Z5000 End User Manual (ENG)

Z5000
Instruction
Manual
Rel: 6.00
Z5000
Foreword
0
Chapter
Use and Maintenance Manual
0 Foreword
Table of Changes
Revision Performer Date Description of change
1.03 S.A. - M.R. - G.Z. 24/03/2008
2.00 M.R 11/10/2012 New manifold
3.00 M.R 02/09/2013 New manifold
4.00 M.R 24/04/2014 Updating for CE test
5.00 M.R 31/10/2017 Safety Chapter
5.01 M.R 05/01/2018 Alarm output updated
6.00 M.R 15/11/2018 Fluid-O-Tech pumps
Page 0.1
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0 Foreword
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Table of contents
0 FOREWORD...................................................................................................................................6
0.1 WARNINGS FOR RECIPIENTS OF THE MANUAL............................................................6
0.2 HOW TO READ THE MANUAL...........................................................................................9
0.2.1 Key to each page.................................................................................................. 11
0.3 PICTOGRAMS CONCERNING “OPERATORS”............................................................... 11
0.4 OTHER PICTOGRAMS..................................................................................................... 11
1 SAFETY........................................................................................................................................15
1.1 DESCRIPTION OF DANGER, OBLIGATION AND PROHIBITION SIGNALS...................15
1.2 DESCRIPTION OF PERSONAL PROTECTIVE EQUIPMENT (PPE)................................17
1.3 PERSONNEL TRAINING...................................................................................................18
1.4 INTENDED USE................................................................................................................18
1.5 USE NOT PERMITTED.....................................................................................................19
1.6 SAFETY DEVICES............................................................................................................19
1.7 NOISE................................................................................................................................20
1.8 ELECTROMAGNETIC EMISSIONS..................................................................................20
1.9 RESIDUAL RISKS.............................................................................................................20
1.9.1 Risk of fire.............................................................................................................20
1.9.2 Risk of electrocution............................................................................................21
1.9.3 Explosive atmosphere risk..................................................................................21
1.9.4 Risk of blindness..................................................................................................22
1.9.5 Risk due to electricity...........................................................................................22
1.9.6 Risk of tripping.....................................................................................................22
1.9.7 Risk of slipping.....................................................................................................23
1.9.8 Risk due to handling............................................................................................23
1.9.9 Risk of exhalations ..............................................................................................23
1.9.10 Risk of cutting.......................................................................................................23
1.10 OBLIGATIONS AND PROHIBITIONS...............................................................................24
1.10.1 User obligations....................................................................................................24
1.10.2 Operators obligations..........................................................................................24
1.10.3 Operators prohibitions.........................................................................................24
1.11 DISPOSAL OF WASTE MATERIALs................................................................................25
1.12 INDICATION FOR WASTE................................................................................................27
1.13 GENERAL REMARKS.......................................................................................................27
1.14 CE DECLARATION OF CONFORMITY.............................................................................28
2 START-UP....................................................................................................................................31
2.1 LIFTING AND HANDLING.................................................................................................31
2.1.1 Unpacking.............................................................................................................31
2.1.2 Storage..................................................................................................................33
2.1.3 Disposal of packaging..........................................................................................33
2.2 SYSTEM INSTALLATION..................................................................................................35
2.2.1 Preparation of the area by the user.....................................................................35
2.2.2 Operational and Maintenance areas....................................................................35
2.2.3 System placement................................................................................................35
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2.2.4 Photocell and Printhead placement....................................................................37

2.2.5 Electrical connection............................................................................................39
2.3 ADJUSTMENTS BEFORE ACTIVATION..........................................................................41
2.3.1 Printhead preparation..........................................................................................41
2.3.2 Ink and Make-Up fill..............................................................................................41
2.4 SYSTEM START-UP..........................................................................................................43
2.4.1 Printhead cleaning................................................................................................45
2.5 SYSTEM SET UP..............................................................................................................47
2.5.1 Product sensor programming..............................................................................47
2.5.2 Print speed ...........................................................................................................47
2.5.3 Print delay with sensor product..........................................................................49
2.5.4 Automatic print repeater......................................................................................49
2.6 SYSTEM SWITCHING OFF...............................................................................................51
2.7 ENCODER (OPTIONAL)...................................................................................................53
2.8 BEACON ALARM (OPTIONAL)........................................................................................53
2.9 VAPOUR RECOVERY.......................................................................................................55
2.10 PRINTHEAD PRESSURIZATION......................................................................................55
3 PROGRAMMING..........................................................................................................................59
3.1 USER INTERFACE..........................................................................................................59
3.2 PROGRAMS AND FUNCTIONS........................................................................................61
3.2.1 Main page..............................................................................................................61
3.2.2 Texts and hypertexts: general remarks..............................................................61
3.2.3 Message selection................................................................................................61
3.2.4 Pre-Edit (to modify the archive)...........................................................................63
3.2.5 Edit.........................................................................................................................63
3.2.5.1 Main properties of the text...................................................................................63
3.2.5.2 Secondary properties of texts.............................................................................65
3.2.5.3 Key shortcuts (simplified editing).......................................................................67
3.2.5.4 Special characters................................................................................................67
3.2.6 Text........................................................................................................................67
3.2.7 Date........................................................................................................................69
3.2.8 Expiry date............................................................................................................71
3.2.9 Hour.......................................................................................................................71
3.2.10 Expiry hour............................................................................................................73
3.2.11 Counters................................................................................................................73
3.2.11.1 Incremental counter...........................................................................................75
3.2.11.2 Decremental counter........................................................................................75
3.2.12 Batch.....................................................................................................................75
3.2.13 Shift.......................................................................................................................77
3.2.14 Barcode.................................................................................................................79
3.2.15 Logo.......................................................................................................................83
3.2.16 Logo editor............................................................................................................83
3.2.17 DataMatrix.............................................................................................................85
3.3 ENCODER ........................................................................................................................87
3.4 PRINT MODE....................................................................................................................87
3.5 SETTINGS ........................................................................................................................87
3.5.1 Load rod amplitude..............................................................................................87
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3.5.2 H.V. value (high voltage on deflection plates)....................................................87

3.5.3 Pressure................................................................................................................89
3.5.4 Suction..................................................................................................................89
3.5.5 Flight Time and Phase Peak.................................................................................89
3.6 SYSTEM PARAMETER.....................................................................................................89
3.6.1 Ink Type.................................................................................................................89
3.6.2 Viscosity................................................................................................................89
3.6.3 Ink Temperature....................................................................................................89
3.6.4 Board Temperature...............................................................................................89
3.7 SYSTEM CONFIGURATION.............................................................................................91
3.7.1 Serial address, Baudrate and Serial Type...........................................................91
3.7.2 Coding type...........................................................................................................91
3.7.3 Language...............................................................................................................93
3.8 ENABLE PAGE.................................................................................................................93
3.9 TIME AND LEVELS SETTINGS........................................................................................95
3.10 REPORT MANAGING AND DISPLAYING........................................................................95
3.11 SYSTEM PROTECTION ...................................................................................................97
3.11.1 Password insertion procedure............................................................................97
3.11.2 Protection management.......................................................................................97
3.12 HOW TO USE BARCODES UCC/EAN-128 AND CODE 128............................................98
3.13 BARCODE UCC/EAN-128 CHARACTERS TABLE........................................................100
4 SYSTEM DESCRIPTION AND MAINTENANCE........................................................................103

4.1 PRELIMINARY INFORMATION ON THE PRINTING SYSTEM..................................103
4.1.1 Main components...............................................................................................103
4.2 WORKING.......................................................................................................................105
4.3 CHARACTER COMPOSITION........................................................................................107
4.4 PRINTING FEATURES....................................................................................................107
4.5 TECHNICAL SPECIFICATIONS......................................................................................109
4.6 MAINTENANCE.............................................................................................................. 110
4.6.1 Maintenance safety conditions.......................................................................... 110
4.6.2 Technical instructions for correct maintenance.............................................. 110
4.7 MAINTENANCE SCHEDULE........................................................................................ 111
4.8 FILTERS.......................................................................................................................... 113
4.8.1 Tubular filters....................................................................................................... 113
4.8.2 Damper................................................................................................................ 113
4.8.3 Main filter............................................................................................................. 113
4.9 ELECTRO-VALVE........................................................................................................... 115
4.9.1 Valve cleaning..................................................................................................... 115
4.9.2 Valve replacing................................................................................................... 115
4.10 VISCOMETER................................................................................................................. 117
4.10.1 Viscosimeter cleaning ....................................................................................... 117
4.10.2 Viscometer replacement .................................................................................... 117
4.11 PRINT HEAD................................................................................................................... 119
4.11.1 Ink stream alignment.......................................................................................... 119
4.11.2 Nozzle cleaning................................................................................................... 119
4.11.3 Nozzle replacement............................................................................................121
4.11.4 Tubus replacement.............................................................................................121
4.11.5 Gutter cleaning...................................................................................................121
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4.12 PUMPS............................................................................................................................123
4.12.1 Suction Pump replacement................................................................................123
4.12.2 Force Pump replacement...................................................................................123
4.13 HYDRAULIC CIRCUIT CLEANING.................................................................................123
4.14 POWER SUPPLY............................................................................................................125
4.14.1 Switching power supply.....................................................................................125
4.14.2 Fuses...................................................................................................................125
4.15 SHIPPING PACKAGING.................................................................................................125
4.16 SYSTEM ALARM............................................................................................................127
4.16.1 *Low priority alarm*............................................................................................127
4.16.2 **High priority alarm**........................................................................................129
4.16.3 Other warnings...................................................................................................129
4.16.3.1 Maintenance Warning......................................................................................129
4.16.3.2 No Flush Warning............................................................................................129
4.16.3.3 Low Ink Temperature Warning........................................................................129
4 HYDRAULIC AND ELECTRONIC DIAGRAMS..........................................................................132

5.1 CHAPTER OVERVIEW...................................................................................................132
5.2 SYSTEM COMPONENTS................................................................................................133
5.3 HYDRAULIC MANIFOLD..............................................................................................134
5.4 PUMP-MOTOR GROUP..................................................................................................135
5.5 VISCOMETER.................................................................................................................136
5.6 PRINT-HEAD...................................................................................................................137
5.7 ELECTRONIC COMPARTMENT.....................................................................................138
5.8 HYDRAULIC COMPARTMENT.......................................................................................139
5.9 TANKS GROUP...............................................................................................................140
5.10 USER INTERFACE: KEYBOARD...................................................................................141
5.11 PHOTOCELL CONNECTION..........................................................................................142
5.12 ENCODER CONNECTION..............................................................................................143
5.13 BCD INPUT CONNECTION.............................................................................................144
5.14 ALARM OUTPUT CONNECTION....................................................................................145
5.15 CONNECTION TO A PC OR OTHER DEVICES..............................................................146
5.16 HYDRAULIC CIRCUIT....................................................................................................148
Page 0.5
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0 Foreword
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0 FOREWORD
The manual is intended for operators in charge to use and maintain the system in all phases
of its technical life. It must be carefully stored and has to follow the system in all ownerships.
In the manual are the themes referring to a proper use of the system, in order to maintain
over time the functional and qualitative features. All the information and warnings are also
reported for the correct use in total safety.
WARNING!
Before proceeding with the installation of the system, or make it operational and
use it, or perform maintenance on it, read carefully way this manual and the eventual
other documentation supplied, faithfully following the instructions and the indications.
0.1 WARNINGS FOR RECIPIENTS OF THE MANUAL
This manual, drafted in English, contains the “Original Instructions” of the system.
The manual, as well as the CE conformity certificate included, is an integral part of the
system and must always follow it in every move or resale. It is the user’s duty to maintain
this documentation unaltered, to allow the consultation, during the whole life of the system.
In case of loss or destruction it’s possible to request a copy to ZANASI srl, specifying ac-
curately the model, the serial number and the year of production.
It is a compulsory requirement that the technical personnel in charge for the maintenance
have read and understood the instructions provided by the manufacturer and that he is
familiar with the connection and wiring practices and electrical schematic symbols. He also
must be experienced in the use of electrical equipment.
Failure to follow the safety rules may cause injury to personnel and damage to the com-
ponents and the system control unit.
However the reading, even if exhaustive, of this manual cannot replace the necessary
experience of the operators.
Operators must be carefully trained on the operation and correct use of safety devices
installed.
This manual is an integral part of the system to which it relates and contain the information
necessary to:
• the proper awareness of operators about the safety
• handling the system, for the packing and unpacking in safety conditions
• the correct installation of the system
• the use of the system in safety conditions
• depth knowledge of its operation
• perform maintenance in a correct and safe way
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WARNING!
The system must only be used by qualified and trained operators on procedures and
in compliance with the recommendations contained in this manual.
The customer and/or the technical personnel in charge for the maintenance can, at any
time, contact the manufacturer for more information in addition to those contained herein.
The documentation provided by ZANASI srl only relates to the equipment provi-
ded by ZANASI srl to the purchaser and/or to end user.
Any other manuals provided in both paper and electronic format are an integral
part of this manual, and they follow the same recommendations/prescriptions of
this manual.
WARNING!
It’s the responsibility of the user to integrate the instructions contained herein with
any operating procedures present in the location of use of the equipment and provide
any additional information to the staff in charge to the use and maintenance of the
system.
The ZANASI srl reserves the right to modify and update this manual at any time without
prior notice.
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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 neces-
sary 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.
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C D E
F G
I M
L N
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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 is the
progressive of overall pages composing 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.
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1 Safety
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A B C D
E F G H
I J
L M N
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1 SAFETY
1.1 DESCRIPTION OF DANGER, OBLIGATION AND PROHIBITION SIGNALS
A Danger of voltage
B Dangerous temperature
C Danger of flammable substances
D Danger of harmful and irritating substances
E Devices sensitive to electrostatic discharge
F Danger of ink jet
G Danger of slipping and falling
H Danger of stumbling and falling
I Danger of handling heavy objects
J Danger of cutting
K Obligation to read the manual
L Prohibition of use of open flames
M Prohibition of touching
N Prohibition of spray water towards electrical equipment
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O P Q
R S
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1.2 DESCRIPTION OF PERSONAL PROTECTIVE EQUIPMENT (PPE)
The personnel in charge for installation, use and maintenance which carries out the activi-
ties on the system, must use personal protective equipment in order to reduce all possible
risks arising from the various activities. The personal protective equipment chosen by the
user must comply with the 89/686/EEC Directive and the technical standards applicable
to the specific cases.
O Mandatory use of protective and insulating gloves
P Mandatory use of goggles for eye protection
Q Mandatory use of safety shoes
R Mandatory use of an appropriate and protective workwear
S Mandatory use of respiratory protection mask
WARNING!
It’s the user’s responsibility to ensure that the personnel involved is properly trained
on residual risks and uses the PPE provided as well as evaluating possible necessary
additions.
The PPE indicated must be provided by the employer and must be complemented
by him in function of the working site, the prescriptions and provisions in force in
the country of use.
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1.3 PERSONNEL TRAINING
The customer must ensure that personnel assigned to install, and/or to use and/or to
maintenance, is formed, instructed and appropriately trained.
The use, installation and maintenance of the system should only be carried out by properly
qualified and trained personnel with operational, technical, electrical, electronic, mechanical,
and pneumatic knowledge (and eventual prescriptions applicable in the country of use of
the system) according to qualification of the personnel stated in this manual.
It is the user’s responsibility to provide to instruct personnel about the risk of accident, the
safety devices and the general rules about the safety provided by the Community directives
and by the law of the country where the equipment is installed and used.
The in charge personnel must be aware of the location and the functioning of all controls
and device characteristics.
All installation and maintenance work must be performed by qualified personnel.
1.4 INTENDED USE
The intended use for the system is to carry out the inkjet marking of products in accordance
to what is described in the contract or according to the instructions in this manual.
The use of material unsuitable can cause serious damage and compromise operation.
The system is realized in order to:

• to satisfy the specific requirements listed in the sales contract
• to be used according to instructions and operating limits specified in this manual
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1.5 USE NOT PERMITTED
The system must be used only for purposes expressly provided by the manufacturer.
Particularly it is forbidden:
• to use the system if it has not been properly installed according to current regulations;
• to use the system with a faulty power supply or without an efficient grounding system;
• to use the system without complying with the required power supply specifications;
• to use the system with different functionality from that for which it was built;
• to use use the system or its units as a foothold even if not working;
• to use use the system outside the environmental conditions permitted;
• to use the system in environments different from those for which it was designed and
built;
• to use the system to mark products other than those for which it was supplied;
• to use the system to mark products not suitable for marking;
• to use the system with inks, solvents and other materials than the ones indicated by
the manufacturer;
• to use the systems without protection and/or with the safety equipment disabled;
• to use the system with weaknesses in maintenance;
• to use the system after modifications or unauthorized intervention;
• to use the system with total or partial inobservance of the instructions;
• to use is not permitted except as specified in paragraph 1.4.
The use of consumables (ink, solvents, etc.) or spare parts not supplied or suggested by
Zanasi srl could damage the system and / or compromise the correct functionality. In this
situation, the manufacturer is held harmless from any liability or guarantee.
Modifications which alter the risk, if performed without the authorization of the ma-
nufacturer, will invalidate any guarantee, responsibility and declaration of EC con-
formity
1.6 SAFETY DEVICES
The system is equipped with safety devices such as fixed protections of the printhead and
the plug/socket system for the isolation of the power source.
The power supply cable is used as power supply cut-off device; it must therefore be
positioned at a height between 0.6 m and 1.7 m and it has to remain clearly visible and
easily accessible for the operator.
WARNING!
Before carrying out any installation work or electrical maintenance, make sure that
the system is disconnected from the power supply taking care to disconnect the
power plug.
The not observance of this mandatory requirement exposes the personnel re-
sponsible for various risks, and indemnifies the manufacturer from any liability.
The “0– I” switch placed on the side of the system must not be considered as a discon-
necting device.
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1.7 NOISE
The noise measurements were made in accordance with the UNI EN 11202 regulations.
During the operating cycles, the A-weighting sound pressure level of emission does not
exceed 70 dB(A).
1.8 ELECTROMAGNETIC EMISSIONS
The system contains electronic components subject to the regulations on Electromagnetic

Compatibility, conditioned by conducted and radiated emissions.
Emission values satisfy the regulatory requirements through the use of components com-
plying with EMC Directive, the appropriate connections and installation in accordance with
the prescriptions of component suppliers.
Compliance with maximum levels of emission and immunity for industrial environment is
obtained by applying the principles of the technical product Harmonised standards and as
a result of laboratory tests carried out by the manufacturer confirming the technical and
design choices implemented.
The equipment is therefore in conformity with the Directive on Electromagnetic Com-

patibility (EMC).
1.9 RESIDUAL RISKS
The printing system is manufactured for safe operation; during the design phase, the
danger zones or parts have been evaluated and have been accordingly taken all ne-
cessary precautions to avoid risks to persons and damage to equipment components
as indicated in the preceding paragraphs.
Although the system is equipped with safety systems, some risks can not be eliminated
but can be reduced through corrective actions by the end user and through mandatory
correct operating mode for anyone working on it.
1.9.1 Risk of fire

In case of faults, the plastic material used (eg. sheaths, electrical cables) is self-extinguish-
ing and comply with current standards.
The raw materials used on the system (consumables such as inks, solvents, etc.) may be
flammable.
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The customer will take all necessary measures to prevent the risk of fire. In particular, it
is recommended:
• Do not smoke near the system.
• Do not use open flames.
• Keep the system clean from dust and ink lumps.
• Do not stack flammable materials nearby the system.
• Inks and solvents must be stored in suitable ventilated places and free of possible
sources of ignition, away from heat sources.
• Do not perform welding operations or similar with sparks nearby the system.
The system does not autonomously generate a fire hazard.
The user factory shall evaluate the need for an appropriate fire extinguishing system on
the premises where the system is installed, in compliance with current safety regulations
and fire prevention in the user country and with the internal regulations of the factory.
Use proper tools with proper electrical isolation.
WARNING!
In case of fire, disconnect the system from the main power supply, cutting off all
power energy.

1.9.2 Risk of electrocution

• Risk of breakage or damage, with possible lowering of the security level, of the com-
ponents of the electrical system after a short circuit.
• Before connecting the system to the power supply, make sure there are no maintenance
work in progress and no one is working on the system.
Use proper tools with proper electrical isolation.
Before making the connection, check that the short-circuit current at the installation
point is not greater than the one shown on the plate system.
1.9.3 Explosive atmosphere risk

The system is not suitable for working in explosive environments, or at risk of explosion.
It is then strictly forbidden to use the system in environments:
• explosive or partially explosive
• where there are corrosive atmospheres
• in which there are oily high concentrations
• with risk of fire caused by any materials or ignition source
Aso be sure that inks and solvents are stored in special ventilated environments, free of
possible sources of ignition and away from heat sources.
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1.9.4 Risk of blindness

It could occur during the maintenance and cleaning phases.
• During operations with the system it is absolutely forbidden to direct the printhead
toward parts of the body and/or of the face.
• Especially during the cleaning phase, the printhead nozzle delivers ink mixed solvent
so it is absolutely forbidden to approach with the face and the eyes, or directing the
nozzle or jet of the printhead towards the face, eyes and parts of the body in order to
avoid injury.
• Periodically check the printhead connection pipes in order to avoid that in case of
damage an uncontrolled exit of ink in the marking process could occour.
WARNING!
It’s mandatory to wear eyes and face protection. Danger of harmful and/or irritating
substances to body parts.
1.9.5 Risk due to electricity

The access and maintenance operations to the internal components of the system expose
the personnel to electrical hazard.
Operations on the energized equipment must be performed by qualified and experienced
personnel. Follow these recommendations about the safety measures:
• Pay maximum attention to the safety labels relating to electrical risk
• Do not perform maintenance to electrical components without having previously dis-
connected the electric power by disconnecting the power plug
• Periodically check the equipotential protection circuit
• Check the efficiency of the system ventilation
1.9.6 Risk of tripping

The disordered deposit of material may create a tripping hazard, and partial or total restric-
tion of the emergency exits when necessary.
Pay attention, even during installation and maintenance activities, to not let material or
equipment which may constitute a tripping hazard for oneself or for other people.
Even the umbilical cord of connection between the system and the printhead, if deposited
in a disorderly manner, can constitute a risk of tripping.
WARNING!
Ensuring operating and transit places and emergency exits free from obstacles and
comply with standards.
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1.9.7 Risk of slipping

Any leakage of ink or solvents can cause slipping for the personnel in charge for the use,
operation and maintenance.
WARNING!
Access to that area with non-slip shoes and always keep them clean.

1.9.8 Risk due to handling

The system is shipped at the user’s factory in a single container (packing with carton).
Operations of:
• Unloading of the cardboard box
• Opening of the cardboard box
• Removing and handling the system
can expose the personnel at risk of crushing, though slight since the weights involved, in
case of non-compliance with the instructions provided by the manufacturer.
The customer has to analyze the risks that may occur during the phase of handling
within its factory (analyzes about handling the system were carried out considering
the only characteristics of the system).
1.9.9 Risk of exhalations

During maintenance operations, ink and solvent used with the system can produce noxious
fumes: about it, refer to the technical and safety data sheets supplied with ink and solvent.
To overcome this risk, the system must not be confined in a small space and the instal-
lation premises must be large and well ventilated.
1.9.10 Risk of cutting

During the phases of unpacking, the operator can be in contact with sharp edges of the
packaging that can cause damage.
WARNING!
Move the system while protecting hands and body with the appropriate personal
protective equipment.
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1.10 OBLIGATIONS AND PROHIBITIONS
1.10.1 User obligations

The user (contractor or employer) must:
• Consider the capacities and conditions of the operators in relation to their health and
their safety.
• Provide personal protective equipment appropriate to the individual procedures.
• Require compliance by individual workers of the rules and company regulations concern-
ing safety and the use of collective and individual protective equipment at their disposal.
• Train the personnel about the procedures in case of injury.
• Train the personnel about the devices predisposed to the operator safety.
• Train the personnel about the general accident prevention regulations set by European
directives and by the law of the country of destination of the system.
• To let operate on the equipment only personnel who has read this manual and who
was suitably trained by checking the real formation.
1.10.2 Operators obligations

The operator must:
• Perform the procedures on the cables and all components of the electric compartment
always with the main switch off and unplugging the power plug.
• At system startup, be sure that there is none in danger zones.
• Properly use the protective equipment provided by the employer.
• Immediately notify to the employer, manager or person in charge, the deficiencies
of the safety devices.
1.10.3 Operators prohibitions

The operator must not:
• Use the system improperly, ie for other purposes than those listed in the “Intended
Use” paragaph.
• Remove or modify without authorization, the safety or signaling devices.
• Autonomously perform operations not of their competence or which may compromise
their own safety or the one of other workers.
• Work with consumables (ink and solvent) other than those specified by the manufacturer.
• Modify the system cycle.
• Modify the electrical connections or switch off the internal safeties.
• Use the system if it has not been properly installed according to current regulations.
• Use the system as a support although not working (with risk of injurious falls and/or
the of damage to the system).
• Use the system outside of the allowable environmental conditions.
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1.11 DISPOSAL OF WASTE MATERIALS
The system, after installation and during its normal operation, does not involve environmen-
tal contamination but during the entire period of use certain types of waste or exhausted
materials are however produced, as the ink container or residues of the same ink.
For disposal of these materials there are in every country specific regulations about
Environmental Protection Agency.
The customer is obligated to be aware of the current laws in his country and to work in order
to comply with these laws in accordance with the instructions given in the specifications
of the products used.
More information about how to dispose inks can be found on the Security sheet of
the inks to which reference is made for details.
It is forbidden to disperse the consumables such as inks and/or solvents into the sewer or
drains that may cause environmental contamination.
The disposal of toxic waste during collection, transport, treatment (intended as the trans-
formation operation necessary for the recovery), as well as the storage and dump on the
ground, constitutes activities of public interest subject to compliance with the following
general principles:
• Any injury or risk to health and to the safety of the community and individual must be
avoided.
• The respect of the hygienic-sanitary requirements must be guaranteed and avoided
any risk of pollution of air, water, soil and subsoil.
Recovery and recycling systems of materials and energy should be initiated, with
the observance of economic criteria and efficient.

The responsible for the disposal is at the user/end customer who has to provide
in accordance with the local laws governing the use of the system.
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1.12 INDICATION FOR WASTE
Residues from industrial processes and materials from the demolition of deteriorated and
obsolete machinery and equipment are hazardous waste. Among these, in the Z5000
system, there are steels, light alloys, plastics materials and electrical equipment.
The producers of the waste are required to provide for disposal of special waste, even toxic
and hazardous, either directly or through companies, authorized agencies or by transfer
of waste to the persons who run the public service with which a special agreement was
stipulated.
Each country/municipality is required to provide the region with all the information available
on waste disposal in their territory.
According to the 2012/19/UE “RAEE” Directive (repealing the 2002/96/CE Directive and
the 2003/108/CE Directive on waste electrical and electronic equipment) the component/
equipment marked with the following symbol of the waste crossed out bin indicates that
the product at the end of its life must be collected separately from other waste.
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.
1.13 GENERAL REMARKS
Serial Number: it is on CE lable on the outer side of the console.

The external lable comprises:
Model Z5000
Serial number univolcal code for the system identification
Year year of production
and a chart with the electrical characteristics.

In the bottom of the label is the CE logo and the symbol of special waste
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1.14 CE DECLARATION OF CONFORMITY
We hereby declare under our responsability that the system
System Description: Continuous Ink Jet Printer

Type: Z5000
Identification: serial nr. from 2007-SYS-01263 to 2009-SYS-01898 and
from AA-SY-00001
Manufacturer: Zanasi s.r.l.
via Marche 10, 41049 Sassuolo (Modena), Italia
complies with the requirement:
Directive 2014/30/EU (ELECTROMAGNETIC COMPATIBILITY - EMC)

Directive 2014/35/EU (LOW VOLTAGE)
Directive 2011/65/CE (ROHS 2)
Directive 2012/19/UE (RAEE)
and has been designed and manufactured in accordance with the harmonized European
standards:
EN60204:2006 + A1:2010 + EC:2010 Electrical Equipment

EN60950-1:2006 Safety of Equipment
EN61000-6-4:2007 + A1:2013 EMC Emissions
EN61000-6-2:2006 EMC Immunity
The manufacturer keeps information about the system technical construction data.
Person authorised to compile the technical file:

Paolo Zanni (technical manager) - via Marche 10, 41049 Sassuolo (Modena), Italy
Sassuolo (Mo), January 09th 2017 Gianni Zanasi (Managing Director)

Release 9.090117
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2 START-UP
2.1 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.
2.1.1 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 printhead (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 beacker 500 ml
• 1 wash bottle
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2.1.2 Storage
When the system is already used with the tank full, follow the preventive maintenance
described in chapter 4.
For long periods of inactivity, the system must be stored in its original packaging and with
hydraulic circuit and tanks without ink or solvent.
2.1.3 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.
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2.2 SYSTEM INSTALLATION
2.2.1 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.
2.2.2 Operational and Maintenance areas
WARNING:
The system placement must allow an easy access for the maintenance or possible
replacement of spare parts.
2.2.3 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 printhead 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.
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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.
2.2.4 Photocell and Printhead 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 5.11 for other types of cabling.
The printhead 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 printhead to the surface to print must be set from 5mm to 20mm.

WARNING:
The printhead must be free of vibrations.
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A) PRINTING ON THE SIDE

The product passes in front of the printhead, from right to left or vice versa.

B) PRINTING ON THE TOP SURFACE
The product passes under the printhead, from right to left or vice versa.
C) PRINTING ON THE BOTTOM SURFACE

The product passes over the printhead, 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 printhead. The printing delay can be set like described in paragraph 2.5.3.
2.2.5 Electrical connection

The system features the following connections:
1. main button
2. socket
3. 5 pin female connector: photocell (product sensor)
4. 18 pin female: BCD inlets
5. 9 pin male: auxiliary serial line
6. 9 pin male: serial line
7. 18 pin male: alarms
8. 5 pin female: encoder (speed 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.
In order to interrupt the flow of electrical current toward the system in case of overload,
short circuit or current leakage, make sure that the electrical wiring to which the system
is connected has a residual-current device (RCD) and a circuit breaker with the following
minimum requirements:
Residual-current device Circuit breaker

icc > 600A icc > 600A
in > 2A in > 2A
i∆m = 30mA type B
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2.3 ADJUSTMENTS BEFORE ACTIVATION
2.3.1 Printhead preparation

The printhead is equipped with covers in order to avoid damages to its components during
transport. Such covers must be removed when the printhead is activated for the first
time:
• Remove the white protection from the printhead
• Remove the casing to get inside the printhead (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)
2.3.2 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 pul-
ling them upwards (A)), and add a further ink and make-up cartridge, as described 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.
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C D
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2.4 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
start-up procedure (B).
After 10 seconds, the system enables automatically the ink stream (C).
After 50 seconds more, the system enables 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.
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2.4.1 Printhead cleaning

If the printhead 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 printhead
3. The solvent evaporates; the surplus quantity must be wiped off with a clean lint-free
cloth.
WARNING:
The inside of the printhead must be perfectly dry. The presence of moisture condi-
tions the system function.
When operating on the printhead, be careful to avoid any damage and to avoid mi-
saligning the ink stream.
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2.5 SYSTEM SET UP
Once the printhead has been cleaned, the system can be prepared for printing.
Make sure that the protection cover (f) is fixed on the printhead.
Press “START/STOP” to start printing process from the main page.
Automatically, the printer is ready to print the current message according to 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
paragraph 3.8)
WARNING:
the system must not be 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.
2.5.1 Product sensor programming

Install the product sensor (photocell) as shown in paragraph 2.2.4.
The product sensor can be used to detect a continuous product (a pipe) 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 the frequency of the repeater previously set up. This funcion is called “print
repeater”.
Press “SPANNER” to enter the PRINTING PARAMETERS page (A) from which the product
sensor (1) can be enabled (PHOTOCELL: Y) or disabled (PHOTOCELL: N).
2.5.2 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.
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2.5.3 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 triggered (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
2.5.4 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.
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2.6 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.
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2.7 ENCODER (OPTIONAL)
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 paragraph 3.3 for encoder set up.
2.8 BEACON ALARM (OPTIONAL)
The beacon alarm is used to indicate the status of the system.

The three lights correspond to:
• green light = system ready to print
• yellow light = a low priority alarm occurred but the system is still able to print
• red light = a high priority alarm occurred and the system is not able to print
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ATTENTION:
DO NOT OBSTRUCT
FILTER - PRESSURE REDUCER
Air Inlet
(max 0.6 bar)
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2.9 VAPOUR RECOVERY
The system produces solvent vapours that are condensed and reused in the system. A
small quantity is expelled through the condenser 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.
2.10 PRINTHEAD PRESSURIZATION
When the system is installed in a dusty and moist room, the printhead 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.
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3 PROGRAMMING
3.1 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.
SPANNER 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.
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a Reference
Text
Code
0 TEST
1 PRINTING TEST 1
... ...

248 PRINTING TEST 248
249 249 THE LAST PRINTING TEST
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3.2 PROGRAMS AND FUNCTIONS
This paragraph explains how to insert texts and includes a description of the printing
possibilities and functions.
3.2.1 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.
3.2.2 Texts and hypertexts: general remarks

The system allows to create an archive (database) of 250 different messages of up to
240 characters and of 50 images (logo) of 32rowsx90columns (with the most advanced
coding type; otherwise 24rowsx90columns). 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 249
and refers to one message only (see table a).
The system will not print if no messages are selected alongside the printing
code.
3.2.3 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 249 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.
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3.2.4 Pre-Edit (to modify the archive)

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.
3.2.5 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”.
3.2.5.1 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).
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In the example shown using the most advanced coding type, the matrixes available
are: 5x5, 7x5, 9x7, 10x8, 16x10, 24x16, 32x18.
Use “ARROW RIGHT” or “ARROW LEFT” to browse the FONTS.
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.
3.2.5.2 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.
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3.2.5.3 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
3.2.5.4 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.
3.2.6 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.
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3.2.7 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 pararaph 3.9.
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) D M Y = Day Month Year

2) M D Y = Month Day Year
3) M Y = Month Year
4) D M = Day Month
5) M D = 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 26/12/2008 becomes 26/DEC/2008 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.
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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/2009
• date with “-”: as separator: 26-DIC-2009
3.2.8 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.
3.2.9 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 paragraph 3.9.
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
By QH we mean the quarter of the current hour as of midnight. The value ranges
between 1 and 96.
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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
3.2.10 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.
3.2.11 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:
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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.
3.2.11.1 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.
3.2.11.2 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.
3.2.12 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:
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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.
3.2.13 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
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• 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.
3.2.14 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
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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 PARAGRAPH 3.12 AND 3.13 FOR PROPER INSERTION OF

BARCODES 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).
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3.2.15 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
3.2.16 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.
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3.2.17 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.
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3.3 ENCODER
Install the encoder as explained in parag.1.7.
Press “SPANNER“ 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.
3.4 PRINT MODE
Press “SPANNER“ 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).
3.5 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:
3.5.1 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.
3.5.2 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.
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3.5.3 Pressure
The PRESSURE parameter (6) refers to the ink pressure inside the hydraulic circuit.
3.5.4 Suction
The SUCTION parameter (7) refers to the suction power of the suction pump.
3.5.5 Flight Time and Phase Peak

Parameters FLIGHT TIME (8) and PHASE PEAK (9) are used for the service procedu-
re.
3.6 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:
3.6.1 Ink Type

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

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

Parameter BOARD TEMPERATURE (13) shows the actual value of the electronic
compartment.
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3.7 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.
3.7.1 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.
3.7.2 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.
32-S 32-STANDARD: it allows to use font from 5x5 to 32x18 up to 32 dot.
32-HQ 32-HIGH QUALITY: it allows to use font from 5x5 to 32x18 up to 32 dot.
4L-7x5 4 LINES 7X5: ideal for messages on four lines with font 5x5 and 7x5 (with
interline respectively 3 and 1).
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).
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3.7.3 Language
Parameter LANGUAGE (18) set the language for the menu pages. To modify it, use “AR-
ROW LEFT” and “ARROW RIGHT”.
3.8 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).
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3.9 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.
3.10 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.
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3.11 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).
3.11.1 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).
3.11.2 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).
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3.12 HOW TO USE BARCODES UCC/EAN-128 AND CODE 128
The barcodes 128 and EAN-128 have many rules established by different authorities:
INDICOD, 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 paragraph 3.13.
There are three series:
UCC/EAN-128A. The A series consists of all numeric characters, the alphabetic upper-
case characters, special and command characters.
UCC/EAN-128B. The B series consists of all numerical characters, the alphabetic up-
percase and lowercase characters, 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.
3.98 Page
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3
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 of a variable

lenght 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 3.99
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Chapter Programming
3.13 BARCODE UCC/EAN-128 CHARACTERS TABLE
3.100 Page
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4
System Description and Maintenance Chapter
4 System description
and maintenance
Page 4.101
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Chapter System Description and Maintenance
1
A
2
3
4
5
B3 B1
B2
4.102 Page
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4
4 SYSTEM DESCRIPTION AND MAINTENANCE
4.1 PRELIMINARY INFORMATION ON THE PRINTING SYSTEM
Z5000 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 printhead (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 .
4.1.1 Main components
PrintHead:
1) Cover sensor
2) Tubus (emitting microdrops)
3) Nozzle (removable)
4) Charge electrode
5) Phase electrode
6) Deflection plates
7) Gutter (drops collector)
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15
8
14
9
13
10
12
11
16
26
17
18
19
25
20
22
21
22
23 24
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4
Electronic compartment:
8) Fans
9) Logic board
10) Power filter: it eliminates all the possible inconveniences from the power supply entering
11) Power supply
12) Motors
13) Adapter board: it allows the connection of the motor-pumps groups with the logic
board
14) “IO-INT” interface board:it is the system interface with the field connecting the pro-
duct sensor, encoder, BCD signals, alarms and serial lines
15) 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:
16) Damper: it keeps the ink pressure in the hydraulic manifold constant
17) Manifold: complete of electro-valves and pressure transducer
18) Main filter: it filters the ink circulating into the system
19) Suction pump: it sucks the ink from gutter, tubus, viscosimeter and make-up
20) Ink Cartridge
21) Force pump: it supplies the pressure to the hydraulic manifold
22) Tubolar filters
23) Ink tank: it contains the mixture ink-solvent
24) Make-Up tank: it contains the solvent (make-up)
25) Make-up Cartridge
26) Viscometer: check the viscosity of the ink
4.2 WORKING
The system Z5000 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 printhead to a distance from 2 to 90
mm.
The product passes in front of the printhead 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 4.105
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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
4.106 Page
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4
4.3 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.
4.4 PRINTING FEATURES
The following font matrix are available:

5x5 7x5 9x7 10x8 16x10 24x16 32x18
32 dots per column are printable, getting from 1 to 5 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 allow
different product orientations or motions.
Page 4.107
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A
370
435
325
227
49
42
4.108 Page
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4
4.5 TECHNICAL SPECIFICATIONS
Electrical specifications:
Power supply # 85-240 Vac, 50-60 Hz, single phase
Power rating # 83 VA
Running current # 0.60 A
IMPORTANT:
The system must be grounded like expressed in paragraph 2.2.3
System specifications:
CABINET IP65 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 (printhead - cabinet): 4 m (13 feet)
Power cable length: 3.0 m (9.9 feet)
Environmental specifications:
Optimum operating temperature 20 °C (68 °F)
Operating temperature range 5 / 40 °C (41 / 104 °F)
Storage and transport temperatures -25 / + 55 °C (-13 / 131 °F)
Operating altitude range 0 / 1000 m MSL
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 5
Character height 2-14 mm
Character width adjustable
Minimum printing distance 2 mm
Maximum printing distance 90 mm
Recommended printing distance 5-20 mm
Other specifications:
Message store: 250 messages with a maximum length of 255 characters
Page 4.109
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4.6 MAINTENANCE
As concerns safety, refer to chapter 1.
Maintenance personnel qualifications

To carry the hydraulic and eletrical maintenance 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.
4.6.1 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.
Where it is necessary to perform an electrical maintenance, before opening the electronic

compartment turn off the system and be sure to unplug the power cable from the electri-
cal outlet. The power cable is only 3 meters long, then the operator is able to monitor its
effective disconnection from its working position in front of the system.
4.6.2 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 paragraph 4.7).
• 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.
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4
For this purpose:
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 printhead.
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 printhead using the solvent.
4.7 MAINTENANCE SCHEDULE
Daily maintenance
1. Check for alarms or warnings.
2. Switch off the system and properly clean the printhead using the solvent.
Yearly ordinary maintenance or every 4000 hours (Service Maintenance)

(the first occurring)
The Service Maintenance consists of:

1. consumables replacement
2. ink stream alignment check-up
3. system cleaning (internal and external)
4. ink tank drainage and cleaning using the cleaning solvent
5. ink tank filling with new cartridges
6. setting and system parameters check-up
In case of larger utilization (more than 4000 hours) the yearly ordinary maintenance
must be defined with the Official Zanasi Service Centers.
The Service Maintenance has to be carried in the Official Zanasi Service Centers.
Page 4.111
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1 2
m
5m
m
5m
IN
OUT
DAMPER
OUT
IN
MAIN FILTER
4.112 Page
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4.8 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 4.7).
4.8.1 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.
4.8.2 Damper
For the damper replacement (A):

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.
4.8.3 Main filter
It has a nominal filtering capacity of 5µm (15µm for pigmented inks).
To replace the main filter (B):

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.
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fixing screws
lock nut
bobbin
A
C
EV. PURGE
EV. MAKE-UP
EV. VISCO
EV. GUTTER
electro-valve sliding box

body solenoid
with spring
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4.9 ELECTRO-VALVE
On the manifold there are four electro-valve (A).
From left to right, they check:

• Ink suction from tubus (purge).
• Make-Up adding in the ink tank and tubus purging.
• Ink suction from gutter
• Ink suction from viscosimeter.
4.9.1 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
4.9.2 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 4.115
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A B
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4.10 VISCOMETER
This paragraph decribes the viscometer spare parts, their cleaning and replacing.
4.10.1 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 viscometer 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.
4.10.2 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 4.117
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3
2
a deflexion axle
b
gutter axle
NO OK
WHITE WHITE
PAPER PAPER
4.118 Page
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4.11 PRINT HEAD
The printhead maintenance includes:

• Printhead cleaning: see paragraph 2.4.1
• Ink stream alignment
• Nozzle cleaning
• Tubus replacement
• Gutter cleaning
4.11.1 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 printhead 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 printhead.
4.11.2 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 4.119
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B
2 1
2 1
D
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4.11.3 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 paraggraph 4.11.1)
The special wrench to remove the nozzle can be provided by the Manufacturer or
the Supplier.
4.11.4 Tubus replacement
Phase 1 - broken tubus removal

1. Switch off the system.
2. Unscrew the 2 fixing screws (fig C).
3. Remove from the printhead 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 printhead.
2. Fix the tubus to the support with the two screws.
3. Solder the black wire.
4. Adjust the ink stream (see paragraph 4.11.1)
4.11.5 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 pro-
blem could be probably caused to the broken suction pump. Please call the manufacturer
assistance service.
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4.122 Page
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4.12 PUMPS
In the hydraulic compartment there are two pumps: - suction pump (a)
- force pump (b)

4.12.1 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) Open the electronic compartment and disconnect the cable of the motor-pump group
from the adapter board (A)
2) Loosen the fittings and disconnect the pipes (B).
3) Unscrew the three fixing screws on the cabinet (C) and remove the group motor-pump
from the electronic compartment.
4) Insert the new pump and fix it with the 3 screws, paying attention to its position, like in
origin.
5) Reconnect pipes and screw the ring-nut.
6) In the electronic compartment, connect the cable of the new motor-pump group to the
adapter board
When the system is ON, check the absence of ink leakage on the fittings.
4.12.2 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) Open the electronic compartment and disconnect the cable of the motor-pump group
from the adapter board (A)
2) Loosen the fittings and disconnect the pipes (B).
3) Unscrew the three fixing screws on the cabinet (C) and remove the group motor-pump
from the electronic compartment.
4) Insert the new pump and fix it with the 3 screws, paying attention to its position, like in
origin.
5) Reconnect pipes and screw the ring-nut.
6) In the electronic compartment, connect the cable of the new motor-pump group to the
adapter board
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.
4.13 HYDRAULIC CIRCUIT CLEANING
It must be operated by the assistance service when a stop of at least 30 days is sched-
uled.
Page 4.123
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-+ 5
+ 24
+ 12
- 12
4.124 Page
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4.14 POWER SUPPLY
4.14.1 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.
4.14.2 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:
• in case of 220V = 1.6A T with breaking capacity 1500A
• in case of 110V = 3.15A T with breaking capacity 1500A
4.15 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 printhead 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 4.125
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A B
D E
F G
4.126 Page
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4.16 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).
4.16.1 *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 paragraph 2.3.2). 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 correct
operation of the printer. Replace the used cartridge with a new one (refer to paragraph
2.3.2). 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 (paragraph 4.10)
Page 4.127
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H I
L M
N O
P Q
4.128 Page
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4
4.16.2 **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 printhead 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.
4.16.3 Other warnings
4.16.3.1 Maintenance Warning
When the message (N) during the system start-up and the logo SERVICE in the main
page (O) appear, contact the assistance service.
4.16.3.2 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.
4.16.3.3 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 4.129
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Hydraulic and Electronic Diagrams
5
Chapter
5 Hydraulic and
electronic diagrams
Page 5.131
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5 Hydraulic and Electronic Diagrams
Chapter
4 HYDRAULIC AND ELECTRONIC DIAGRAMS
5.1 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
Printhead
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.
5.132 Page
Z5000
5
Chapter
5.2 SYSTEM COMPONENTS
1 3
01. USER INTERFACE COMPARTMENT (KEYBOARD)

02. HYDRAULIC COMPARTMENT
03. ELECTRONIC COMPARTMENT
Page 5.133
Z5000
Chapter
5.3 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
5.134 Page
Z5000
5
Chapter
5.4 PUMP-MOTOR GROUP
4
1
01. OUTLET FITTING

02. INLET FITTING
03. MOTOR
04. PUMP (SUCTION OR FORCE)
Page 5.135
Z5000
Chapter
5.5 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
5.136 Page
Z5000
5
Chapter
5.6 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 5.137
Z5000
Chapter
5.7 ELECTRONIC COMPARTMENT
11 10
9
2
3
8
4 7
5
01. FANS
02. LOGIC BOARD
03. H.V. BLOCK
04. POWER FILTER
05. POWER SUPPLY
06. GROUND
07. FORCE PUMP MOTOR
08. SUCTION PUMP MOTOR
09. ADAPTER BOARD
10. IDRA BOARD
11. IO-INT BOARD
5.138 Page
Z5000
5
Chapter
5.8 HYDRAULIC COMPARTMENT
13 12
1
11
2
4
10
5
7
6
7 9
8
01. DAMPER
02. MANIFOLD
03. MAIN FILTER
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 5.139
Z5000
Chapter
5.9 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
5.140 Page
Z5000
5
Chapter
5.10 USER INTERFACE: KEYBOARD
1 4
01. KEYBOARD DOOR

02. DOOR HANDLE
03. KEYBOARD
04. DISPLAY
Page 5.141
Z5000
Chapter
5.11 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
5.142 Page
Z5000
5
Chapter
5.12 ENCODER CONNECTION
1. +24 VDC
2. Product signal
3. Common
4.
5. GND
Connections for the encoder are: Female connector
Page 5.143
Z5000
Chapter
5.13 BCD INPUT CONNECTION
1. BCD 0 10.
2. BCD 1 11.
3. BCD 2 12.
4. BCD 3 13. GND
5. BCD 4 14. BCD input common
6. BCD 5 15. +24 VDC
7. BCD 6 16.
8. BCD STROBE 17.
9. 18. Female connector
Connections for the external devices are:
5.144 Page
Z5000
5
Chapter
5.14 ALARM OUTPUT CONNECTION
18 pin male connector pinout (front view):
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:

Contact n° 1 - Relais Aux Contact n° 2 - Warning Contact n° 3 - System Ready
System System System

off or off or off or
State Warning System
1 not active Ready
not active
State Warning System

2 active Ready
active
Page 5.145
Z5000
Chapter
5.15 CONNECTION TO A PC OR OTHER DEVICES
A serial line allows the connection of PC or other devices to the system.

Two serial lines are available: main ad auxiliiary. The main is used to connect to PC; the
auxiliary to the field according to proper requirement.
The main serial line is 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
2 RX232
3 TX232
4
5 GND
6 TX- (422)
7 TX+ (422)
8 RX- (422/485)
9 RX+ (422/485) Male connector
5.146 Page
Z5000
5
Chapter
The auxiliary serial line use the electrical standard RS232C.
1
2 RX232
3 TX232
4
5 GND
6
7
8
9 Male connector
Connection to a PC through serial line RS232
Page 5.147
Z5000
Chapter

5.16 HYDRAULIC CIRCUIT
5.148 Page

Z5000 End User Manual (ENG)

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Z5000

Use and Maintenance Manual

1.03 S.A. - M.R. - G.Z. 24/03/2008

2.00 M.R 11/10/2012 New manifold

3.00 M.R 02/09/2013 New manifold

4.00 M.R 24/04/2014 Updating for CE test

5.00 M.R 31/10/2017 Safety Chapter

5.01 M.R 05/01/2018 Alarm output updated

6.00 M.R 15/11/2018 Fluid-O-Tech pumps

Use and Maintenance Manual

Use and Maintenance Manual

2.2.4 Photocell and Printhead placement....................................................................37

Use and Maintenance Manual

3.5.2 H.V. value (high voltage on deflection plates)....................................................87

4 SYSTEM DESCRIPTION AND MAINTENANCE........................................................................103

Use and Maintenance Manual

4 HYDRAULIC AND ELECTRONIC DIAGRAMS..........................................................................132

Use and Maintenance Manual

0.1 WARNINGS FOR RECIPIENTS OF THE MANUAL

Use and Maintenance Manual

Use and Maintenance Manual

Use and Maintenance Manual

0.2 HOW TO READ THE MANUAL

Chapters are structured as follows:

Use and Maintenance Manual

Use and Maintenance Manual

0.2.1 Key to each page

A Logo of the manufacturer

0.3 PICTOGRAMS CONCERNING “OPERATORS”

L Electrical maintenance engineer:

0.4 OTHER PICTOGRAMS

O Respect of the environment

End User Manual

End User Manual

1.1 DESCRIPTION OF DANGER, OBLIGATION AND PROHIBITION SIGNALS

C Danger of flammable substances

D Danger of harmful and irritating substances

E Devices sensitive to electrostatic discharge

F Danger of ink jet

G Danger of slipping and falling

H Danger of stumbling and falling

I Danger of handling heavy objects

K Obligation to read the manual

L Prohibition of use of open flames

N Prohibition of spray water towards electrical equipment

End User Manual

1.2 DESCRIPTION OF PERSONAL PROTECTIVE EQUIPMENT (PPE)

O Mandatory use of protective and insulating gloves

P Mandatory use of goggles for eye protection

Q Mandatory use of safety shoes

R Mandatory use of an appropriate and protective workwear

S Mandatory use of respiratory protection mask

1.3 PERSONNEL TRAINING

1.4 INTENDED USE

The system is realized in order to:

End User Manual

1.5 USE NOT PERMITTED

1.6 SAFETY DEVICES

1.8 ELECTROMAGNETIC EMISSIONS

The system contains electronic components subject to the regulations on Electromagnetic

The equipment is therefore in conformity with the Directive on Electromagnetic Com-

1.9 RESIDUAL RISKS

1.9.1 Risk of fire