SOFTWARE MANUAL

DHD

ENGLISH
Issue: DHD.062015
Revision: 00
FOREWORD

This manual:
– is an integral part of the supply and must be carefully
Publication released by: IN.TE.SA. S.p.A.
read so as to use the machine properly and according
© 2013 - Reproduction rights reserved
to the basic safety requirements;
– was originally drawn up in Italian.

rel. 3.0
internal PJM - PLC

II
 1 - GENERAL INFORMATION

DHD

IN.TE.SA. S.p.A., the manufacturer of DHD, congratulates you on the purchase of the
digital decorating machine dealt with in this document.
DHD was designed in compliance with the European directive regarding the free
movement of industrial products in the EEC countries. Therefore it is provided with the
documentation that this directive requires.
Read the information given in the manual and in the attached technical documentation
with care so as to properly use the decorating machine in safety conditions.

PURPOSE OF THE TECHNICAL DOCUMENTATION

The technical documentation includes a number of attached manuals, diagrams and
drawings. It is an integral part of the supply; if a document gets lost or damaged,
immediately ask for a copy to the manufacturer.
If changes are made in the Decorating Machine and IN.TE.SA. S.p.A. requires the
technical documentation to be updated, the company will inform the user and give him
an updated copy of the parts that were changed. The User will destroy the obsolete
parts.
IN.TE.SA. S.p.A. is held responsible for Italian descriptions. Translations cannot be fully
checked; therefore, if an inconsistency is found, refer to the Italian version and contact
our office to make the suitable change.
Keep the technical documentation in a place that can be easily accessed, close to the
Decorating Machine. All the users should know it (operators as well as maintenance
staff). Operators and maintenance staff must be able to quickly consult it in any situation.
Before any operation on the Decorating Machine, read the documentation so as to avoid
damages to the decorating machine, persons and objects.
Do not work in case of doubts on how to interpret instructions.
IN.TE.SA. S.p.A. is not held responsible for improper use of the Decorating Machine,
and for damages deriving from operations that are not dealt with in the technical
documentation.

III
1 - GENERAL INFORMATION

TABLE OF CONTENTS

1 GENERAL INFORMATION ......................................................... 1-1

1.1 Introduction ...........................................................................................................................1-1
1.2 Symbols in the manual...........................................................................................................1-1
1.3 Terms and abbreviations........................................................................................................1-1
1.4 Personnel skills ....................................................................................................................1-2
1.5 General precautions for safe use ..........................................................................................1-2

2 OPERATOR INTERFACE SOFTWARE............................................. 2-1

2.1 Description of the system ......................................................................................................2-1
2.2 System start-up and description............................................................................................2-1
2.2.1 How to log in..............................................................................................................2-1
2.3 Basic rules.............................................................................................................................2-2
2.4 Homepage.............................................................................................................................2-3
2.5 Pjm.........................................................................................................................................2-6
2.5.1 Pjm homepage...........................................................................................................2-6
2.5.2 Wizard........................................................................................................................2-7
2.6 Print......................................................................................................................................2-18
2.6.1 Section "Print jobs"..................................................................................................2-19
2.6.2 Function "Start printing"...........................................................................................2-20
2.6.3 Function "Tile selection"...........................................................................................2-21
2.6.4 Job main parameters...............................................................................................2-21
2.6.5 Function "Test".........................................................................................................2-22
2.7 Configuration........................................................................................................................2-23
2.8 Color bar..............................................................................................................................2-33
2.9 Idra.......................................................................................................................................2-36
2.10 Tools.....................................................................................................................................2-39

3 PROBLEMS,-CAUSES AND SOLUTIONS.......................................... 3-1

3.1 Alarms....................................................................................................................................3-1
3.1.1 Alarms page...............................................................................................................3-2
3.1.2 Diagnostics page.......................................................................................................3-2
3.2 Fault messages - Possible solutions......................................................................................3-3

IV
 1 - GENERAL INFORMATION

1 GENERAL INFORMATION

1.1 Introduction
This manual deals with the man-machine interface program named DHD software rel.
3.0 installed on Windows 7 64-bit operating system only. Click the r.h. key in the icon
on the side and select "Properties" to identify the version.
It is drawn up for three types of operators:
• 1st level operator (OPERATOR). Person in charge of machine operation limited
to screen display and editing of some function parameters (uploading graphic
designs and prints produced).
• 2nd level operator (TECHNICIAN). Person in charge of editing function parameters given by the
manufacturer.
• 3rd level operator (ADMINISTRATOR). Assistance technician of the manufacturing company
(Service), or person authorized by the manufacturing company to work on the machine.

1.2 Symbols in the manual

WARNING - DANGER!
Indicates personal hazardous situations, refers to accident prevention rules, recommends
behaviors.

CAUTION!
Indicates hazardous situations for the machine and/or for the product being processed.

NOTE!
It highlights important information for manual consultation and for the efficient operation of
the machine.

SKILLED TECHNICIAN
Indicates the procedures assigned to IN.TE.SA. S.p.A. assistance technician or to the technician
authorized by the same company.

1.3 Terms and abbreviations

• Machine: DHD digital decorating machine

• Printing unit: printing system that consists of the color bars
• Color bar: printing equipment that consists of a number of print heads
• Print head: part for ink printing on a printing support
• Printing support: ceramic support (tile) decorated with ceramic glaze.
• E.C.: Electrical cabinet
• Control panels: operator panel provided with touch screen and keyboard used to control and
program production and to operate manual controls.
• Operator: any person that may work on the Machine.
• Exposed person: any person that may be, fully or partly, in a dangerous zone.
• Dangerous zone: any zone within the machine or next to it which is dangerous for personal
safety and health.
• P.P.E.: Personal Protective Equipment.
• SERVICE: Technical Assistance Center.

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1 - GENERAL INFORMATION

1.4 Personnel skills

The operators should carefully read the documents provided and meet a number of requirements,
attained also through proper training, like:
- have general and technical skills good enough to understand the content of the documents that
deal with the use and maintenance instructions as well as properly interpret the drawings and
diagrams provided;
- know the main hygienic, accident prevention and technological rules regarding the production
process used;
- have specific skills in the technology used, in addition to a general knowledge of the machine, in
particular the position of the emergency stop buttons, of energy shutoff devices and know what
to do in the event of an emergency, know the location of the personal protective equipment and
how to use it;
- be enough trained to perform the assigned tasks with competence, in particular in emergency
situations.
In addition, the technical skills of the maintenance workers should be suitable for the operations
required, in particular the workers should know the main construction modes.

1.5 General precautions for safe use

DO NOT:
- work on moving parts;
- work on electric parts without cutting power off. Only authorized electricians can work on live parts;
- start the work cycle without first making sure nobody is working on the machine, and no foreign
objects (screwdrivers, screws, etc.) are in the machine;
- bypass the safety systems and remove the guards. Guards can be removed for maintenance or
adjustment purposes only and, if movements are performed, the operator should keep a safe
distance from the moving parts;
- use the machine for purposes other than those indicated in this manual and in the purchase contract;
- alter or remove the safety plates;
- allow unauthorized staff to work on the machine;
- change nameplate data;
- make changes in the machine without the manufacturer's approval;
- operate or misadjust the control equipment or the instruments applied to the machine without
authorization or without knowing how to operate them;
- use the machine if it is faulty;
- pour water on motors or electric parts;
- drill conduits or raceways for electric cables;
- operate the machine without first checking the regular execution of the operations cycle by cycle;
- use inadequate or inappropriate materials;
- use expired inks, unapproved inks or inks that do not comply with the indications given by IN.TE.
SA. S.p.A.;
- perform function changes not approved by IN.TE.SA. S.p.A.;
- use the machine in an inadequate work place/room (very dusty or with extreme temperatures).

1-2
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2 OPERATOR INTERFACE SOFTWARE

2.1 Description of the system

PRINTHUBs are connected to electronic cards called PERSONALITY CARDS (PCARDS) that
transfer information coming from PRINTHUBs to print heads.
Each PRINTHUB can control up to 4 bars.
Each PCARD is connected to up to 2 print heads.
Each PRINTHUB controls up to 16 PCARDs, therefore up to 32 print heads.

2.2 System start-up and description

Click on the icon in the desktop to access the "DHD" software.
Double click to display a screen with a number of circles that represent the PRINTHUBs
installed in the machine. The number ranges from 1 to 8, in relation to the number of
heads present.
The color of the circles indicates the state of PRINTHUBs during initialization, i.e.:
- gray: heads off
- green: heads on
- green + flags: initialization completed
- red: fault (contact SERVICE).
During the initialization of the electronic part,
the current state of the matrix is canned. If
malfunctions are found, a button is displayed in
the bottom right-hand part of the screen. It can be used to access a report which includes the list of
faults that can be found.
For example, the indication that the serial number of the device has changed is given when a head
or a PCARD is changed so as to confirm replacement after machine hardware has been updated.

2.2.1 How to log in

The Homepage (see next page) is shown as after the system has been started. Edit on the
top left side to log in and access the work pages.

Edit to enable the functions for the 2nd level operator (TECHNICIAN). Type in the password,
then press "OK" when this screen is displayed.

When the following actions are required:

- enable the functions for the 3rd level
operator (ADMINISTRATOR): repeat the
procedure that has just been described;
- quit: edit "Logout";
- change the password: edit "Change
Password".

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2.3 Basic rules

• Confirm parameters with "APPLY"
• Use "RESET" to reload parameters that were changed
• "PRINTED TILES" or "SKIPPED TILES" are direct controls which can only be reset if confirmed
with "APPLY".

When the page is changes and the homepage shows one or more values other than those saved
in the system (e.g. changes were made without pressing "RESET" or "APPLY"), the window
below is displayed. Save changes with "YES"; delete them with"NO"; do not go to the next
step with "CANC".

YES. Data items are confirmed and the next page is displayed
NO. Data items are canceled and the next page is displayed
CANC. The current page is displayed

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 3 - PROBLEMS,-CAUSES AND SOLUTIONS

2.4 Homepage
The homepage shows the model of the current machine (DHD708-DHD908-DHD1208-DHD1808)
on the top right-hand side of the page.
It includes the sections indicated below:
1. Functions
2. Status bar
3. Color bars
4. IDRA section for ink feed
5. PRINTHUB temperature
6. Job to be printed

The various functions, defined "Tasks", can be selected in this bar; they are:
1. Home
2. PJM
3. Print
4. Configuration
5. Color bar
6. Idra
7. Tools

Each task is detailed hereafter in this manual.

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Status bar
A. Button Login. The various users (detailed in par. 1.1) use it to access the program functions by
means of passwords
B. Messages are displayed on neutral background during regular operation, warning messages are
displayed on yellow background and error messages on red background.
C. Machine state:

automatic;
A B C D
manual;

bypass;

fault.
D. The profile of the user that was previously logged in is displayed. Par. 1.1 deals with the features
of the profiles listed below:
- OPERATOR;
- TECHNICIAN;
- ADMINISTRATOR.

Color bars
The color bars installed in the
machine are displayed. Each bar is
identified by the color for decoration.
The number of the color bars may
vary from 1 to 8 and more than one
bar may have the same color.

IDRA ink feed

The main information indicated by each color bar is displayed in this section:
• Idra state.
OK: regular operation
CONTROL: special operations are performed on the color bar (filling or drainage, etc..)
• Tank level (%). It displays the percentage of color in the Idra unit
• Meniscus (mbar). It displays the pressure exerted on the meniscus
• Temperature (°C). It displays temperature in the Idra unit

GREEN identifies regular operation, whereas RED irregular operation. The transparent squares
indicate that the color bar is in OFF-LINE mode.

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PRINTHUB temperature
The values of temperature in PRINTHUB modules are displayed.
The color difference, from green = OK to red = DANGER, is the state of the PRINTHUB module.
When the shade is close to red, check the reason to prevent the print heads from being
damaged.
The transparent squares indicate that the color bar is in OFF-LINE mode.

Job to be printed
• Printed tile. It displays the number of tiles printed
• Tiles cleaning. It displays the number of tiles to be cleaned
• Active printing job. It displays the job that is currently USED

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2.5 Pjm

2.5.1 Pjm homepage

The jobs of the library are displayed in this screen: job information and the information with which it
was processed can be accessed.

List of ripped jobs in which the data items below are indicated:
- name Used to create a new
- flow* graphic job
- date of creation

Used to edit the data of a

graphic job

Used to align the graphic

files to current settings

Used to update the list of

jobs

It displays the Rip jobs in

line

Preview of the graphic

designs included in a job

Information regarding the job selected in the list.
• Dimension of the graphic designs included in a job
• Job compliance with machine configuration
Job in compliance with current machine
configuration
Job not in compliance with current machine
configuration; it can be made compliant with
re-ripping
Information regarding printing and the type of rip
setting used
Certified rip setting, created by Sacmi. If
this logo is not provided, the rip setting
is not certified (created by the user).
Click this icon to display the data
regarding the settings of the selected Rip
setting

Job not in compliance with current machine

configuration; it CANNOT be re-ripped.
In this case a message which indicates the cause
of the fault is displayed.

*Flow: for machines with several lines, the flow corresponds to a line to which the ripped job is applied.

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2.5.2 Wizard

Procedure arranged on several pages that guides the operation to the rip step of one or more source images.
Press on the PJM homepage to access the screen below

Sources from which the graphic designs can be selected:

- desktop
- removable peripheral devices (for example USB pen drive)

Click the source in the left field to obtain the list of files for a given path.

Double click "..." Select a folder name to display a list on the right which includes the
to scroll back the compatible graphic jobs in the current folder. The job names are
subfolders displayed as "not selected".

It includes the selected

graphic designs of the
created job.

It displays the information

regarding the source
graphic design and the
destination graphic design.
Graphic designs having
different sizes cannot be
loaded into the destination
folder.
If it is not so, a fault
message is displayed.

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Click the name to display the information

regarding the file in the "INFORMATION"
area underneath.

Click to activate the check.

Only the jobs with an active check can be
shifted to the right list.

Type of file
The types of compatible files are “PSB” and “TIFF”. Change the filter “Type” to hide the
files with incompatible extensions.
For example, if the PSB box is checked off, only the files with this extension are
displayed.

Type of channels
“Composite” (i.e. each selected file includes all the graphic channels)
“Separated” (i.e. each graphic file is monochromatic, renamed with “-c” to indicate the
channel to be associated with. For example, if the job “Vasi.tif” was “separated”, it would
actually consist of several files renamed “Vasi-c1.tif”, “Vasi-c2.tif”, …, “Vasi-c6.tif”)

Use the fast buttons to fast select-deselect the graphic designs in the current folder.

Press the "update" button to force folder updating.

Press “Add” to add the currently selected graphic designs (active check) to the list of the
graphic designs included in the job.

It removes the file selected from the destination folder

It goes to the next screen

It quits the page without saving the data that have just been entered

Press "NEXT" to access the next screen

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The screen below is displayed

List of the graphic designs previously

loaded into the destination folder

If the machine has several lines, the line

It displays the preview of the selected graphic can be selected.
design
Line 1: left line in relation to tile infeed side
Line 2: right line in relation to tile infeed
1
side
2 3 Center: middle part (for machines with
single line)
4
It is enabled only if the
requirements below are
6 7
satisfied:
- "Rip-setting" selected
- the name of the job must be
different from that found in
the library
- the values in fields "Tiles"and
"Printer" must be other than
zero.

1. Information on the selected file: path of the selected file, dimensions of the file.
2. Job name: it must be different from the name of the jobs already in the library, otherwise the corresponding
cell becomes red and the “Forward” key is deselected. The name of the first graphic design included in the
“Source files” is loaded by default when the pages are accessed but it can be changed.
3. Flow: for machines with several lines, the flow corresponds to a line to which the ripped job is applied.
"Center" is set by default but also 1 and 2 can be selected.
4. Rip settings: information regarding the type of screen to be used for the job, the number of levels to be
used in each channel and the linearization curve to be used.
Add or remove one or more rip settings with buttons .

Rip-setting selected

Invalid rip setting: the conditions of the machine that have invalidated rip setting have been
changed, for example the waveforms associated with a given color bar.

5. Channel mapping: association of the graphic channel with the color bar.
6. Tile parameters: width, length, height. The fields regarding these values are automatically entered in
relation to the selected rip setting; however, they can be changed.
If a printing width greater than machine width is incorrectly entered, the program automatically corrects the
value to the maximum printing width.
The values that can be edited in "TILE PARAMETERS" change in relation to the type of flow selected. For
example, if one line is selected (line 1 or line 2) the printing area coincides with the width of the selected
line.
7. Operating parameters of the printer
The fields regarding these values are automatically entered in relation to the selected rip setting; however,
they can be changed.
Resolution, conveyor speed, centering in relation to the belt (left offset).
The value "LEFT OFFSET" is automatically calculated in relation to the width of the conveyor and the width
of the tile to be printed. The calculation is performed by default so as to center the tile on the conveyor but
also in this case the value could be changed.

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2.5.2.1 Channel map

Click in this screen The screen below is accessed: it is used to associate

a channel with each color bar.
The same color can sometimes be on several bars:
in this case the same channel is associated with the
bars.

Name of the channel provided Color compensation (+/-10%)

Percentage of ink
for a given graphic design; that is possible for a given
released by each
if a channel is not provided, color. Color compensation is
bar
"NONE" is shown particularly performed for pale
colors that tend to fade during
firing.

It displays the color bars of the

machine; the icon indicates
if each bar is enabled or
disabled

Bar enabled

Bar disabled

It reloads the data saved for a

given channel map

It is used to save the channel

map configuration which is
currently set with a name used
to retrieve it from the drop
window

It deletes the channel map selected A channel map that was previously saved can
in the drop window. be selected in the drop window

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The screen below is accessed: the name of the channel map that has just been created can be edited here

Edit the name of the channel map

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2.5.2.2 Adding a new rip setting

Click icon on this screen to add a new rip setting

A difference can be made in relation to the selected It is used to apply a corrective

type of heads and waveforms curve. After the check has been
- HIGH SPEED with few levels checked off, a type of linearization
- HIGH DRAINAGE with many levels can be selected.

Name of the rip setting

Printer data previously entered. Press

"Confirm" to access the "Cut" section and
change the dimensions of the tile

It applies a screen to the color bars (for example CSS). Used to quit the page without
The screen makes a graphic file compatible with printing. saving
NONE: when the screen was applied beforehand

Used to save entered data

Used to associate a level with each color
and return to the page below
bar (only existing levels are displayed)

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Two situations are possible if

is pressed in this screen.

1. If the dimensions of the tile do

not change, the next page used
to edit the graphic designs can
be accessed.
2. If the dimensions of the tile
are smaller than the original
dimensions, access the screen
regarding cuts.

If the selected dimensions are equal to those of the original graphic designs, cuts are not required. Press
"NEXT" to access the screen below in which the list of the graphic designs can be displayed

Progressive number
Progressive number It selects/deselects the It selects/deselects all the
of the cut on a given
of the graphic design created graphic designs graphic designs
graphic design

It performs the
"Rip"

It displays the preview

of the selected graphic
design

List of the created graphic It returns to the Used to quit the

designs. previous page page without saving

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2.5.2.3 "Cut" mode

Press "NEXT" in this screen to access the

"CUT" mode

Example "Grid"
Tiles are created removing from the "Graphic source" the cuts with dimensions defined by setting
the data below:
- Left offset: start value of the cut from the left (for ex. 0)
- Upper offset: start value of the cut from the top (for ex. 0)
- Incremental X: horizontal distance between cuts (for ex. 20)
- Incremental Y: vertical distance between cuts (for ex. 10)

The results of the grid cut settings are indicated in the image below

200
20

10

200 Dimensions of the cut for

reading only

Number of cuts to be made

Select the cut mode

Press "Next" to access the page in

which graphic designs are displayed and
processed

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Example "Incremental"
Tiles are created removing from the "Graphic source" the cuts with dimensions defined by setting
the data below:
- Increment: the incremental value of the offset between the tiles can be set. (for ex. 160)

The results of the incremental cut settings are indicated in the image below

200

200

160 160

Dimensions of the cut for

200 reading only

Number of cuts to be made

Select the cut mode

Press "Next" to access the page in

which graphic designs are displayed and
processed

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Example "Random"
This cutting mode is used to set the number of tiles to be produced, the width and the height of the
cut, considering that the system randomly selects a zone to be printed within the graphic sheet.

The results of the cut settings are indicated in the image below

Dimensions of the cut for reading

only

Number of cuts to be made

Used to change the position of cuts

on the selected graphic design

Select the cut mode

Press "Next" to access the page in which

graphic designs are displayed and printed

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Press "NEXT" to access the screen below in which the list of the graphic designs can be displayed

Progressive number
Progressive number It selects/deselects the It selects/deselects all the
of the cut on a given
of the graphic design created graphic designs graphic designs
graphic design

It performs the
rip

It displays the preview of the

selected graphic design

List of the created graphic designs. The suffix "Crop" is It returns to the Used to quit the
displayed if a cut has been made, for example: vasi.psb- previous page page without saving
Crop 19

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2.6 Print
The graphic design to be printed can be selected and printed on this screen.

Functions active only with

machine provided with DOUBLE
LINE conveying system.
NOT provided for standard
machine (single line)

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2.6.1 Section "Print jobs"

Press "Print jobs" to open a screen from which one of the jobs already
filed in the library can be selected for printing.

Select the job to be printed and press the button "Select" to upload a printing job.

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After the job to be printed has been uploaded, go back to the previous screen where all the job
parameters are displayed; in particular, the tiles that make up the selected job are displayed with a
number in the section "Preview".

2.6.2 Function "Start printing"

Press "Start printing" to launch the desired printing.

Read the information given in items "Height" and "Conveyor speed"
before using this control.

After "Start printing" has been pressed, the conveyor is started and the tile to be printed is highlighted
in green in the Preview (in real time). Press "Stop printing" to stop.

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2.6.3 Function "Tile selection"

Press this function to display the window used

to select and/or deselect the tiles to be printed.

2.6.4 Job main parameters

The job main parameters defined when the printing job was added (Paragraph 3.4.8.2) are summarized at the
bottom of the screen.
The function "Tile selection" has already been described; the function "Color bar" is described below whereas
the function "Piece under head" indicates the tile is moving forward below the print head.

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2.6.5 Function "Test"

Press "Test" to open a page that is the same as that used to select PRINT
JOB. The list shows the "compatible" jobs only.
A JOB is compatible when it has the same print resolution as the JOB in use.
Several faces belonging to the same JOB can be selected as TEST tiles,
even if their sizes are different from the sizes of the project that is currently printed.
The faces selected as TEST will be printed after the selection has been confirmed.

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2.7 Configuration
The operator and the technician can access only two screens in function "Config": "Machine" and
"Language".

The number of color bars installed in the machine as well as the number of heads in each color bar
is displayed in the screen "Machine" (for 1st level operators).

The parameters detailed below can be set in the screen "Machine" by 2nd level technicians.

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The language used by the OPERATOR and/or the ASSISTANCE TECHNICIAN is selected in the
screen "Language".

The page used to turn the selected PRINTHUB on or off can be accessed in the screen "PRINTHUB".

Key for HUBS-PCARD on/off

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Parameter setting data, if required, can be controlled in the screen "Service".

Upstream trigger pulse

- Controls deactivated: if it is active, the machine does not consider line trigger pulses.

Suction fan
- Suction on: suction is on if it is activated.
- Suction speed: suction percentage is set.

Current
- Head current: it indicates the current absorbed by the vertical transfer motor
- Conveyor current: it indicates the current absorbed by the motor of the conveying system

Production: (production information)

- Printed tiles: it indicates the number of tiles detected by the photocell for print detection.
- Skipped tiles: it indicates the number of tiles detected by the photocell for piece too high.
They can be reset by pressing buttons "Reset printed tiles" and/or "Reset skipped tiles".

- Total no. of printed tiles: it indicates the total number of tiles detected by the photocell for print detection.
This value cannot be reset.
- Total no. of skipped tiles: it indicates the total number of tiles detected by the photocell for piece too high.
This value cannot be reset.

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1 8

2 5 9

3 6 10

4 7 11

12

13

14

15

16

1. The activation of the automatic cleaning cycle based on pieces and/or on time is set
2. The activation of the automatic cleaning cycle based on pieces is set
3. It indicates the number of tiles after which the cleaning cycle is requested.
4. It indicates the number of tiles remaining before the cleaning cycle is requested.
5. The activation of the time-based cycle is set
6. It indicates the standby time between the moment cleaning was requested and the moment when tiles are
removed from the line
7. It indicates the length of time elapsed in relation to the length of time set in the cleaning interval
If the cleaning cycle is deactivated, fields "3" and "6" are deactivated
.

8. The cleaning request in automatic mode is activated, considering that the system detects the presence of
pieces passing by.
9. Cleaner suction during the return step is activated
10. The duration of the cleaning cycle is set, starting when the printing unit is raised until it returns to the Homing
position
11. Suction duration is set
12. The forward speed of the cleaner is set (operator side)
13. The backward speed of the cleaner is set (rear side)
14. The number of cleaning cycles for the cleaner is set. It is intended as back and forth transfer = 1 cycle;
15. Machine performance if pieces arrive during the cycle is selected:
- Cleaning on: cleaning continues;
- Stop: the cycle stops and the cleaner returns to the Homing position;
- Go on + remove: cleaning continues and the upstream line is stopped.
16. Empty line request is deleted

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 2 - SOFTWARE

2 5

4 3

Read-only data that only qualified technicians can change. These data items detect temperature at
printing unit infeed side.

1. It indicates whether the procedure is active or not.

2. Max. allowable temperature for ingoing pieces.
3. If the tile exceeds the max. allowable temperature for ingoing pieces, it is considered dangerous
and the value displayed in this field is increased.
4. It indicates the maximum number of tiles that can pass below the printing unit with temperature
greater than field "2" before stopping the conveyor.

If the tile exceeds the max. allowable temperature for ingoing pieces and the maximum number
of tiles passed below the printing unit has been exceeded, the conveyor stops and start only
if an operator provides the command. Counter 3 is reset when the conveyor stops.

5. The temperature of the tile passing by is displayed.

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2 - SOFTWARE

Press "IDRA" to access the corresponding page which can give access to four sections:
- Layout
- General information
- Procedures
- Ids

1 6

Layout. The parameters in relation to the type of Idra can be set in this section

1. IP address and communication port of the PLC

2. Mixer: it indicates the presence of the ink mixer.
Mixer counter: it indicates the presence of a rotation detector for the mixer
Mixer ON: time during which the mixer is active (in the example it remains active for twenty
seconds)
Mixer OFF: Time during which the mixer is not active (in the example it remains off for 500
seconds)
If the mixer is shown on the Idra page (par. 2.9) the corresponding indicator is displayed; if it is
not so, it is not provided.
3. If a mixer is not provided, a pump recirculates ink.
Refill Pump ON: time during which the pump is active
Refill Pump Mixer OFF: Time during which the pump is not active
4. It indicates the presence of heating elements.
A single or double heating element is provided in relation to the type of machine (only one heating
element is in the example)
5. Check on the temperature reached in the heating band installed on the tank. If temperature
exceeds the preset value, the machine reaches a fault condition and is shut down.
6. The type of sensor provided in the main tank is selected:
- digital, indicate the sensors provided in the drop window (two or three sensors)
- analog, the number of sensors does not require to be selected.
Two/three indicator lights are displayed on the Idra page (par. 2.9) for digital sensors. A percentage
is displayed for analog sensors.

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 2 - SOFTWARE

General information. The screen below is displayed: the general parameters that are not connected
with the type of Idra unit or to machine process are defined here.

1 7

2 8

3 9

1. Setpoint of the maximum temperature that ink can reach when leaving the tank
2. Tolerance in relation to the setpoint beyond which the system indicates a fault but does not shut
the machine down.
3. Tolerance in relation to the setpoint beyond which the system indicates a malfunction and shuts
the machine down.
4. Tolerance beyond which the meniscus fault is activated, the system indicates a malfunction and
shuts the machine down.
5. Maximum length of time required for filling the secondary tank. After this length of time has
elapsed, the system reaches a fault condition.
6. Maximum length of time required for filling the secondary tank. After this length of time has
elapsed, the system reaches a fault condition. In this case the tank is fully empty, for example
due to a drainage cycle, or when filled for the first time.
7. Time during which the filling pump continues to be active with the secondary tank full
8. Maximum speed that the pumps can reach
9. Minimum speed that the pumps can reach

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2 - SOFTWARE

Procedures. The screen below where the values for machine processes are performed is displayed.

1 4 13

2 5

3 6

7 11

8
12

10

1. Drainage procedure for Idra circuit: time for ink drainage in the circuit
2. Drainage procedure for Idra circuit: delivery pump speed
3. Drainage procedure for Idra circuit: return pump speed
4. Filling procedure for Idra circuit: time for ink filling in the circuit
5. Filling procedure for Idra circuit: Delivery pump speed
6. Filling procedure for Idra circuit: Return pump speed
7. It activates/deactivates the standby cycle for Idra start until the preset temperature is reached.
The modes can be as follows:
- cycle deactivated (parameters cannot be set)
- cycle activated with pumps stationary (only temperature can be set)
- cycle activated with pumps on (used to set the value of temperature, pump speed and the value
of the meniscus)
8. Delivery pump speed set during the preheating cycle
9. Return pump speed set during the preheating cycle
10. Maximum length of the preheating cycle
11. Temperature setpoint of the preheating stage
12. Meniscus value to be kept during the preheating stage.
13. Meniscus value set during the head cleaning cycle (menisci other than those produced can be
used during the cleaning cycle)
Check off the box to enable all the Idra units installed in the machine. Then each Idra unit can be
enabled or disabled on the "Ids" page.
The duration of the drainage cycle is indicated.

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 2 - SOFTWARE

Ids. The screen below where the values for each Idra unit are set is displayed.
It is used to select the Idra state. The Idra units that are not in the machine can be set to the “Offline”
mode. In this configuration the software does not show the errors regarding that Idra unit as the
offline state is equal to "Idra unit not present".
Parameters can be set for the meniscus recovery procedure on this page. This procedure is used to
stabilize meniscus control.
INTESA technicians should provide parameter setting for this procedure.

1 8

2 9

3 10

4
11
5

6
12

Used to select the page

corresponding to each Idra unit

1. Used to set the Idra unit either online (enabled) or offline (disabled).
2. Proportional correction coefficient to be used when the meniscus value is close to the setpoint
3. Integral correction coefficient to be used when the meniscus value is close to the setpoint
4. Proportional correction coefficient to be used when the meniscus value is away from the setpoint
5. Integral correction coefficient to be used when the meniscus value is away from the setpoint
6. The difference between actual meniscus and set meniscus defines a range. If the latter is lower
than Ths, parameters “KPn” are used; if it is higher, parameters “KPf” are used.
7. Derivative coefficient
8. Correction coefficient which compensates the height difference between the head level and the
position of pressure sensors
9. Correction coefficient for heated tank temperature
10. Correction coefficient for bar temperature
11. It enables/disables drainage during cleaning for each bar. If it is enabled, the meniscus value
used during the drainage cycle is used.
12. It is used to access the step for calibrating the analog level sensor installed on the main tank (if
provided).

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2 - SOFTWARE

Page that can be seen only when the machine is a double row

The width of each conveying row is defined. The

Read-only indication: the machine can parameters of each row should be set in relation to
operate in a double row maximum width and to the position of the centering
guides.

Machine operation in single row

is activated, even if double row is
installed

It indicates how many

conveying lines are
provided at machine
infeed side

"PD sensor" and "Trigger pulse sensor": a double

row machine requires 2 PDs (one for each row) "Downstream trigger pulse"-"Upstream trigger pulse"-
and 2 trigger pulses (if several conveyors are in "Conveyor full": these are indications of the state of these
the infeed side). When the machine operates in values. Read-only values.
single row, it has to know whether data coming
from the photocell - l.h. or r.h. trigger pulse should
be taken into account

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 2 - SOFTWARE

2.8 Color bar

A number of functions regarding the "electronic part" of the printing unit are provided in this window.
It is divided into three sections:
1. right section, list of the color bars installed in the machine;
2. top section, functions dedicated to the color bar;
3. bottom section, functions dedicated to the single print head.

State: it indicates the state that corresponds to the selected color bar
• Disabled: the color bar is not enabled for printing.
• Enabled: the color bar is enabled for printing. It indicates the color of the
• Offline: the color bar is installed but it is "OFFLINE". selected color bar

Settings: see
the next page

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2 - SOFTWARE

VOffset: the quantity of the drop can be set in relation to the It indicates the color of the
graphic effect to be obtained (use keys "+" and "-"): change selected color bar
the voltage to be applied to each line of print heads in the
relevant color bar.

Key for color selection

Type of head used
Head pilot signal

• Ink: name of the ink used

• Density: ink density expressed in g/ml
• Ink per droplet: quantity of ink per drop expressed in pl
• Offset P.D.: it is the longitudinal distance (in the direction of the belt, expressed in µ) between the color
bar and the P. D. (Product Detect) photocell. "P. D. offset" is usually zero for the bar that is closer to the
Product Detect sensor because the distance of that bar is used for reference value when the other offsets
are calculated. "P. D. Offset" value can be changed in this screen.

Voltage: setting of the offsets on the voltage applied to each line of nozzles that correspond to
the selected print head. Information regarding the PTrim and voltage on each nozzle line can be
displayed/edited in this screen.

Graph that indicates the voltages regarding the

Id of the selected print head
lines of the selected print head. "Line 1 orange"
Serial number XAAR "Line 2 light blue".

List of the print heads installed on

XAAR Default VOffset: it displays the
default VOffset set on the selected print
head
the color bar to be selected
PTrim: each nozzle line in the selected print head is divided into eight
sections. Each section can be separately controlled with the keys "+"
and "-".
With the keys "ALL", voltage can be changed on both nozzles at the
same time.

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 2 - SOFTWARE

Geometry: information regarding the position of the print heads installed on the color
bar can be displayed/edited in this section.

Left Line

Line: distance of the first "Line" of head printing nozzles expressed in microns.
Delta": distance between the two lines of nozzles installed in the head (standard "Delta" value from bar offset = 4800 µm).
The values "Offset" are summed up to the offset of "Offset P.D." and to the offset of the bar to give the distance between
the single line of nozzles and the photocell
Distance between the photocell "Product Detect" and a line of nozzles = General offset (a1) + Bar offset (a2) + Nozzle
line offset (a3=Line).
Left: distance between the first pixel of the head and the l.h. edge of the color bar. This parameter is used to transfer one
single head in relation to the next heads (see diagrams below)
Overlap: pixels overlapped between one head and the next one. This parameter, placed between two lines, is used to
define the crosswise overlapping (in relation to the forward direction of the conveyor) between two heads; this parameter
indicates how many pixels are deactivated for each head during printing. (see diagrams below)

a1
LONGITUDINAL DIRECTION
a3 Delta

CONVEYOR TOWARD
Nozzle
PRODUCT DECT rows
LE
TI

Head

Color bar
CONVEYOR
TRANSVERSE DIRECTION

LONGITUDINAL DIRECTION
a2

CONVEYOR TOWARD
Nozzle
PRODUCT DECT rows
LE
TI

Head

COLOR
CONVEYOR BAR
TRANSVERSE DIRECTION

2-35
2 - SOFTWARE

2.9 Idra
Select IDRA to display the layout (5) of the color feed system (it is displayed also when "Synoptic" is
selected). Information regarding the points of use relevant to the color bar is also provided. The color
bar can be selected in the vertical column of the tanks (6).

N.B: information is only displayed for "OPERATORS", whereas "TECHNICIANS" can also
change some data items.

2-36
 2 - SOFTWARE

Synoptic. Information regarding the ink path and the state of the points of use that control the Idra
circuit is given in this screen.
The RED segment identifies the delivery flow whereas the GREEN segment identifies the return flow.
The meaning of the symbols is given below:
A) Main tank E) Filter
B) Refill pump F) Color bar
C) Secondary tank G) Head
D) Delivery pump

A F

D E G

Points of use
• Ink temperature: it indicates ink temperature for the selected Idra
• Ink temp. setpoint: it indicates the value of the parameter desired for ink temperature. (This
value can be changed only when logged in as TECHNICIAN).
• Ink level: it indicates the ink level in the main tank
• Return frequency: it indicates the frequency of the return pump
• Return pressure: it indicates ink pressure in the return circuit
• Return temperature: it indicates ink temperature in the return circuit
• Diff. press: it indicates pressure difference between the delivery circuit and the return circuit
• Supply frequency: it indicates the frequency of the delivery pump
• Supply frequency setpoint: it indicates the value of the parameter desired for delivery pump
frequency. (This value can be changed only when logged in as ADMINISTRATOR)
• Supply pressure: it indicates ink pressure in the delivery circuit
• Meniscus: reference value, expressed in mbar, able to ensure the ideal curve that prevents
head dripping. It is calculated in relation to the operations required for the use of the machine.
This value can be different in each color bar.
• Meniscus setpoint: it indicates the pressure value desired for the ideal curve of the meniscus.
(This value can be changed only when logged in as TECHNICIAN).

2-37
2 - SOFTWARE

The section dedicated to IDRA operating states is in the bottom left

part of the screen. The messages are displayed next to the warning
light "1".
• Stop: circuit stopped, GRAY warning light on
• Shutdown: the circuit is about to shut down, RED warning light on 1
• Error: error, RED warning light on
• Started: circuit on, GREEN warning light on

Four controls are provided at the bottom of the screen:

• Apply: confirms the data item to be set;
• Reset: returns to the previous value without
confirming the change
• Start/stop: starts/stops the volumetric pumps
• Drain: it activates the drainage mode of the ink circuit (Shutdown), so that it is completely
conveyed into the primary tank.

2-38
 2 - SOFTWARE

2.10 Tools
A number of useful buttons/tools are provided in this screen.
• Quit. It is used to quit the program
• Log. It displays the operations that the system performed
• Alarms. It displays the alarms or warning messages in the machine (chapter 3)
• Config. backup Machine main parameters are saved in the current state
• Config. restore It restores backup
• Reduce. It reduces the current window
• Manual. It displays a number of pages (manual SPIT, manual purge, standby) that deal with
operations in manual mode
• Diagnostics. It displays messages that deal with the print electronic system
• Calc. Calculator
• Info. It displays software information

2-39
2 - SOFTWARE

Press this button to display the window "Save configuration backup" used to save the machine
state. Press the button "Browse" and select the directory where data are saved. Then press
"Save".

Press this button to display the window "Load configuration backup" used to restore machine
backup. Press the button "Browse" and select the file in the directory in which backup was
executed. Then press "Load".

2-40
 2 - SOFTWARE

Press this button to display the window which includes the data regarding the software name
and release.

2-41
2 - SOFTWARE

Press this button to access the windows indicated below: manual SPIT, manual purge,
standby in which operating conditions other than those regularly used can be defined for
the heads and/or the IDRA unit.

Manual SPIT parameters (cycle parameter setting): used to

have the head print either with the conveyor system stationary
or running. The parameters below can be defined, so as to
Head selection for spit procedure.
protect the print quality of the head:
Click the head so as to select it: the SPIT
1. drop intensity in DPD;
procedure is activated (it comes on with
2. SPIT cycle quantity;
the color of ink used for printing).
3. SPIT duration;
4. duration of the pause between the end of a SPIT and the
start of the next one.

Quick selection controls

It resets settings Cycle start of the printing unit

Cycle start of the selected color bar

2-42
 2 - SOFTWARE

Purge duration is set

The duration of the pause between the end
of a purge and the start of the next one is
set.
The number of purge cycles is set.

IDRA purge activation Cycle start of the

printing unit

It resets settings Cycle start of the selected

color bar

Meniscus target set for purge.

This data item can be defined only if the IDRA unit purge is active, otherwise
the operating targets set in the IDRA unit are kept.

Values in the IDRA page CANNOT BE CHANGED while this cycle is active.

2-43
2 - SOFTWARE

Data items for keeping the heads in good conditions during prolonged
periods of inactivity are set in this page.

Parameters in the Standby page can be set only if the conditions below are satisfied or provided:
- machine in bypass mode;
- bowls below color bars;
- safety devices active.

They cannot be set if the setting of a MENISCUS TARGET is next to zero m/bar in relation to the operating
target.
SPIT cycle activated
Time interval between two SPITS
SPIT duration
DPD drop intensity

Ink flow reversal in IDRA unit It stops the cycle

activated

It resets settings It starts the cycle for keeping heads in

good conditions.
After the button has been pressed,
PRINT MODE is displayed

Values in the IDRA page CANNOT BE CHANGED while this cycle is active.

2-44
 3 - PROBLEMS,-CAUSES AND SOLUTIONS

3 PROBLEMS,-CAUSES AND SOLUTIONS

3.1 Alarms
Alarms have priority over warnings.
They are displayed in the upper state bar with a different color:
- red, alarm message that indicates a serious condition for machine regular use;
- yellow, warning message that indicates a fault condition that does not stop machine operation.

ALARM CAUTION

A yellow or red message is indicated in the alarm banner in relation to the type of alarm.

The page with the list of alarms or warnings can be displayed in two manners:
1. press the upper banner;
2. press the Alarms button in the Instruments page.

1 2

3-1
3 - PROBLEMS,-CAUSES AND SOLUTIONS

3.1.1 Alarms page

The alarm or warning messages are given in this page in priority order.
1. Click the message of the list to activate button "open documentation": it is used to open a HELP
document for the solution of the problem.
2. Press reset to empty the alarms list.

3.1.2 Diagnostics page

The diagnostics regarding the print electronic system is indicated in this page

3-2
 3 - PROBLEMS,-CAUSES AND SOLUTIONS

3.2 Fault messages - Possible solutions

Description
Message

Solution
Warning

Alarm
Code

Error The color bar is "disabled" and Restore the bar if you wish to
1 Color bar disabled X
cannot print print with it

2 Color bar offline
3 Idra unit stopping
4 Idra unit being drained
5 Low level in the tank
Invalid speed of the filling
6 X
pump
Invalid speed of the delivery
7 X
pump
Invalid speed of the return
8 X
pump
Invalid frequency of the
9 X
delivery pump
Invalid frequency of the
10
return pump
Invalid pressure of the
11
delivery pump
Invalid pressure of the return
12
pump
13 Invalid tank temperature
14 Invalid delivery temperature
15 Invalid return temperature
16 Invalid "meniscus"
The color bar is "offline" and Put the bar online if you wish to
X
cannot print print with it
The ink circuit is going to stop:
Press "Start" in the Idra panel or
X the delivery and return pumps
in DHD
of the Idra unit are stationary
Wait for the shutdown to be
X The color bar is being drained completed and press "Start" in
the Idra panel or in DHD to start
Check the level and fill with
The level sensor has detected that
X ink if required or check sensor
ink level is low in the main tank
operation
The operation of the diaphragm
Check power supply and
pump for filling the secondary
operation of the pump
tank is not efficient
Idra unit is operating but RPM Check connection and the value
is zero in the delivery pump in the tachometer generator
Idra unit is operating but RPM Check connection and the value
is zero in the return pump in the tachometer generator
The frequency of the delivery
Check inverter and pump
pump is zero for more than 5
operation
consecutive seconds
The frequency of the return
Check inverter and pump
X pump is zero for more than 5
operation
consecutive seconds
The pressure of the delivery
Check pump operation,
pump is not within range
X connection and pressure sensor
(+20,+70) for more than 5
value
consecutive seconds
The pressure of the return
Check pump operation,
pump is not within range (-120,-
X connection and pressure sensor
50) for more than 5 consecutive
value
seconds
The temperature of the
secondary tank is not included
Check actual setting, connection
X in the setpoint (+/- 5 °C) for
and temperature sensor value
more than 5 consecutive
seconds
Delivery temperature is not
included in the setpoint (+/- 5 Check actual setting, connection
X
°C) for more than 5 consecutive and temperature sensor value
seconds
Return temperature is not
included in the setpoint (+/- 5 Check actual setting, connection
X
°C) for more than 5 consecutive and temperature sensor value
seconds
The "meniscus" is not within
Check actual setting and pump
X range (-55,-10) for more than 3
operation
consecutive seconds

3-3
3 - PROBLEMS,-CAUSES AND SOLUTIONS

Description
Message

Solution
Warning

Alarm
Code

Error Voltage (Vi+Voffset+Ptrim)

Invalid voltage for the
17 X of one or more heads out of Check setting.
following head/s:
range (+12, +26)
Identify the problem and check the
Invalid parameters for the Improper state of one or more
18 X connections PRINTHUB- PCARD-
following head/s: heads
head
The waveform is not loaded The waveform of one or more Load the waveform on the color
19 X
in the following head/s: heads is not set or loaded bar and start software
One or more PID control
The "meniscus" cannot parameters of the "meniscus" Check pump and "meniscus"
20 X
be set are not valid (>900) for more operation
than 5 seconds
The printing speed should Conveyor speed is not
Adjust conveyor speed in relation
21 be included between {min} X compatible with the chosen
to the required resolution
and {max} resolution
Clean the cooling fan grid of
Invalid temperature in the Invalid temperature in one or the PRINTHUB. Replace the
22 X
following PRINTHUBs: more PRINTHUBs PRINTHUB cooling fan. Replace
the PRINTHUB module.
The ink in the tank of an Idra
23 The tank is empty X Add ink to the tank.
unit is not enough for printing
Turn the PRINTHUB module on
and off. Check the connections of
the PRINTHUB module. Clean the
Invalid state in the following The operation of one or more
24 X cooling fan grid of the PRINTHUB.
PRINTHUBs: PRINTHUBs is not efficient
Replace the PRINTHUB cooling
fan. Replace the PRINTHUB
module.
Turn the PRINTHUB module on
and off. Check the connections of
The following PRINTHUBs One or more PRINTHUBs do the PRINTHUB module. Clean the
25 do not properly respond to X not respond to the controls in cooling fan grid of the PRINTHUB.
the controls: the given times Replace the PRINTHUB cooling
fan. Replace the PRINTHUB
module.
It appears when a description is
General error coming from the
26 PLC error X not given for that alarm. Contact
PLC
INTESA personnel
Place the machine selector to
"manual" and start the belt in
27 Tile under head X Tile under head manual mode; the head moves up
so that the remaining tiles can pass
below.
If it is requested by the operating
28 Suction off X Suction off mode, turn the suction system on
so that the alarm is cleared
It appears when a description is
General warning coming from
29 PLC error without shutdown X not given for that warning. Contact
the PLC
INTESA personnel.

3-4
 3 - PROBLEMS,-CAUSES AND SOLUTIONS

Description
Message

Solution
Warning

Alarm
Code

Error
The HMI tries to communicate
with the Idra card that controls Restart the program for
30 Idra unit does not respond X
a specific Idra unit, however connection
communication fails
The head is not calibrated and
31 The head is not calibrated X Calibrate the head
the belt cannot be operated
After a certain period of Set the machine to bypass
Set the machine in standby inactivity of the machine, set it mode, provide bowls and
32 X
mode to the standby mode for proper activate the standby mode with
maintenance. the software
While the machine is in
production, a piece that is The machine is automatically
33 Too high a piece detected X too high may pass by and protected as it is temporarily
is detected by the safety raised to let the piece pass by.
photocell.
While the machine is in The machine stops the belt.
production, a tile partially The operator should remove
34 Double tile detected X overlapped to another one the machine, set the machine to
might pass by and activate a manual mode and empty the belt
safety photocell in manual mode before printing.

3-5
 IN.TE.SA S.p.A.
legal head office: via Selice Provinciale, 17/A - 40026 IMOLA (BO) - Tel. +39-0542-607111
administrative headquarters and registered office: via dell’Industria, 45 41042 Spezzano MO - Italy
Tel. +39.0536.1814052 - Fax +39.0536. 1810269