMATION
5.4 UNALLOWED USES AND CONTRA-INDICATIONS
It’s forbidden use the system:
• without covers and/or when the safety devices are deactivated;

• in case of maintenance failures;
• after unauthorized changes or interventions;
• in case of either partial or total failure to comply with the instructions provided;
The printer cannot be used:

• in an esplosive atmosphere
• with relative humidity exceeding 95%;
Any changes unauthorized by the Manufacturer affecting the proper functioning of the
machinery by means of altered hazards and/or by adding further hazards will be the sole
responsibility of the person(s) carrying out such changes, relieving Zanasi of any respon-
sability.
Such changes, when carried out without the permission by the manufacturer, will make
the warranty and the declaration of conformity as provided by the Machinery Directive
98/37/CE null and void.
WARNING:
Specific parts of the system are powered with high voltage. The electronic com-
partment should not be opened and the print head cover should not be removed
by untrained personnel
WARNING:
The print head must be mounted onto a fixed support free of vibrations.
5.4.1 Electric safety
Installation procedures must be complied according to the instructions provided

in Chapter 1. Pay particular attention to the paragraphs concerning specifications and
requirements of electric power supply.
When replacing electric or electronic components, the POWER SUPPLY of the system must
be OFF. The power supply cable must be disconnected from the system before removing
covers to compartments or before accessing such compartments.
It’s forbidden to deactivate the electrical safety devices of the system.
PAGE 5.135
Z4500
CHAPTER
5.5 RESIDUAL RISKS
Fire hazard
IMPORTANT!
Fire hazard degree varies and depends on the nature as well as on the composition
of the substances. Inks made up of alcohol mixtures can burn.
Specific information can be found in the safety or material data sheets provided together
with inks and solvents.
In case of fire, use powder or dry extinguishers. Do not use water. Smothering a small fire
with a blanket is an effective means to extinguish a fire. In case you are not sure about
the precautions to take in case of fire, comply with the instructions provided by the local
fire authority.
Exalations hazard
Inks and solvents used with the system can produce hazardous exhalations (see safety
and material data sheet provided with inks and solvents).
In order to avoid such hazard, the system must be installed in a large, well-ventilated
space.
5.136 PAGE
Z4500
CHAPTER
GENERAL INFORMATION
5.6 RAEE DIRECTIVE
Standards on the disposal of equipments in the European Union:
according to the implementation of Directives 2002/95/CE, 2002/96/CE and 2003/108/

CE on the restriction of the use of certain hazardous substances in electrical and
electronic equipment and on waste disposal.
The crossed-out trash bin on the equipment means that the product, at the end of its
useful life cycle, must be separatedly collected.
The divesified garbage of this equipment at the end of its useful life cycle is organized
and managed by the manufacturer. The user that would get rid of this equipment must
contact the manufacturer and follow the way he choose to allow the diversified garbage
for it.
The adequate divesified garbage for the equipment recycing, treatment and disposal en-
vironmentally compatible contributes to avoid possible negative effects on the environ-
ment and to the health and thus favouring recycling of materials making up the product.
Illegal WEEE disposal shall be sanctioned according to the laws in force.
PAGE 5.137
Z4500
CHAPTER
5.7 CE DECLARATION OF CONFORMITY
We hereby declare under our responsability that the system
System Description: Continuous Ink Jet Printer

Type: Z4500
Identification: from serial number AB-SYS-00649
Manufacturer: Zanasi s.r.l.
via Marche 10, 41049 Sassuolo (Modena), Italy
complies with the requirements:
EMC Directive 2004/108/CE

LOW VOLTAGE Directive 2006/95/CE
and has been designed and manufactured in accordance with the harmonized European
standards:
EN60950:2001 Safety of Equipment

EN61000-6-4:2001 EMC Emissions
EN61000-6-2:2001 EMC Immunity
The manufacturer keeps information about the system technical construction data.
Sassuolo (Mo), October 29th 2008 Gianni Zanasi (Managing Director)
Version 2.291008
5.138 PAGE
Z4500
CHAPTER
GENERAL INFORMATION
5.8 GLOSSARY
High Voltage (H.V.): deflects the drops.
Binary Coded Decimal (BCD): prints messeges selected from external devices such as
PLC.
Umbilical cord: it’s the armored conduit from the cabinet to the print-head.
Display: it’s the user interface to program the system and visualize parameters.
Charge electrode: provides the correct amount of charge to each droplet.
Encoder: sensor to detect the product speed to be printed.
Photocellul/product sensor: detects the product to print.
Gutter: collects the ink droples not used in the printing process.
Serial lines RS232/RS485: data comunication lines to connect the system to an external
device (Personal Computer - PLC).
Make-up: fluid to keep the system viscosity constant.
Character Matrix: it’s made of rows and columns, made by ink droplets.
Oscillator: changes the ink stream into singles droplets.
Deflection plates: electrically deflect the charged droplets.
Print Head: generates the ink stream to create the printed characters.
Pressure transducer: sensor to measure the ink pressure inside the system.
Tubus: generathes the doplets.
Viscosimeter: measure the ink viscosity in the system.
PAGE 5.139
Z4500
CHAPTER
5.9 SOFTWARE RELEASE UPDATES
5.140 PAGE

Instruction Manual Z4500 Rel 1.01 ENG

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Instruction Manual Z4500 Rel 1.01 ENG

Uploaded by

Copyright:

Available Formats

Z4500

Revision Performer Date Description of changes

1.00 M.R. 19/07/2010

1.01 M.R. 08/10/2010 Added bracket for sensor

3 SYSTEM DESCRIPTION AND MAINTENANCE .........................................................................85

3.7 MAINTENANCE SCHEDULE ...........................................................................................93

4 HYDRAULIC AND ELECTRONIC DIAGRAMS ......................................................................... 114

5 GENERAL INFORMATION ........................................................................................................133

USE AND MAINTENANCE MANUAL 0

Before carrying out any operation on the machinery, operators and

0.1 HOW TO KEEP THE MANUAL

0.2 HOW TO READ THE MANUAL

Chapters are structured as follows:

USE AND MAINTENANCE MANUAL 0

A Logo of the manufacturer

0.3 PICTOGRAMS CONCERNING “OPERATORS”

L Electrical maintenance engineer:

0.4 OTHER PICTOGRAMS

O Respect of the environment

USE AND MAINTENANCE MANUAL 1

1.1 LIFTING AND HANDLING

THE SYSTEM IS DISPATCHED IN A RIGID BOX PLACED ONTO A PALLET

The material contained in the packing comprises:

A) 1 console complete of 1 cabinet (A1) with print head (A2)

USE AND MAINTENANCE MANUAL 1

CONSOLE PROTECTION DEGREE: IP55

1.1.3 Disposal of packaging

Keep the packaging for a further use of a transport.

USE AND MAINTENANCE MANUAL 1

1.2.1 Preparation of the area by the user

In dusty environments, the filters must be replaced every six months.

1.2.2 Operational and Maintenance areas

1.2.3 System placement

Be sure that the ground connection is properly working. An ordinary grounding

USE AND MAINTENANCE MANUAL 1

The UPS must absorb at least 300VA.

1.2.4 Photocell and Print head placement

Different sensors may be used:

USE AND MAINTENANCE MANUAL 1

B) PRINITNG ON THE TOP SURFACE

C) PRINITNG ON THE BOTTOM SURFACE

1.2.5 Electrical connection

85-240 VAC, 50-60 HZ SINGLE PHASE WITH GROUNDING.

• AVOID sudden interruptions in the power supply.

USE AND MAINTENANCE MANUAL 1

1.3.1 Print head preparation

1.3.2 Ink and Make-Up fill

USE AND MAINTENANCE MANUAL 1

Switch on the system by pressing the main button (INT).

USE AND MAINTENANCE MANUAL 1

USE AND MAINTENANCE MANUAL 1

1.5.1 Product sensor programming

1.5.2 Print speed

USE AND MAINTENANCE MANUAL 1

The value to set up can be obtained tentatively or by the following calculation:

PRINT DELAY = (Distance [m] / Speed [m/min]) x 60 x 10000

Example: Distance = 0.003 m, Speed = 30 m/min

1.5.4 Automatic print repeater

The value to set up can be obtained tentatively or by the following calculation:

REPEATER TIME = (Distance [m] / Speed [m/min]) x 60 x 4505

Example: Distance = 0.2 m, Speed = 30 m/min

USE AND MAINTENANCE MANUAL 1

In order to switch off the system:

USE AND MAINTENANCE MANUAL 1