KIPP 200 IDS Pad Printer

Machine Operation Manual

with SCMIC setup
Serial No.:

INTERNATIONAL
 Content
Section Page

Introduction _______________________________________________ 1
Installation:
Mechanical Part________________________________________ 2.1
Electrical Part _________________________________________ 2.2
Pneumatic Part ________________________________________ 2.3
Machine Setup:
Ink Cup Installation __________________________________ 3.1-3.3
Ink Cup Removal ____________________________________ 3.4-3.5
Printing Pad Setup _____________________________________ 3.6
Pad Clean Tape Setup __________________________________ 3.7
Pad In/Out Cushion Adjustment __________________________ 3.8
Pad Stop Position for Pad Clean Adjustment _______________ 3.9
Ink Cup Platform Adjustment ___________________________ 3.10
Worktable Adjustment _________________________________ 3.11
Control Feature:
Front Control Panel ____________________________________ 4.1
Pneumatic Control Panel ________________________________ 4.2
Control Sequence ____________________________________ 5.1-5.10
Sensor Layout ________________________________________ 6.1-6.2
IO Assignment _____________________________________________ 7
Electrical Circuit Diagram _______________________________ 8.1-8.5
Pneumatic Circuit Diagram___________________________________ 9
Maintenance ________________________________________ 10.1-10.5
Spare Parts List:
Electrical Spare Parts List __________________________ 11.1-11.2
Mechanical Spare Parts List ______________________________ 12
Pneumatic Spare Parts List _________________________ 13.1-13.2
 INTRODUCTION
The following manual will familiarize you with the setup, use and maintenance of
your printer. Please note that the diagrams shown within this manual are not to
scale, and may not show all details.
We would like to draw your special attention to the following notes:

WARNING
It is the operator’s responsibility to comply with the following safety instructions to
prevent any personal injury.
1. Please disconnect the main power supply before attempting any machine
maintenance. Foot-switch or side doors is to stop machine for adjustment only.
2. The air pressure must be released before attending to any service inside the
machine or any moving accessories.
3. Always use the emergency stop switch to stop the machine in an emergency.
The foot switch is used for normal operations only.
4. Guards CANNOT be removed when machine is in operation.

We have used the followings signs to show special dangerous situations:

Warning!

Electrical Warning!

Warning - Danger of Fire!

Warning -
Danger of hands being crushed while working on pneumatic elements!

Warning -
Do not smoke while working on the machine!

Symbol to identify earth ground terminals.

1
Installation
Mechanical Part:
Machine Standing Horizontal Adjustment:
Place machine on flat place. If not, you need to adjust machine foot levers to adjust machine
level:

1. Place level scale on ink cup platform of machine to survey machine horizontal.
2. Release upper screw nut of foot lever.
3. Turning foot lever supporter up or down to adjust supporting level.
4. Tighten upper screw nut to fix supporter position.

Upper Screw Nut

Ground Supporter

Foot Lever

Remark:
- Machine should be located where is
• with good ventilation
• not damp and wet
• without combustible and corrosive gases
- Machine should be kept away from the wall at least 600mm, facilitate operation of the control
panel and servicing purpose.
- Machine should have at least 600mm space with any other equipment.

2.1
Installation
Electrical Part:

5-way connector (CN1)

8-way connector
(CN2)

6-way connector
(CN3) DRE Digital Shuttle 5-way connector (CN1)

8-way connector (CN2)

6-way connector (CN3)

(cables from machine stand)

- Connect 5-way, 6-way and 8-way connectors from machine stand to DRE shuttle.

Buzzer

ON

Main Power Switch OFF

Main Power Cable

Printer Rear Control Panel

(RHS of printer)
- Plug in the main power cable with correct power plug to main power connector.
Machine is suitable for 230V 50/60Hz.
Note: The ground lead of power plug must be wired correctly.

WARNING

- The ground lead of power plug must be wired correctly.

- All external flexible cables should be run in conduits as not to present a tripping hazard.

2.2
Installation
Pneumatic Part:

adjust knob

pressure gauge compressed air inlet

Service Unit for Whole Printer

(at the rear of machine body)

- Connect the compressed air line to machine main service unit.

(Please use only clean and dry air)

- Set pressure of main service unit for machine operation to 5-6 bar.

2.3
Machine Setup
Ink Cup lnstallation:

1. Press REMOVE INK CUP function key in Printer

Setup - 2 screen once to move the ink cup stroke
back. Keep pad at the front. The key will be 1
highlighted.

Printer Setup - 2
2. Cover ink cup by thin steel plate upside down as right diagram.
Remark: The image side of plate cover faces ink cup.

3. Insert ink cup setup unit into thin steel plate with ink cup and then turn it upside down.

ink cup setup unit insert setup unit into thin steel plate turn upside down

4. Move ink cup holder to back side. Release ink cup holder swing arm locks and lift up swing arm.

swing arm

swing arm locks

3.1
Machine Setup
Ink Cup lnstallation:
5. Place ink cup setup unit with ink cup and steel plate on ink
cup platform. Buckle rear hole of steel plate with rear
registration pin of platform.

rear registration pin

6. While slide ink cup setup unit out, put hand on ink cup top
to stay it on plate. Buckle front hole of steel plate with front
registration pin of ink cup platform.

front registration pin

7. Push ink cup against the internal back side of the ink cup holder.
Then pull down the swing arm and tighten swing arm locks.

swing arm locks

8. Release bleeding screw of ink cup.

bleeding screw

3.2
Machine Setup
Ink Cup lnstallation:
9. Use allen key to adjust ink cup holder pad position.
(This step apply for first setup of new ink cup holder)

ink cup holder pad

10. Press REMOVE INK CUP key again to

return ink cup stroke outward.
10

Printer Setup - 2

3.3
Machine Setup
Ink Cup Removal:

1. Press REMOVE INK CUP function key in Printer

Setup - 2 screen once to move the ink cup stroke
back. Keep pad at the front. The key will be 1
highlighted.

Printer Setup - 2

2. Tighten ink cup bleeding screw.

swing arm locks

bleeding screw

3. Release swing arm locks of ink cup holder and lift up swing arm.

4. Lift up the front side of thin steel plate. Insert ink cup setup unit between ink cup platform and
thin steel plate. Push it forward to against rear registration pin. Remove the thin steel plate
and ink cup with ink cup setup unit.

3.4
Machine Setup
Ink Cup Removal:
5. Press REMOVE INK CUP key again to return ink cup
stroke outward.
5

Printer Setup - 2

6. Hold the ink cup, turn ink cup over and then remove ink cup
setup unit and thin steel plate.

7. Clean the ink cup ring and then cover it well.

8. Use thinner to clean the thin steel plate. Apply grease on its
surface and store it in plastic bag to prevent oxidation.

3.5
Machine Setup
Printing Pad Setup:
1. Fasten printing pad to pad mounting by 4 screws.

pad mounting

2. Loosen Y-axis locking screw of pad holer assemby.

Insert assembly onto pad Y-slide of printer. Tighten
Y-axis locking screw to fix the position.

pad Y-slide

Spare:
X-axis locking screw

Y-axis locking screw

Completed Setup

Pad Holder Assembly

3.6
Machine Setup
Pad Clean Tape Setup:

tape roll
pad clean tape platform

rotor

tape roll mount

tape roll

Steps:

1. Insert empty core of tape roll onto the mount with rotor.

2. Insert new tape roll onto the mount without rotor.

3. Pull tape from the new tape roll and through the pad clean tape platform.
The sticky side of tape faces upward.

4. Stick the tape onto the empty core.

3.7
Machine Setup
Pad In/Out Cushion Adjustment:
Cushion of pad cylinder needs to be adjusted when 2 occasions occurred.
a. Carriage moves at high speed and creates bang at both ends (should close cushion).
b. Carriage becomes very slow at 10 mm from both ends and creates vibration
(should open cushion).
Use very short handle screw driver, turn clockwise to close; counter-clockwise to open
cushion.

2 cushion screws

3.8
Machine Setup
Pad stop position for tape clean adjustment
Pad stop position over the tape clean platform can be adjusted by moving the slider knob
accordingly:

1. Loosen slider lock knob on the right hand side of machine head.
2. Slide lock knob left or right to adjust pad stop position over the tape clean platform.
Remark:
- move to the left: pad stops further to the front.
- move to the right: pad stop further to the back.
3. Tighten slider lock knob to fix position.

lock knob

Machine RHS

Note: There is another slider lock knob on the left hand side of machine. The position of this
slider determines when machine power should be cut off automatically in case pad fails to
stop over the tape clean platform (sensor failure). It is recommended to leave it in the current
position.

Machine LHS

3.9
Machine Setup
Ink Cup Platform Adjustment:

In-out and angle:

1. Loosen both locks at the front and back of ink cup platform.
2. Turn both adjustment knobs (at the back) in the same direction for in-out adjustment or in
opposite direction for angle adjustment.
3. Fasten both locks.

lock

front

lock

adj. knobs

back

3.10
Machine Setup
Worktable Adjustment:
X-Axis Lock Handle
Angle Lock Screw
X-Axis Screw Knob
Angle Lock Screw

Angle Screw Knobs Y-Axis

Lock Handle
Up/Down
Lock Handle
Y-Axis Screw Knob

Handwheel

X-Axis Adjustment:
1. Release X-axis lock handle.
2. Screw X-axis screw knob to adjust X-axis position.
3. Lock X-axis lock handle to fix X-axis position.

Angle Adjustment: Left Right

1. Release two angle lock screws and two angle screw knobs.
2. a. Turn Left: Loosen left angle screw knob and tighten right
angle screw knob.
b. Turn Right: Loosen right angle screw knob and tighten left
angle screw knob.
3. After adjustment, tighten two angle screw knobs and two
angle lock screws to lock the position.

Y-Axis Adjustment:
1. Release Y-axis lock handle.
2. Screw Y-axis screw knob to adjust Y-axis position.
3. Lock Y-axis lock handle to lock Y-axis position.

Up / Down Adjustment:
1. Release three Up/Dn lock handles.
2. Turn the handwheel to adjust up/down position.
3. Lock three Up/Dn lock handles to lock up/down position.

3.11
Control Feature
Front Control Panel:

2
3

1. Display:
Control machine and adjust printing function.
(Display feature detail please refer to Control Feature: Touch Screen section)

2. Emergency Stop Switch:

to cut main power and air in an emergency.

3. +/- Key:
to increase or decrease paramter value, e.g. pad stroke depths.

4.1
Control Feature
Pneumatic Control Panel:

1 2 3 4 5 6
(RHS of printer)

1. Pad stroke downward speed control knob:

a flow regulator to control downward speed of pad stroke.

2. Pad stroke upward speed control knob:

a flow regulator to control upward speed of pad stroke.

3. Carriage forward speed control knob:

a flow regulator to control forward speed of pad carriage.

4. Carriage backward speed control knob:

a flow regulator to control backward speed of pad carriage.

5. Platform forward speed control knob:

a flow regulator to control forward speed of ink cup platform.

6. Platform backward speed control knob:

a flow regulator to control backward speed of ink cup platform.

Note: 6 speed control knobs are turning clockwise to decrease speed or anti-clockwise
to increase.

4.2
Control Sequence
Machine Start Up:

1. Turn on Main Power Switch at the rear of machine stand.

2. Release Emergency Stop Switch.
3. The first time machine is activated a pasword must be entered.
Ask your local dealer for more info.
4. Press START key to start machine.

Machine resumes and screen enters manual mode.

1
2

Printer Rear Control Panel Front Control Panel

3 4

5.1
Control Sequence
Main Screen (Manual Mode):

D E

A B

C J

F G H I K

A. Printer status and message display bar

- shows printing status and error message.
B. Cycle Counter display
C. Pad Stroke Setting Key
D. DRE Shuttle Position Key
E. Timer Key
F. Start / Stop Key
- Activates a cycle in auto printing mode and manual mode.
- In auto printing mode, the key becomes “ STOP ” to stop printer during a cycle.
G. Pad Clean Key
- Press key once to move pad to pad clean position in manual mode.
- Press key once again to perform pad cleaning and return pad to the front.
H. Pad Up Down Key
- Activates pad up/down motion in manual mode.
I. Pad In Out Key
- Activates pad in/out motion in manual mode.
J. MORE Key
- Enters DRE setup-1 screen.
K. Index Key
- Advances digital shuttle to the print stations in manual mode.

5.2
Control Sequence
DRE Shuttle Stations Selection
Select/deselect print stations (up to 6 available).

Cycle group-1 Cycle group-2

images/pads

print stations
1 2 3 2 3 4

1. On the main screen, press/hold the “MORE” Key

1
until “DRE Setup-1” screen appears.
2. Press “Station Select” key to enter new screen.
3. Press a station key to select (becomes
highlighted) or deselect related station.
2
4. Press “EXIT” key to return to the main screen.

DRE Shuttle Loading Station Selection

1. On the main screen, press/hold the “MORE” Key
until “DRE Setup-1” screen appears. 1

2. Press “Load Position” key to enter new screen.

3. Press a station key to select the loading position,
“LOAD” apears on key.
Choose between Home, 1st, 2nd, 3rd and 4th 2
stations.
4. Press “EXIT” key to return to the main screen.

5.3
Control Sequence
Setting DRE Shuttle Printing Stations

1. Press the “Index” Key repeatedly to select a printing position. Index key
1
moves between preselected stations (1-6 available).
2. Press “DRE Shuttle Position” Key once to activate setting function.
3. Press “+/-” Key on front control panel to change value. 2

or
without moving the shuttle 3

1. On the main screen, press/hold the “DRE Shuttle

Position” Key until a new screen appears.
2. Select a DRE station by pressing related “P1-P6” 1
key.
3. Input value then press “ENT” key.
4. Press “EXIT” to return to the main screen.

Setting DRE Shuttle Speed

1. On the main screen, press/hold the “MORE” Key 1

until DRE Setup-1 screen appears.
2. Press “DRE Shuttle forward” or “DRE Shuttle
backward” key.
2
3. Press “+/-” Key on front control panel to change
percentage.
4. Press “EXIT” key to return to the main screen.

5.4
Control Sequence
Pad Stroke Adjustment

for Printing
1. Stop pad carriage at the front by pressing Pad In/out Key.
2. Press Index Key to select desired printing station. 1
3. Press Pad Stroke Setting Key once to activate the setting function.
The key will be highlighted.
4. Press +/- Key on front control panel to change stroke depth. 2

for Inking
1. Stop pad carriage at the back by pressing Pad In/out Key. 1
2. Press Pad Stroke Setting Key once to activate the setting function.
The key will be highlighted.
3. Press +/- Key on front control panel to change stroke depth. 2

5.5
Control Sequence
Setting Delay before Ink/Print, Dwell for Ink/Print, Cycle Auto Restart
1. From the main screen, press/hold the “Timer” key until the “Time Setup” screen appears.
2. Press/Select a time delay of your choice.
3. Press “+/-” switch to increase or reduce delay.
4. Press EXIT to return to the main printing screen.

1 2 3

Delay before Ink:

Pad pauses above plate for a preset time before moving down for inking.
Delay before Print:
Pad pauses above product for a preset time before moving down for printing.
Dwell for inking:
Pad dwells on the cliché’s surface for a preset time.
Cycle Auto Restart Delay:
Allows to preset a time delay for product unload-load. Cycle restarts automatically
once time delay has elapsed. For auto cycle mode printing ONLY.
Dwell for printing:
Pad dwells on the product’s surface for a preset time delay. Setting avail-
able for up to six prints as followed:

Cycle group-1 Cycle group-2

ink 1 2 3 4 1 2 3 4

dwell for print

available 1 2 3 4 5 6

5.6
Control Sequence
Printing Mode Selection:
1. From the main screen, press/hold the “Pad Stroke”
1
key until the “Printer Setup-1” screen appears.
2. Press the “Print Mode” key repeatedly to select
either single cycle mode or auto cycle mode.
Single Cycle Mode:
Step on foot switch once to start one printing cycle.
2 3
Auto Cycle Mode:
Press Start key to start continuous printing cycle.
3. Press EXIT to return to the main printing screen.

Print Cycle Selection:

1. From the main screen, press/hold the “Pad Stroke”
1
key until the “Printer Setup-1” screen appears.
2. Press the “Print Cycle” key of 1st group and 2nd
group repeatedly to select single cycle or double
cycle print. 2 2
Single Cycle Printing:
3
Executes [one ink - one print] per cycle
Double Cycle Printing:
Executes [one ink - one print]x2 per cycle
3. Press EXIT to return to the main printing screen.

Pad Clean Rotor Setting:

Allows to set a number of rotations to unroll a clean
piece of tape clean. 1

1. From the main screen, press/hold the “Pad Stroke”

key until the “Printer Setup-1” screen appears. 2
2. Press the "Next" key.
3. Press the "Pad Clean Rotor Key”.
4. Press +/- key to set a number of rotation.

5.7
Control Sequence
Cycle Counter Reset:

1. From the main screen, press/hold the “Pad Stroke”

key until the “Printer Setup-1” screen appears. 1
2. Press the "Next" key.
3. Press/hold the "RESET” key untill 00000 is
displayed. 2
4. Press EXIT to return to the main printing screen.

Moving Ink Cup In or Out:

Move ink cup in or out when setting up machine with plates and cups.

1. From the main screen, press/hold the “Pad Stroke”

key until the “Printer Setup-1” screen appears. 1
2. Press the "Next" key.
3. Press "Remove Ink Cup” key to move ink cups
in or out. 2
4. Press EXIT to return to the main printing screen.

5.8
Control Sequence
Printing:

Auto Cycle Mode:

Before running this mode, it is necessary to set the
printing function to “AUTO cycle” mode. Refer to
the “Printing mode selection” section.
1. In manual mode, turn off any highlighted manual 1

keys.
2. Press the “START” key once to execute
continuous printing.
3. The START key becomes the STOP key and is
2
used for stopping Auto Cycle Mode printing and 3
entering Manual Mode.

Manual Mode:
1. Press any manual key (key will be highlighted).
2. Press the “START” key to enter manual mode
and execute related function.
1

Single Cycle Mode:

Before running this mode, it is necessary to set the
printing function to “ SINGLE cycle” mode. Refer to
the “Printing mode selection” section.
1
1. In manual mode, turn off any highlighted manual
keys.
2. Press the “START” key once to enter "SINGLE
cycle" mode.
3. Press the foot switch once to activate one print 2
4
cycle.
4. Press “STOP” Key to stop cycle.
3

5.9
Control Sequence
Stop and Restart:
1. Foot switch:
Press the emergency stop switch to cut off the main power
and air supply of machine in the event of an emergency.
Release switch by turning its mushroom head clockwise.

Emergency Stop Switch

2. Emergency Stop Switch:

Press the foot switch to stop machine movement. Press the START key
on the touch screen panel to restart.

Foot switch

3. Side door:
When a side door is opened all movable parts will stop
immediately. All manual function keys and START key
won't be responsive. Close the side doors then press the
START key once to restart. Side
doors

Lubrication Warning:

A lubrication warning will appear every 30,000 cycles. If machine requires a password, please
contact your local dealer.

1. Activate the lubrication pump ON and OFF.

2. Input password (Optional).
3. Press OK.

5.10
Sensor Layout
Printer:
X005 X001 X007 X004
X000------ Pad stroke optical ruler sensor (PS2).
X001------ Pad stroke home optical sensor (PS1).
X004------ Pad carriage home micro switch (PS5).
X005------ Pad carriage actuated micro switch (PS6).
X007------ Ink cup stroke home micro switch.
X010------ Middle pad clean sensor. X000 X010

X006 X016
X006------ Ink cup stroke home micro switch (PS7).
X015------ Left side door sensor (SR2).
X016------ Right side door sensor (SR4).

X015

X040------ Oil pump handle sensor.

X040

6.1
Sensor Layout
Shuttle:

X024 X023 X027

X023------ DRE shuttle home sensor (MS1).

X024------ DRE shuttle far limit sensor (MS2).
X027------ DRE shuttle registration home sensor.

6.2
IO Assignment
INPUTS (FX1N-60MT MASTER PLC) OUTPUTS (FX1N-60MT MASTER PLC)
X000 Pad stroke optical ruler sensor (PS2) Y000 DRE shuttle servo pulse signal
X001 Pad stroke home optical sensor (PS1) Y001 Pad clean tape rotor solenoid
X002 +/- key (-) Y002 DRE shuttle motor direction signal
X003 +/- key (+) Y003 Spare output
X004 Pad carriage home micro switch (PS5) Y004 DRE shuttle servo driver SON signal
X005 Pad carriage actuated micro switch (PS6) Y005 Spare output
X006 Ink cup stroke home micro switch (PS7) Y006 Buzzer
X007 Middle pad clean sensor Y007 Spare output

X010 Middle pad clean stop protect sensor Y010 Main air solenoid
X011 Spare input Y011 Pad stroke up/down solenoid
X012 Spare input Y012 Ink cup carriage in/out solenoid
X013 Spare input Y013 Pad carrage in/out solenoid
X014 Spare input Y014 Middle stop of pad clean solenoid
X015 Left safety side door sensor (SD2) Y015 Pad stroke dwell solenoid
X016 Right safety side door sensor (SD4) Y016 Pad clean lock cyclinder solenoid
X017 Foot switch Y017 Spare output

X020 15 ways connector pin 5 configuration Y020 Spare output

X021 15 ways connector pin 4 configuration Y021 Spare output
X022 15 ways connector pin 3 configuration Y022 Extend pad stroke solenoid 1
X023 DRE shuttle home sensor (MS1) Y023 Extend pad stroke solenoid 2
X024 DRE shuttle far limit sensor (MS2) Y024 Extend pad stroke solenoid 3
X025 DRE shuttle servo driver ready OK signal Y025 Extend pad stroke solenoid 4
X026 Spare input Y026 Spare output
X027 DRE shuttle registration home sensor Y027 Spare output

X030 Spare input

X031 Spare input
X032 Spare input
X033 Spare input
X034 Spare input
X035 Spare input
X036 Spare input
X037 Spare input

X040 Oil pump hander sensor

X041 Spare input
X042 Spare input
X043 Spare input

7
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A A
X000 X001 X002 X003 X004 X005 X006 X007 X010 X015 X016 X017 X040

NH\ 
NH\ 
Foot switch
B B
Oil pump handle sensor

Middle pad clean sensor

Left side door sensor (SR2)
Right side door sensor (SR4)
C C

Ink cup stroke home micro switch

Pad stroke optical ruler sensor (PS2)

Pad stroke home optical sensor (PS1)
Pad carriage home micro switch (PS5)
Ink cup stroke home micro switch (PS7)

Pad carriage actuated micro switch (PS6)

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8.1.6

E E

LABEL KENT PART NO. '(6&5,37,21 LABEL KENT PART NO. '(6&5,37,21 LABEL KENT PART NO. '(6&5,37,21
; $1(& 6(1625((6; ; (& 0ICRO SWITCH ; (& 6(16257/40&
F ; $1(& 6(1625((6; ; (& 6(16257/40& F
;a +9$(& 6:,7&+ ;a (& 6(16257/40&
;a (& 6(16257/40& ; (&$ FOOT SWITCH
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

(/(&75,&$/&,5&8,7',$*5$03/&2873876   8.4

A A
Y001 Y006 Y010 Y011 Y012 Y013 Y014 Y015 Y016 Y022 Y023 Y024 Y025

Buzzer
B B

Main air solenoid

Pad stroke dwell solenoid

3DGcarriage in/outVROHQRLG

3DGVWURNHXSGRZQVROHQRLG

Pad clean tape rotor solenoid

([WeQGSDGVWURNHVROHQRLG
([WeQGSDGVWURNHVROHQRLG
([WeQGSDGVWURNHVROHQRLG
([WeQGSDGVWURNHVROHQRLG

,QNFXSFDUULDJHLQRXWVROHQRLG
PDGFOHDQlock cyclinder VROHQRLG

0LGGOHVWRSRISDGFOHDQVROHQRLG
C C

Fan1 Fan2

1 - 1 1 1 1 1 1 1 1 1 1 1 M M
+ 2 1 2 1
2 2 2 2 2 2 2 2 2 2 2 2
D D

0V
8.1.7

24V
8.1.7
E E

LABEL KENT PART NO. '(6&5,37,21 LABEL KENT PART NO. '(6&5,37,21 LABEL KENT PART NO. '(6&5,37,21
< 0326(& %8==(5 < .339$ 62/(12,'9$/9( <a
PVA-070 6OLENOID COIL
F < PVA-070 62/(12,'&2,/ < 39$ SINGLE 62/(12,' FDQ .63(& Fan F
< KP20039$ 62/(12,'9$/9( < 39$ SINGLE 62/(12,' )DQ KSP3-EC-000 Fan

< KP20039$ 62/(12,'9$/9( < 39$ SINGLE 62/(12,'

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

PLC AND TOUCH PANEL LAYOUT 8.5

A A

SANMOYION
AC SERVO SYSTEMS
R
SANYO DENKI RS1A01AA

RS1A01AA
MOOE ▲

▼
▼ WR/
MPOS-EC-110 SERVO P50B07040HXS00
CHARGE POWER
SD1
B Touch screen P
B
T C

S C
R N
A
t
MR1
r

C
N
DL1 1
C
DL2
N
B
24V 0V E P
'5(VKXWWOH
RB1
RB2

C MPOS-EC-120 W C
ENCODER CABLE C
C N
V N 2
C
U

E S2
R2 0V POWER CABLE

D D

MITSUBISHI

FX1N-60MT

E E

0V

F F

1 2 3 4 5 6 7 8
 Pneumatic Circuit Diagram 9

PAD STROKE CYLINDER

'6%$)&$
.33&<
PAD CARRIAGE INDEPENDENT INK CUP
CYLINDER STROKE CYLINDER
/&*%1 '6%$)&$
.33&< &/3&<

$6&
ASC200-08
PAD CLEAN LOCK

.33)5
$6&
ASC200-08
ASC200-08
ASC200-08

(KP150-PFR-011)
([WHQGSDGF\OLQGHUV ([WHQGSDGF\OLQGHUV ([WHQGSDGF\OLQGHUV ([WHQGSDGF\OLQGHUV

.33)5
CYLINDE
(KP150-PFR-011)
(KP150-PFR-011)
(KP150-PFR-011)

&4$'& &4$'& &4$'& &4$'& AEVC-25-10-I-P

(; (; (; (; (HVA150-PCY-050)
VT-307-5G-02

HGL-1/4B
(15-PVA-120)
(Y014) PAD CLEAN ROTOR

(KP200-PFR-010.01)
CYLINDE
94=*%) AEVC-25-10-I-P
94=*%) .339$ (HVA150-PCY-050)
.339$ <
94=*%) <

ASL6-01
ASL6-01
ASL6-01
$6/
.339$
ASL6-M5B

<

(;3)5

(EX-PFR-011.01)
(EX-PFR-011.01)
(EX-PFR-011.01)
(10-PFR-011.01)

97
0)+% MFH-5-1/8-B MFH-5-1/8-B MFH-5-1/8-B 39$ VT-307-5G-02 VT-307-5G-02
39$ (15-PVA-090) (15-PVA-090) (15-PVA-090) < (15-PVA-120) (15-PVA-120)
< (Y023) (Y024) (Y025) (Y016) (Y001)

63&*&'&
$:
3)7
368
0)+(% PCF-06-G01 CDC
39$ (15-PFT-330)
<
Maintenance
Safety instructions for doing maintenance:
• Electrical and pneumatic energy sources must be cut off from machine before doing
maintenance. Complete separation of power plug from socket and air hose from compressed
air line by mean of lever or quick connector coupling is mandatory to prevent injuries caused
by unexpected energizing or start up of machines.
• Only an authorized electrician is allowed to access the control of machine.
• Do not wear loose or hanging clothes or jewelers.
• Do not clean machine with high pressure compressed air.

Daily inspection:
• Compressed air supply pressure for machine is higher than 5.5bar and stable. Pressure for air
blower is kept in 1-2bar.
• Compressed air supply must be clear of water and oil.
• Drain water from bowl of service unit if there is deposited water.
• Electricity supply is kept in 220V AC and stable.
• Earth line is connected properly.
• No cables and air hoses lay on working floor.
• Check whether buzzer sound is normal.
• Check whether printing pad surface is damaged. It needs to be replaced whenever its surface
is scratched. Finishing of pad surface begins degrading after 5000 cycles used. Usual life of
printing pad is 20000 cycles or longer.
• Check whether ink cup ring edge is chipped. Recommended to do reconditioning per 2 days or
4 shifts. If ring edge is widen than 0.25mm, the ring needs to be regrinded.
• Check whether printing plate surface was worn out or scratched. Maximum life of aluminum
plate is 50000 cycles and that of thin steel plate is 100000 cycles.

Maintenance after each printing job or working day:

• Release water from service unit. (See page 10.4 "Discharge Water from Service Unit" for
details)
• Unload ink cups from printing plates. Cover ink cups by polymer plate covers after cleaning.
• Clean ink on printing plates with thinner. Coated plates with grease to avoid oxidisation.
• Clean ink on pads with thinner. Store pads in cool place. Never put pads into any plastic bag.
• Keep ink cup platforms clean.
• Apply grease to easy-rusty parts and areas.

10.1
Maintenance
Weekly maintenance:
• Do daily maintenance as usual.
• Clean machine cabinet and inside with mild cleaning solvent.
• Check the overall operation of machine.
• Check whether there is air leakage from pneumatic devices and connections.
• Check whether there are visible damages of cables, air hoses and mechanisms.
• Check whether all movable parts move smoothly, without abnormal sound.
• Check visually whether any electrical and pneumatic connectors are loosed.
• Check sensors position and sensitivity adjustments.
• Check and clean the sensor lenses.
• Check and tighten if any screws are loosed by vibration from machine movement.
• Lubricate machine movable parts as indicated. (See page 10.3 "Lubrication" for details)

Monthly maintenance:
• Do daily and weekly maintenance as usual.
• Check filter of anti-dust blower.
• Check cables and connectors of servo motors.
• Check condition of ball screws and guide rails.
• Check fuses of all devices.
• Check function of all emergency switches.

10.2
Maintenance
There are some regular maintenance works to keep printer in smooth operation.

1. Lubrication:
Weekly lubricate machine parts by injecting grease into grease nipples
indicated in the following pictures.
a. Grease nipples of pad carriage.
b. Grease nipples of shafts of ink cup stroke.
c. grease ball screw bearing system of DRE shuttle by pressing oil pump handle.

a
Remark:
It is recommended to apply Kent grease (DP-0047) for parts a b and e.

Remark:
If DRE shuttle has not been lubricated by oil pump for running over 20000 print cycles, a
lubrication remind screen will be shown on touch screen panel when machine is powered on
and system resume completed. Press oil pump handle once, then Press OK key to return
manual screen.

handle

OK

lubrication remind screen

piston handle grease container

Operation of Grease Pump:

Fit nozzle onto grease nipple and then press injection handle to
inject grease.
Remark:
- When piston handle is retracted into container completely, the
pump is needed to refill. (See page 10.5 for details)
injection handle nozzle

10.3
Maintenance
2. Scale Ruler Cleaning:
Please weekly clean the scale ruler up.

scale ruler

3. Refill Oil Pump:

a. fit nozzle of grease gun to refill inlet of oil pump.
b. press handle of grease gun to inject grease into oil pump.

Nozzle

Handle

Grease pump Refill inlet

4. Discharge Water from Service Unit:

If there is water inside bowl of service unit, discharge the water everyday.
Main Service Unit Service Unit For Air Blower
(at the rear of machine body) (at the rear of machine body)

discharg water from here

Remark:
If there is excessive water drained into the bowl, a filter/dryer should be considered and installed
upstream at the back of air compressor to extract moisture and other contaminants.

10.4
Maintenance
Refill of Grease for Grease Pump:
- When piston handle retracted into container completely, it is time to refill grease into the pump.

1. Open grease pump.

grease container

injection handle

2. Dig top opening of pump body into grease container.

3. Pull piston handle out. Grease will be sucked inside the pump body.

piston handle

4. Cover the grease pump.

5. Press release button to release piston handle lock.

release button

10.5
 Electrical Spare Parts List
15-EC-131 KP150-EC-A990
Proximity sensor Foot switch
TL-Q5MC1

15-EC-420 KSD130-EC-000
Emergency Stop Switch Metal resistor
YW1B-V4E01R 47OHM/50W

15-EC-590 KSDTT-EC-100.01
Micro switch 2 Poles fuse holder
VX-5-1A3

15IDS-EC-000 KSDTT-EC-111
Main power switch Fuse 10X38mm
194E-E25-1753-6N 4A 500V

AN10-EC-620 KSDTT-EC-112
Optical sensor Fuse 10X38mm
EE-SX672 10A 500V

AN15-EC-300 KSDTT-EC-151
Servo motor 18A/220V Contactor
P50B07040HXS LC1-D18M7C

DRE70-EC-022 KSP3-EC-000
Pad carriage servo motor driver Fan
RS1A01AA (4 1/2INCH) DC24V

EM-EC-040 MPOS-EC-040
Switching power supply Buzzer
24VDC 2.7A B11S3240 24VDC

HVA90-EC-001 MPOS-EC-100
+/- switch PLC
FX1N-60MT

11.1
 Electrical Spare Parts List
MPOS-EC-110
4.2" mono touch-screen DISPLAY

MPOS-EC-120
Cable for F900GOT & FX2N
(LENGTH 3M)

11.2
 Mechanical Spare Parts List
15-GIC-A021 KP200-SC-094
Dia. 130mm flat ceramic Left side door
magnetic ink cup (30X600X690mm)

15-ICT-A022 KP200-SC-104
150mmx300mm polymer Right side door
plate & thin plate support plate (30X600X690mm)
(for dia.130mm ink cup)

15-MB-120 KP200-SC-115
Rubber ring Back safety cover
I.D.27mm X O.D.38mm (6X149.5X668mm)
X L.3mm

15-PC-680 KP200-SC-122
0.7mm Optics scale Front safety cover
(1.5X20X177.7mm) (6X296.5X648mm)

21-MB-131 MT-815
Gray sponge Grease pump
(53X72X85mm) (BULK 400C.C)

CMIC-A051.11 MT-871
Ink cup set up unit Manual grease pump
(for dia.120~130 ink cup) (YGL-T08 800 C.C.)

ICH-A006.04
130mm swing arm ink
cupholder ass'y

KP200-ICT-A060
4 Colors ink cup platform
assembly

KP200-PA-A030
104mm pad mounting plate

12
 Pneumatic Spare Parts List
10-PFT-020 15-PVA-120
Fitting (GCK-1/4-PK-4KU) 3/2 Single solenoid valve
PT 1/4
(VT-307-5G-02)

15-PFT-020 20-PFT-010
Fitting (CK-1/4-PK-6KU) Fitting
(GCK-3/8-PK-9-KU)

15-PFT-060 20-PFT-020
Fitting (GCK-1/8-PK-6-KU) Fitting
(CK-3/8-PK-9-KU)

15-PFT-150 20-PFT-030
Fitting (GCK-1/4-PK-6-KU) Straight male connector
(CK-1/4-PK-9-KU)

15-PFT-280 20-PFT-080
T-connector (T-6-4-6) M6 straight grease nipple

15-PFT-311 20-PSL-010
Quick connector coupling U-1/8 silencer
(SPC06-G01 CDC)

15-PFT-330 21-PSU-020.01
Quick connector coupling R1/8 blade pressure gauge
(PCF-06-G01) (QY-40Z)

15-PVA-060 22-PSU-010
Solenoid valve Filter regulator
(MFHE-3-1/4-B) (AW30-02+AR30P-270AS)

15-PVA-090 C12L-PCY-012.01
Solenoid Valve Independent ink cup stroke
(MFH-5-1/8-B) cylinder
(DSBA-F-50-160-CA)

13.1
 Pneumatic Spare Parts List
C4-PFT-020 KP200-PVA-010
Fitting 1/4" solenoid valve
(T-PK-4) (VQZ3121-5GB-02F)

EX-171.01
Extend pad cylinder
(64.5X71X88.5mm)

EX-PFR-011.01
Flow regulator
(ASL6-01)

HVA150-PCY-050
Pad clean (middle stop)
cylinder
(AEVC-25-10-I-P)

KP150-PFR-011
Flow regulator
(ASC200-08)

KP200-PCY-020
Pad carriage cylinder
(L-CG1BA32-300)

KP200-PCY-050.02
Pad stroke cylinder
(DSBA-F-100-100-CA)

KP200-PFR-010.01
NON-Retune valve
HGL-1/4B

KP200-PFR-020
3/8" Flow regulator
(ASC300-10)

13.2