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Manual

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Table of Changes

Revision Performer Date Description of changes

1.00 M.R. 24/03/2014

2.00 M.R. 05/04/2017 Safety chapter

2.01 M.R. 28/04/2017 Communication protocol updated

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

2.03 M.R. 06/06/2018 Alarm output and protocol

2.04 M.R. 03/09/2018 Note about serial line RS232

3.00 M.R. 07/11/2018 Fluid-O-Tech pumps

3.01 M.R. 04/02/2019 BCD, logic board and protocol

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Table of contents
0 FOREWORD...................................................................................................................................8
0.1 WARNINGS FOR RECIPIENTS OF THE MANUAL............................................................8
0.2 HOW TO READ THE MANUAL......................................................................................... 11
0.2.1 Key to each page..................................................................................................13
0.3 PICTOGRAMS CONCERNING “OPERATORS”...............................................................13
0.4 OTHER PICTOGRAMS.....................................................................................................13

1 SAFETY........................................................................................................................................17
1.1 DESCRIPTION OF DANGER, OBLIGATION AND PROHIBITION SIGNALS...................17
1.2 DESCRIPTION OF PERSONAL PROTECTIVE EQUIPMENT (PPE)................................19
1.3 PERSONNEL TRAINING...................................................................................................20
1.4 INTENDED USE................................................................................................................20
1.5 USE NOT PERMITTED.....................................................................................................21
1.6 SAFETY DEVICES............................................................................................................21
1.7 NOISE................................................................................................................................22
1.8 ELECTROMAGNETIC EMISSIONS..................................................................................22
1.9 RESIDUAL RISKS.............................................................................................................22
1.9.1 Risk of fire.............................................................................................................22
1.9.2 Risk of electrocution............................................................................................23
1.9.3 Explosive atmosphere risk..................................................................................23
1.9.4 Risk of blindness..................................................................................................24
1.9.5 Risk due to electricity.........................................................................................24
1.9.6 Risk of tripping.....................................................................................................24
1.9.7 Risk of slipping.....................................................................................................25
1.9.8 Risk due to handling............................................................................................25
1.9.9 Risk of exhalations ...........................................................................................25
1.9.10 Risk of cutting............................................................................... 25
1.10 OBLIGATIONS AND PROHIBITIONS...............................................................................26
1.10.1 User obligations....................................................................................................26
1.10.2 Operators obligations......................................................................................26
1.10.3 Operators prohibitions.........................................................................................26
1.11 DISPOSAL OF WASTE MATERIALs................................................................................27
1.12 INDICATION FOR WASTE................................................................................................29
1.13 GENERAL REMARKS.......................................................................................................29
1.14 CE DECLARATION OF CONFORMITY.............................................................................30

2 START-UP....................................................................................................................................33
2.1 LIFTING AND HANDLING.................................................................................................33
2.1.1 Unpacking.............................................................................................................33
2.1.2 Storage..................................................................................................................33
2.1.3 Disposal of packaging..........................................................................................33
2.2 SYSTEM INSTALLATION..................................................................................................35
2.2.1 Preparation of the area by the user.....................................................................35
2.2.2 System placement................................................................................................35
2.2.3 Photocell and Printhead placement....................................................................37
2.2.4 Electrical connection............................................................................................39

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2.3 ADJUSTMENTS BEFORE ACTIVATION..........................................................................41

2.3.1 Printhead preparation..........................................................................................41
2.3.2 Printhead cleaning................................................................................................41
2.3.3 Ink and Make-Up fill..............................................................................................41
2.4 SYSTEM START-UP..........................................................................................................43
2.4.1 Product sensor.....................................................................................................43
2.4.2 Encoder (optional)................................................................................................43
2.4.3 Beacon alarm (optional).......................................................................................43
2.5 VAPOUR RECOVERY.......................................................................................................45
2.6 PRINTHEAD PRESSURIZATION......................................................................................45
2.7 SYSTEM SWITCHING OFF...............................................................................................47

3 SYSTEM FEATURES...................................................................................................................51
3.1 PRELIMINARY INFORMATION ON THE PRINTING SYSTEM....................................51
3.1.1 Main components.................................................................................................51
3.2 WORKING.........................................................................................................................53
3.3 USER INTERFACE............................................................................................................55
3.4 CHARACTER COMPOSITION..........................................................................................57
3.5 PRINTING FEATURES......................................................................................................59
3.6 TECHNICAL SPECIFICATIONS........................................................................................61
3.7 MAINTENANCE...............................................................................................................62
3.7.1 Maintenance safety conditions............................................................................62
3.7.2 Technical instructions for correct maintenance................................................62
3.8 MAINTENANCE SCHEDULE..........................................................................................63
3.9 FILTERS AND DAMPER...................................................................................................65
3.9.1 Main filter...............................................................................................................65
3.9.2 Tubular filters........................................................................................................65
3.9.3 Damper..................................................................................................................65
3.10 MANIFOLD........................................................................................................................67
3.10.1 Electrovalve..........................................................................................................67
3.11 VISCOMETER...................................................................................................................67
3.11.1 Viscometer replacement ......................................................................................67
3.12 PRINTHEAD......................................................................................................................69
3.13 PUMPS..............................................................................................................................69
3.13.1 Suction Pump replacement..................................................................................69
3.13.2 Force Pump replacement.....................................................................................69
3.14 HYDRAULIC CIRCUIT CLEANING...................................................................................69
3.15 LOGIC BOARD.................................................................................................................71
3.16 POWER SUPPLY..............................................................................................................73
3.16.1 Switching power supply.......................................................................................73
3.16.2 Fuses.....................................................................................................................73
3.17 EXTERNAL CONNECTIONS.............................................................................................74
3.17.1 Encoder.................................................................................................................74
3.17.2 Photocell...............................................................................................................75
3.17.3 Bcd.........................................................................................................................76
3.17.4 Alarm output.........................................................................................................78
3.17.5 Serial connections................................................................................................79
3.17.6 Ethernet connection.............................................................................................80
3.17.7 USB connection....................................................................................................81

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3.18 HYDRAULIC CIRCUIT......................................................................................................82

3.19 PACKING FOR THE SHIPMENT.......................................................................................83

4 COMMUNICATION PROTOCOLS................................................................................................86
4.1 TCP/IP PROTOCOL..........................................................................................................86
4.1.1 Rules......................................................................................................................86
4.1.2 List of parameters.................................................................................................91
4.1.3 Reading and writing of the parameters...............................................................94
4.1.3.1 Encoder Enabling.................................................................................................94
4.1.3.2 Speed line.............................................................................................................94
4.1.3.3 Encoder settings..................................................................................................94
4.1.3.4 Stretch...................................................................................................................94
4.1.3.5 Bold.......................................................................................................................94
4.1.3.6 Codify....................................................................................................................95
4.1.3.7 Reverse Print........................................................................................................95
4.1.3.8 Inverted Print........................................................................................................95
4.1.3.9 Photocell enabling...............................................................................................95
4.1.3.10 Print delay..........................................................................................................95
4.1.3.11 Indexed message...............................................................................................95
4.1.3.12 Synchronization or BCD for indexed messages.............................................96
4.1.3.13 Repeater.............................................................................................................96
4.1.3.14 Distance between printings..............................................................................96
4.1.3.15 Pressure set ......................................................................................................96
4.1.3.16 Suction set ........................................................................................................96
4.1.3.17 Deflection Plates................................................................................................96
4.1.3.18 Oscillator Amplitude .........................................................................................96
4.1.3.19 Pressure Alarm..................................................................................................96
4.1.3.20 High Voltage Alarm............................................................................................97
4.1.3.21 Gutter Alarm.......................................................................................................97
4.1.3.22 Force Pump Alarm.............................................................................................97
4.1.3.23 RS232 Serial Connection..................................................................................97
4.1.3.24 Buadrate RS232 Serial Connection..................................................................97
4.1.3.25 RS485 Serial Connection..................................................................................97
4.1.3.26 Buadrate RS485 Serial Connection..................................................................97
4.1.3.27 Ink used into the System...................................................................................98
4.1.3.28 Set Point Viscometer.........................................................................................98
4.1.3.29 Nozzle Diameter.................................................................................................98
4.1.3.30 Threshold Warning Ink Level Low....................................................................98
4.1.3.31 Threshold Warning Make Up Missing..............................................................98
4.1.3.32 Threshold Warning Tank Too Full....................................................................98
4.1.3.33 Threshold Gutter Alarm.....................................................................................98
4.1.3.34 Time of use (read-only).....................................................................................98
4.1.3.35 Time to next maintenance (read-only)..............................................................99
4.1.3.36 Maximum date next maintenance (read-only).................................................99
4.1.3.37 Number of printings since last reset (read-only)............................................99
4.1.3.38 Number of printings to next maintenance (read-only)....................................99
4.1.3.39 Valorization of the String external field ...........................................................99
4.1.3.40 Valorization of the Bitmap external field .........................................................99

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4.1.3.41 Valorization of the Table external field ............................................................99

4.1.3.42 Opening/Closing Purge Valve.........................................................................100
4.1.3.43 Opening/Closing Visco Valve..........................................................................100
4.1.3.44 Opening/Closing Makeup Valve......................................................................100
4.1.3.45 Opening/Closing Ink Valve..............................................................................100
4.1.3.46 Simulation of one printing start......................................................................100
4.1.3.47 Execution of the function xxx.........................................................................100
4.1.3.48 Last function executed (read-only)................................................................100
4.1.3.49 Printing disabling............................................................................................101
4.1.3.50 Printing enabling.............................................................................................101
4.1.3.51 Back to the starting value of counters-batches of the current message....101
4.1.3.52 Back to the starting value of counters-batches of all the messages...........101
4.1.3.53 Setting the starting value of a counter or batch............................................101
4.1.3.54 Number of messages loaded into the Bcd list (read-only)...........................101
4.1.3.55 Report of the printing message (read-only)...................................................101
4.1.3.56 Report of the all the 64 possible indexed messages (read-only).................101
4.1.3.57 Index of the printing message........................................................................102
4.1.3.58 Names of messages loaded into the Bcd list (read-only).............................102
4.1.3.59 Horizontal resolution of the printing message (read-only)..........................102
4.1.3.60 Vertical resolution of the printing message (read-only)..............................102
4.1.3.61 Bcd input of the printing message (read-only)..............................................102
4.1.3.62 Current state of the system (read-only).........................................................102
4.1.3.63 Alarms in the system (read-only)...................................................................102
4.1.3.64 Warnings in the system (read-only)...............................................................102
4.1.3.65 Valves opened in the system (read-only).......................................................102
4.1.3.66 Errors in the system (read-only).....................................................................103
4.1.3.67 Hardware devices working (read-only)..........................................................103
4.1.3.68 Index and total report of the printing message (read-only)..........................103
4.1.3.69 Last functions executed (read-only)..............................................................103
4.1.3.70 Active auxiliary outputs (read-only)...............................................................103
4.1.3.71 All the states (read-only).................................................................................103
4.1.3.72 Temperature Logic Board (read-only)............................................................103
4.1.3.73 Temperature Ink (read-only)............................................................................103
4.1.3.74 Level Missing Ink (read-only)..........................................................................104
4.1.3.75 Level Full Ink (read-only)................................................................................104
4.1.3.76 Level Missing Make-Up (read-only)................................................................104
4.1.3.77 Level ink into the Gutter (read-only)..............................................................104
4.1.3.78 Phase Peak (read-only)...................................................................................104
4.1.3.79 High Voltage between the Deflection Plates (read-only)..............................104
4.1.3.80 Fly Time (read-only).........................................................................................104
4.1.3.81 Force Pump revolutions (read-only)..............................................................104
4.1.3.82 Current Pressure (read-only)..........................................................................104
4.1.3.83 Current Set Point (read-only)..........................................................................105
4.1.3.84 Reference Set Point (read-only).....................................................................105
4.1.3.85 All the measures (read-only)...........................................................................105
4.1.3.86 Current date and time (read-only)..................................................................105
4.1.3.87 System locked for Make-Up missing (read-only)..........................................105

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4.1.3.88 Time to system locking for Make-Up missing (read-only)............................105

4.1.3.89 System locked for Ink missing (read-only)....................................................105
4.1.3.90 Time to system locking for Ink missing (read-only)......................................105
4.1.3.91 Length manual purge (read-only)...................................................................106
4.1.3.92 All the info on the system locking (read-only)..............................................106
4.1.3.93 ID Peripheral (read-only).................................................................................106
4.1.3.94 Serial Number (read-only)...............................................................................106
4.1.3.95 Communication Protocol Version (read-only)...............................................106
4.1.3.96 All the info about Peripheral (read-only)........................................................106
4.1.3.97 Date and Time (read-only)...............................................................................106
4.1.3.98 Events on the system (read-only)...................................................................106
4.1.3.99 Proto Version (read-only)................................................................................106
4.2 SERIAL PROTOCOL.......................................................................................................107
4.2.1 Valorization of an external field.........................................................................107
4.2.2 Query about the content of an external field.................................................... 110
4.2.3 Printing start....................................................................................................... 111
4.2.4 Choosing the message to print......................................................................... 111
4.2.5 Enable/Disable the character of printing succesfully..................................... 111
4.2.6 Serial commands of termination....................................................................... 112
4.2.7 Outcome action commands of the external device.......................................... 112
4.2.8 Enable/Disable the printing................................................................................ 113
4.2.9 Set counter or batch value................................................................................. 113

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0 FOREWORD
The manual is intended for operators in charge to use and maintain the system in all phases
of its technical life. It must be carefully stored and has to follow the system in all ownerships.
In the manual are the themes referring to a proper use of the system, in order to maintain
over time the functional and qualitative features. All the information and warnings are also
reported for the correct use in total safety.

WARNING!
Before proceeding with the installation of the system, or make it operational and
use it, or perform maintenance on it, read carefully way this manual and the eventual
other documentation supplied, faithfully following the instructions and the indications.

0.1 WARNINGS FOR RECIPIENTS OF THE MANUAL

This manual, drafted in English, contains the “Original Instructions” of the system.

The manual, as well as the CE conformity certificate included, is an integral part of the
system and must always follow it in every move or resale. It is the user’s duty to maintain
this documentation unaltered, to allow the consultation, during the whole life of the system.

In case of loss or destruction it’s possible to request a copy to ZANASI srl, specifying ac-
curately the model, the serial number and the year of production.

It is a compulsory requirement that the technical personnel in charge for the maintenance
have read and understood the instructions provided by the manufacturer and that he is
familiar with the connection and wiring practices and electrical schematic symbols. He also
must be experienced in the use of electrical equipment.

Failure to follow the safety rules may cause injury to personnel and damage to the com-
ponents and the system control unit.
However the reading, even if exhaustive, of this manual cannot replace the necessary
experience of the operators.

Operators must be carefully trained on the operation and correct use of safety devices
installed.

This manual is an integral part of the system to which it relates and contain the information
necessary to:
• the proper awareness of operators about the safety
• handling the system, for the packing and unpacking in safety conditions
• the correct installation of the system
• the use of the system in safety conditions
• depth knowledge of its operation
• perform maintenance in a correct and safe way

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WARNING!
The system must only be used by qualified and trained operators on procedures and
in compliance with the recommendations contained in this manual.

The customer and/or the technical personnel in charge for the maintenance can, at any
time, contact the manufacturer for more information in addition to those contained herein.

The documentation provided by ZANASI srl only relates to the equipment provi-
ded by ZANASI srl to the purchaser and/or to end user.

The help on-line present on the system and any other manuals provided in both
paper and electronic format are an integral part of this manual, and they follow
the same recommendations/prescriptions of this manual.

WARNING!
It’s the responsibility of the user to integrate the instructions contained herein with
any operating procedures present in the location of use of the equipment and provide
any additional information to the staff in charge to the use and maintenance of the
system.

The ZANASI srl reserves the right to modify and update this manual at any time without
prior notice.

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0.2 HOW TO READ THE MANUAL

The manual is divided into separate chapters and/or paragraphs, each of which addresses
a specific operator (INSTALLER and/or MAINTAINANCE ENGINEER) for whom the neces-
sary skills have been identified in order to operate the machinery under safety conditions.

In order to make understanding of the text easier, abbreviations, symbols and pictograms
have been used whose meaning is explained in paragraphs 0.3 and 0.4.

Chapters are structured as follows:

A Introductory page
B Pages with figures referring to the text on “C” type pages
C Descriptive pages containing the different paragraphs

NOTE: pages showed alongside are deliberately blurred as only examples of layout and
structure of the chapters, regardless of the content

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C D E

B
A

I M

L N

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0.2.1 Key to each page

Every page of the manual displays different kinds of information whose meaning is the
following:

A Logo of the manufacturer

B Name of machinery
C Title of the chapter
D Title of the publication (the whole manual)
E Number of the corresponding chapter
F Space for description or images
G Space for pictograms on safety standards and other information
H Page number (the first digit indicates the number of the chapter, the second the ove-
rall pages of the manual)

NOTE: the page showed alongside is deliberately blurred as only explicative example of
the information, regardless of the content

0.3 PICTOGRAMS CONCERNING “OPERATORS”

I Operator:
Personnel trained and skilled to operate the machinery. In order to understand the
instructions (text and figures) the operator must have (or obtain by means of ade-
quate training) the following characteristics:
• general and technical culture enabling him to read and understand the
contents of the parts of the manual referring to the operator, and to correctly
interpret pictures and drawings;
• ability to understand and interpret symbols, pictograms, and video messages;
• his tasks are: machinery start-up, use of machinery, machinery stop.

L Electrical maintenance engineer:

At this level, the operator must be able to carry out electrical operations including
the set up and the ordinary maintenance.

0.4 OTHER PICTOGRAMS

M Warning!
The texts accompanied by this symbol contain important information about safety

N Note
Texts accompanied by this symbol contain further information.

O Respect of the environment

Texts accompanied by this symbol contain notices about the environment.

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A B C D

E F G H

I J

L M N

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1 SAFETY

1.1 DESCRIPTION OF DANGER, OBLIGATION AND PROHIBITION SIGNALS

A Danger of voltage

B Dangerous temperature

C Danger of flammable substances

D Danger of harmful and irritating substances

E Devices sensitive to electrostatic discharge

F Danger of ink jet

G Danger of slipping and falling

H Danger of stumbling and falling

I Danger of handling heavy objects

J Danger of cutting

K Obligation to read the manual

L Prohibition of use of open flames

M Prohibition of touching

N Prohibition of spray water towards electrical equipment

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O P Q

R S

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1.2 DESCRIPTION OF PERSONAL PROTECTIVE EQUIPMENT (PPE)

The personnel in charge for installation, use and maintenance which carries out the activi-
ties on the system, must use personal protective equipment in order to reduce all possible
risks arising from the various activities. The personal protective equipment chosen by the
user must comply with the 89/686/EEC Directive and the technical standards applicable
to the specific cases.

O Mandatory use of protective and insulating gloves

P Mandatory use of goggles for eye protection

Q Mandatory use of safety shoes

R Mandatory use of an appropriate and protective workwear

S Mandatory use of respiratory protection mask

WARNING!
It’s the user’s responsibility to ensure that the personnel involved is properly trained
on residual risks and uses the PPE provided as well as evaluating possible necessary
additions.

The PPE indicated must be provided by the employer and must be complemented
by him in function of the working site, the prescriptions and provisions in force in
the country of use.

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1.3 PERSONNEL TRAINING

The customer must ensure that personnel assigned to install, and/or to use and/or to
maintenance, is formed, instructed and appropriately trained.
The use, installation and maintenance of the system should only be carried out by properly
qualified and trained personnel with operational, technical, electrical, electronic, mechanical,
and pneumatic knowledge (and eventual prescriptions applicable in the country of use of
the system) according to qualification of the personnel stated in this manual.

It is the user’s responsibility to provide to instruct personnel about the risk of accident, the
safety devices and the general rules about the safety provided by the Community directives
and by the law of the country where the equipment is installed and used.

The in charge personnel must be aware of the location and the functioning of all controls
and device characteristics.
All installation and maintenance work must be performed by qualified personnel.

1.4 INTENDED USE

The intended use for the system is to carry out the inkjet marking of products in accordance
to what is described in the contract or according to the instructions in this manual.

The use of material unsuitable can cause serious damage and compromise operation.

The system is realized in order to:

• to satisfy the specific requirements listed in the sales contract
• to be used according to instructions and operating limits specified in this manual

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1.5 USE NOT PERMITTED

The system must be used only for purposes expressly provided by the manufacturer.

Particularly it is forbidden:
• to use the system if it has not been properly installed according to current regulations;
• to use the system with a faulty power supply or without an efficient grounding system;
• to use the system without complying with the required power supply specifications;
• to use the system with different functionality from that for which it was built;
• to use use the system or its units as a foothold even if not working;
• to use use the system outside the environmental conditions permitted;
• to use the system in environments different from those for which it was designed and
built;
• to use the system to mark products other than those for which it was supplied;
• to use the system to mark products not suitable for marking;
• to use the system with inks, solvents and other materials than the ones indicated by
the manufacturer;
• to use the systems without protection and/or with the safety equipment disabled;
• to use the system with weaknesses in maintenance;
• to use the system after modifications or unauthorized intervention;
• to use the system with total or partial inobservance of the instructions;
• to use is not permitted except as specified in paragraph 1.4.

The use of consumables (ink, solvents, etc.) or spare parts not supplied or suggested by
Zanasi srl could damage the system and / or compromise the correct functionality. In this
situation, the manufacturer is held harmless from any liability or guarantee.

Modifications which alter the risk, if performed without the authorization of the ma-
nufacturer, will invalidate any guarantee, responsibility and declaration of EC con-
formity

1.6 SAFETY DEVICES

The system is equipped with safety devices such as fixed protections of the printhead and
the plug/socket system for the isolation of the power source.

The power supply cable is used as power supply cut-off device; it must therefore be
positioned at a height between 0.6 m and 1.7 m and it has to remain clearly visible and
easily accessible for the operator.

WARNING!
Before carrying out any installation work or electrical maintenance, make sure that
the system is disconnected from the power supply taking care to disconnect the
power plug.
The not observance of this mandatory requirement exposes the personnel re-
sponsible for various risks, and indemnifies the manufacturer from any liability.

The “0– I” switch placed on the side of the system must not be considered as a discon-
necting device.

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1.7 NOISE

The noise measurements were made in accordance with the UNI EN 11202 regulations.
During the operating cycles, the A-weighting sound pressure level of emission does not
exceed 70 dB(A).

1.8 ELECTROMAGNETIC EMISSIONS

The system contains electronic components subject to the regulations on Electromagnetic

Compatibility, conditioned by conducted and radiated emissions.

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

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

patibility (EMC).

1.9 RESIDUAL RISKS

The printing system is manufactured for safe operation; during the design phase, the
danger zones or parts have been evaluated and have been accordingly taken all ne-
cessary precautions to avoid risks to persons and damage to equipment components
as indicated in the preceding paragraphs.

Although the system is equipped with safety systems, some risks can not be eliminated
but can be reduced through corrective actions by the end user and through mandatory
correct operating mode for anyone working on it.

1.9.1 Risk of fire

In case of faults, the plastic material used (eg. sheaths, electrical cables) is self-extinguish-
ing and comply with current standards.

The raw materials used on the system (consumables such as inks, solvents, etc.) may be
flammable.

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The customer will take all necessary measures to prevent the risk of fire. In particular, it
is recommended:
• Do not smoke near the system.
• Do not use open flames.
• Keep the system clean from dust and ink lumps.
• Do not stack flammable materials nearby the system.
• Inks and solvents must be stored in suitable ventilated places and free of possible
sources of ignition, away from heat sources.
• Do not perform welding operations or similar with sparks nearby the system.

The system does not autonomously generate a fire hazard.

The user factory shall evaluate the need for an appropriate fire extinguishing system on
the premises where the system is installed, in compliance with current safety regulations
and fire prevention in the user country and with the internal regulations of the factory.
Use proper tools with proper electrical isolation.

WARNING!
In case of fire, disconnect the system from the main power supply, cutting off all
power energy.

1.9.2 Risk of electrocution

• Risk of breakage or damage, with possible lowering of the security level, of the com-
ponents of the electrical system after a short circuit.
• Before connecting the system to the power supply, make sure there are no maintenance
work in progress and no one is working on the system.

Use proper tools with proper electrical isolation.

Before making the connection, check that the short-circuit current at the installation
point is not greater than the one shown on the plate system.

1.9.3 Explosive atmosphere risk

The system is not suitable for working in explosive environments, or at risk of explosion.
It is then strictly forbidden to use the system in environments:
• explosive or partially explosive
• where there are corrosive atmospheres
• in which there are oily high concentrations
• with risk of fire caused by any materials or ignition source

Aso be sure that inks and solvents are stored in special ventilated environments, free of
possible sources of ignition and away from heat sources.

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1.9.4 Risk of blindness

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

WARNING!
It’s mandatory to wear eyes and face protection. Danger of harmful and/or irritating
substances to body parts.

1.9.5 Risk due to electricity

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

1.9.6 Risk of tripping

The disordered deposit of material may create a tripping hazard, and partial or total restric-
tion of the emergency exits when necessary.
Pay attention, even during installation and maintenance activities, to not let material or
equipment which may constitute a tripping hazard for oneself or for other people.
Even the umbilical cord of connection between the system and the printhead, if deposited
in a disorderly manner, can constitute a risk of tripping.

WARNING!
Ensuring operating and transit places and emergency exits free from obstacles and
comply with standards.

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1.9.7 Risk of slipping

Any leakage of ink or solvents can cause slipping for the personnel in charge for the use,
operation and maintenance.

WARNING!
Access to that area with non-slip shoes and always keep them clean.

1.9.8 Risk due to handling

The system is shipped at the user’s factory in a single container (packing with carton).
Operations of:
• Unloading of the cardboard box
• Opening of the cardboard box
• Removing and handling the system
can expose the personnel at risk of crushing, though slight since the weights involved, in
case of non-compliance with the instructions provided by the manufacturer.

The customer has to analyze the risks that may occur during the phase of handling
within its factory (analyzes about handling the system were carried out considering
the only characteristics of the system).

1.9.9 Risk of exhalations

During maintenance operations, ink and solvent used with the system can produce noxious
fumes: about it, refer to the technical and safety data sheets supplied with ink and solvent.

To overcome this risk, the system must not be confined in a small space and the instal-
lation premises must be large and well ventilated.

1.9.10 Risk of cutting

During the phases of unpacking, the operator can be in contact with sharp edges of the
packaging that can cause damage.

WARNING!
Move the system while protecting hands and body with the appropriate personal
protective equipment.

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1.10 OBLIGATIONS AND PROHIBITIONS

1.10.1 User obligations

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

1.10.2 Operators obligations

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

1.10.3 Operators prohibitions

The operator must not:
• Use the system improperly, ie for other purposes than those listed in the “Intended
Use” paragaph.
• Remove or modify without authorization, the safety or signaling devices.
• Autonomously perform operations not of their competence or which may compromise
their own safety or the one of other workers.
• Work with consumables (ink and solvent) other than those specified by the manufacturer.
• Modify the system cycle.
• Modify the electrical connections or switch off the internal safeties.
• Use the system if it has not been properly installed according to current regulations.
• Use the system as a support although not working (with risk of injurious falls and/or
the of damage to the system).
• Use the system outside of the allowable environmental conditions.

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1.11 DISPOSAL OF WASTE MATERIALS

The system, after installation and during its normal operation, does not involve environmen-
tal contamination but during the entire period of use certain types of waste or exhausted
materials are however produced, as the ink container or residues of the same ink.

For disposal of these materials there are in every country specific regulations about
 Environmental Protection Agency.

The customer is obligated to be aware of the current laws in his country and to work in order
to comply with these laws in accordance with the instructions given in the specifications
of the products used.

More information about how to dispose inks can be found on the Security sheet of
the inks to which reference is made for details.

It is forbidden to disperse the consumables such as inks and/or solvents into the sewer or
drains that may cause environmental contamination.

The disposal of toxic waste during collection, transport, treatment (intended as the trans-
formation operation necessary for the recovery), as well as the storage and dump on the
ground, constitutes activities of public interest subject to compliance with the following
general principles:
• Any injury or risk to health and to the safety of the community and individual must be
avoided.
• The respect of the hygienic-sanitary requirements must be guaranteed and avoided
any risk of pollution of air, water, soil and subsoil.

Recovery and recycling systems of materials and energy should be initiated, with
the observance of economic criteria and efficient.

The responsible for the disposal is at the user/end customer who has to provide
in accordance with the local laws governing the use of the system.

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External label

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1.12 INDICATION FOR WASTE

Residues from industrial processes and materials from the demolition of deteriorated and
obsolete machinery and equipment are hazardous waste. Among these, in the Z4700
system, there are steels, light alloys, plastics materials and electrical equipment.

The producers of the waste are required to provide for disposal of special waste, even toxic
and hazardous, either directly or through companies, authorized agencies or by transfer
of waste to the persons who run the public service with which a special agreement was
stipulated.

Each country/municipality is required to provide the region with all the information available
on waste disposal in their territory.

According to the 2012/19/UE “RAEE” Directive (repealing the 2002/96/CE Directive and
the 2003/108/CE Directive on waste electrical and electronic equipment) the component/
equipment marked with the following symbol of the waste crossed out bin indicates that
the product at the end of its life must be collected separately from other waste.

The divesified garbage of this equipment at the end of its useful life cycle is organized
and managed by the manufacturer. The user that would get rid of this equipment must
contact the manufacturer and follow the way he choose to allow the diversified garbage
for it.

The adequate divesified garbage for the equipment recycing, treatment and disposal en-
vironmentally compatible contributes to avoid possible negative effects on the environ-
ment and to the health and thus favouring recycling of materials making up the product.

1.13 GENERAL REMARKS

Serial Number: it is on CE lable on the outer side of the console.

The external lable comprises:

Model Z4700
Serial number univolcal code for the system identification
Year year of production

and a chart with the electrical characteristics.

In the bottom of the label is the CE logo and the symbol of special waste

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1.14 CE DECLARATION OF CONFORMITY

We hereby declare under our responsability that the system

System Description: Continuous Ink Jet Printer

Type: Z4700
Identification: from serial number AE-SY-00303
Manufacturer: Zanasi s.r.l.
via Marche 10, 41049 Sassuolo (Modena), Italia

complies with the requirement:

Directive 2014/30/EU (ELECTROMAGNETIC COMPATIBILITY - EMC)

Directive 2014/35/EU (LOW VOLTAGE)
Directive 2011/65/CE (ROHS 2)
Directive 2012/19/UE (RAEE)

and has been designed and manufactured in accordance with the harmonized European
standards:

EN60204:2006 + A1:2010 + EC:2010 Electrical Equipment

EN60950-1:2006 Safety of Equipment
EN61000-6-4:2007 + A1:2013 EMC Emissions
EN61000-6-2:2006 EMC Immunity

The manufacturer keeps information about the system technical construction data.

Person authorised to compile the technical file:

Paolo Zanni (technical manager) - via Marche 10, 41049 Sassuolo (Modena), Italy

Sassuolo (Mo), January 09th 2017 Gianni Zanasi (Managing Director)

Release 9.090117

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2 START-UP

2.1 LIFTING AND HANDLING

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

During transport, the ink tank is empty. The system can be handled even if the ink tank is
full. In any case take care not to overturn the cabinet.

Be careful, with smooth and linear movements, during transport and handling of the system.

2.1.1 Unpacking
Take great care in not accidentally damage the system while unpacking it.

The material contained in the packing comprises:

A) 1 console complete of 1 cabinet (A1) with printhead (A2)

(Keep the printhead in its protections to the moment of installation)
B) 1 power cable 3 meters long
C) 1 cabled photocell (with bracket and screwdriver for adjustment)
D) 1 instruction manual
E) 1 maintenance kit including:
• 1 beacker 500 ml
• 1 wash bottle

2.1.2 Storage
When the system is already used with the tank full, follow the preventive maintenance
described in chapter 3.

For long periods of inactivity, the system must be stored in its original packaging and with
hydraulic circuit and tanks without ink or solvent.

2.1.3 Disposal of packaging

Respect rules and regulations in force in the country of use of the system.

Keep the packaging for a further use of a transport.

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2.2 SYSTEM INSTALLATION

2.2.1 Preparation of the area by the user

It is task of the user to prepare:
• rooms for installation as provided for by local rules and regulations about health and
safety at the workplace.
• power supply in compliance with the rules and regulations in force in the place of in-
stallation.
• a properly working grounding.

2.2.2 System placement

Place the control cabinet on a steady support with the keyboard at about 1 meter from the
floor.

The system placement must allow an easy access for the maintenance or possible repla-
cement of spare-parts.

WARNING:
be sure that the support do not obstruct the vapors exit fitting placed on the floor
of the cabinet.

WARNING:
The cabinet must be free of vibrations, must be kept horizontally and be electrically
isolated from any other equipment.

The support of the cabinet can be provided by the Manufacturer or the Distributor.

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

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

If the supply line has frequent black outs and/or voltage peaks and disturban-
ces, a sinusoidal wave UPS should be inserted on the line in order to avoid
damages to the system and/or difficulties in managing it.

The UPS must absorb at least 300VA.

The UPS will help and “filter”, and therefore to optimize, supply as well as to
support supply in the event of a black out, allowing the operator to properly
shut down the system in compliance with the standard procedure.

A dedicated supply line should be used to supply the system. AVOID to connect
with machinary powered with 380V.

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2.2.3 Photocell and Printhead placement

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

Different sensors may be used:

• Direct reflection photocell (standard)
• Photocell with reflector
• Optical fiber photocell
• Inductive/capacitive sensor

The printhead must be easily accessible for cleaning and maintenance.

WARNING:
The printhead must be free of vibrations.

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The distance from the printhead to the surface to print must be set from 5mm to 20mm.

The system can print either on the side, the top or the bottom of a product.

A) PRINTING ON THE SIDE

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

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

C) PRINTING ON THE BOTTOM SURFACE

The product passes over the printhead, from right to left or vice versa.

In the three cases, set the eventual printing delay so the product can get the right position
in front of the printhead.

2.2.4 Electrical connection

Before connecting the system to the electrical supply, make sure supply voltage and fre-
quency are compatible with the system.
The power supply must be:

100-240 VAC, 50-60 HZ SINGLE PHASE WITH GROUNDING.

(Refer to the lable with the serial number)

The power supply must be free of any voltage interruptions or variations. In case of a large
number of voltage variations, the use of a 300 VA Uninterruptible Power System (UPS) is
recommended.

• AVOID sudden interruptions in the power supply

• AVOID voltage variations exceeding 10%
• AVOID to surrounding devices to cause damages or disturbances to the system
• AVOID to connect the system power supply to a panel supplying other equipment
• VERIFY the condition of socket and plug

In order to interrupt the flow of electrical current toward the system in case of overload,
short circuit or current leakage, make sure that the electrical wiring to which the system
is connected has a residual-current device (RCD) and a circuit breaker with the following
minimum requirements:

Residual-current device Circuit breaker

icc > 600A icc > 600A
in > 2A in > 2A
i∆m = 30mA type B

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2.3 ADJUSTMENTS BEFORE ACTIVATION

2.3.1 Printhead preparation

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

2.3.2 Printhead cleaning

If the printhead is dirty of ink, it must be cleaned before use.

Clean:
• nozzle (1)
• charge electrode (2)
• phase electrode (3)
• deflection plates (4)
• gutter (5)

1. Use the wash bottle and the solvent provided with the system to clean the printhead
2. The solvent evaporates; the surplus quantity must be wiped off with a clean lint-free
cloth.

Once the printhead has been cleaned, place the carter on and fix it by the knob

WARNING:
The inside of the printhead must be perfectly dry. The presence of moisture condi-
tions the system function.

When operating on the printhead, be careful to avoid any damage and to avoid mi-
saligning the ink stream.

2.3.3 Ink and Make-Up fill

Ink and make-up tanks are located in the front of the cabinet and can be accessed by
opening the keyboard door.
When delivered, the system is ready to print with a reserve of ink inside the tank.
For the insertion of new ink and make-up cartridges refer to the on-line help on the system.

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2.4 SYSTEM START-UP

Switch on the system by pressing the main switch (a).

After a few seconds of initialization, the display will show the login page (A).

Select the user-configuration by which to access the Setup and Common Option pages
of the module PARAMETERS (B) in order to configure the settings of the system and the
connected devices.

Then enter the module HOME (C) in order to start the motors and the high voltage on the
printhead.

For the selection and configuration of the modules, refer to the on-line help on the system,
accessible at any time by the icon displayed beside.

At the end of the procedure, the system is ready to print.

2.4.1 Product sensor

The product sensor can be used to detect a continuous product (a pipe) or the presence
of a single product (a bottle).

Single product: the sensor detects the edge of the product and activates the printing.
Continuous product: while the sensor detects the presence of the product, the system
prints with a repeater frequency previously set up. This funcion is called “print repea-
ter”.

2.4.2 Encoder (optional)

When the product line speed is not constant, the use of an encoder is necessary.
The encoder is a speed sensor connected to the production line used to syncronize prin-
ting according to the product speed.

2.4.3 Beacon alarm (optional)

The beacon alarm is used to indicate the status of the system.
The three lights correspond to:
• green light = system ready to print
• yellow light = a warning occurred but the system is still able to print
• red light = an alarm occurred and the system is not able to print

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2.5 VAPOUR RECOVERY

The system produces solvent vapours that are condensed and reused in the system. A
small quantity is expelled through the condenser outlet placed on the floor of the cabinet

WARNING:
Be sure not to obstruct the vapor exit connector by closing the fitting in the bottom
of the system.
This would increase the pressure inside the system thus causing damage to the
system.

2.6 PRINTHEAD PRESSURIZATION

When the system is installed in a dusty and moist room, the printhead must be pressurized
with cleaned compressed air.

Connect the filter-pressure regulator (provided separately by Zanasi or by the distributor)

to the air inlet as shown in figure, by using a pipe diameter 4 and regulate the manometer
to 0.6 bar.

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2.7 SYSTEM SWITCHING OFF

In order to switch off the system:

• Entre the HOME (C) module and press the shutdown icon.

• Confirm choosing the shutdown of the entire system: the hydraulic circuit is automati-
cally flushed and at the end the final screen (D) will appear.

• At the end of the procedure press the main switch.

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Cabinet

Printhead

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3 SYSTEM FEATURES

3.1 PRELIMINARY INFORMATION ON THE PRINTING SYSTEM

Z4700 is a continuous ink jet printing system, suitable for printing on various types of pro-
ducts and substrates.

The system is composed of two main parts: the printhead and the control cabinet, con-
nected by an umbilical cord.

The control cabinet is built in stainless steel to offer maximum resistance to external agents
in every industrial environment. It is divided into three main parts:

• (A) electronic section: it contains the control system (logic board, power supply and
motors)

• (B) hydraulic section: it contains the hydraulic circuit (tanks, pumps, hydraulic block,
viscometer and filters)

• (C) operator interface: includes the touch screen display with as interface for the
operator

3.1.1 Main components

PrintHead:
1) Cover sensor
2) Tubus (emitting microdrops)
3) Nozzle (removable)
4) Charge electrode
5) Phase electrode
6) Deflection plates
7) Gutter (drops collector)

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14
8

13
9
12

10

11

Electronic compartment

16

17 26

18 25

19 22
22
20

21

23 24

Hydraulic compartment

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Electronic compartment:
8) Fans
9) Logic board
10) Power filter: it eliminates all the possible inconveniences from the power supply
entering
11) Power supply
12) Earth ground
13) Adapter board: it allows the connection of the motor-pumps groups with the logic
board
14) Idra board: it controls the electronic components placed in the hydraulic compart-
ment, as the electro-valves, the pressure transducer, the viscometer and the probes
for the alarms in the tanks
15) “IO-INT” interface board:it is the system interface with the field connecting the pro-
duct sensor, encoder, BCD signals, alarms and serial lines

Hydraulic compartment:
16) Damper
17) Manifold: complete of electro-valves and pressure transducer
18) Main filter: it filters the ink circulating into the system
19) Ink Cartridge
20) Suction pump: it sucks the ink from gutter, tubus, viscosimeter and make-up
21) Force pump: it supplies the pressure to the hydraulic manifold
22) Tubolar filters
23) Ink tank: it contains the mixture ink-solvent
24) Make-Up tank: it contains the solvent (make-up)
25) Make-up Cartridge
26) Viscometer: check the viscosity of the ink

3.2 WORKING

The system Z4700 prints on the side, on the top or on the bottom of the product.

The product to be printed must pass in front of the printhead to a distance from 2 to 90
mm.

The product passes in front of the printhead indifferently from left to right or from right to
left. The product passing is detected by a photocell (product sensor).

If the product motion is discontinuous, an encoder must be wired to the line to detect the
speed changes to get always the same width.

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3.3 USER INTERFACE

The user interface pages are divided into three zones:

1. in the lower part (1) choose which module to select, from among those available to
the user:

HOME: the main module of the user interface, it displays the currently printing message,
the the system status and the possible “alarms” and “warnings”

PRIMT PARAMS: for the general parameters of the printing messages

SETTINGS: for the basic settings of the system

MESSAGE EDIT: for the creation of the messages to print

MESSAGE LOADER: to select and upload the messages to print previously created

MANUAL CONTROLS: to check the status of the solenoid valves on the print head and in
the hydraulic compartment, and eventually operate with these last

NETWORK: to configure the system for the access to a local network

DATE TIME: to set the date and the time of the system

USB UTILITY: to copy logos from an USB device to the system and vice versa

USERS: for the creation and the management of users that will access to the system

SERIAL INTERPRETER: to select which configuration to use for the correct interpretation
of serial commands

INPUT/OUTPUT: to select which configuration to use for inputs and outputs

REPORT STAMPE: to view and reset the print report

2. The central part (2) shows the menu pages of the selected module

3. On the right the menu toolbar (3) for application management; the color of the bar
reflects the state of the system:

Green: system ready

Yallow: the system has a “warning” but it is still able to print
Red: the system is not more able to print
Grey: system off-line

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Row 7
Row 6
Row 5
1 Row 4
Row 3
Row 2
Row 1

Column 1 2 3 4 5 6

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Icons on the bar are:

EXIT: it allows to exit the application and return to the login page

USER: it shows the name of the user currently logged in

AIUTO: HELP: it calls the help on-line for the selected module

HOME: it allows to return to the own homepage (the default module available at startup)

PRINTHEAD: it shows the name of the printhead currently used

STATUS: it shows the last posts of status of the system

LEFT ARROW: it allows to return to the previous page of the help on-line

RIGHT ARROW: it allows to return to the next page (previously visited) of the help on-line

MENU: it allows to access to the list of modules for which it is available the help on-line

CLOSE: it allows to exit the help on-line

Then for each module used, through the HELP icon, it is possible to consult the help on-line.

The pages of help on-line contain textual descriptions, pictures and eventually video to
illustrate how to operate in the the selected module or in the other available modules (se-
lectable through the MENU icon).

Through some modules it is also possible to watch the video of the system maintenance;
in these cases, press the corresponding icon at the end of the page in order to enter the
page with the list of available videos.

3.4 CHARACTER COMPOSITION

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

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

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C D

F G

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3.5 PRINTING FEATURES

In addition to standard fonts of the operating system, are also available special font deve-
loped by “Zanasi”:

5x4 5x5 6x4 7x4 7x5 8x6 9x5 9x7 10x8 16x10 24x16

24 dots per column are printable, getting from 1 to 4 rows

The system prints upper cases (A) and lower cases (B).

The height (C) and the width (D) of the character are adjustable as preferred.

Characters are printable with an intensity (bold) (E) up to 8 times.

Counters allow printing incremental numbers (F) or decremental (G).

Date and/or time (H) are printable using the internal clock of the system, used also to print
batches and shiftes.

The system prints logos (I) and barcodes, with or without text, standard (L-Q) or bidi-
mensional (R).

It’s possible to use external fields in order to change the message content through the use
of remote communication via serial line and/or via ethernet network.

The text is printable upside down (reversed print) or backwards (inverted print) to allow
different product orientations or motions.

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370 mm 325 mm

439 mm

42 mm
42 mm

439 mm

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3.6 TECHNICAL SPECIFICATIONS

Console protection degree: IP55

Electrical specifications:
Power supply # 100-240 Vac, 50-60 Hz, single phase
Power rating # 140 VA

IMPORTANT:
The system must be grounded like expressed in paragraph 2.2.2

System specifications:
System Weight: 20 kg
Cabinet Height: 439 mm (17.3inches)
Width: 370 mm (14.6 inches)
Length: 325 mm (12.5 inches)
Print Head (B) Height: 49 mm (1.9 inches)
Width: 42 mm (1.6 inches)
Length: 227 mm (8.9 inches)
Umbilical cord length (printhead - cabinet): 1.8 m / 4 m (5.9 / 13 feet)
Power cable length: 3.0 m (9.9 feet)

Environmental specifications:
Optimum operating temperature 20 °C (68 °F)
Operating temperature range 5 / 40 °C (41 / 104 °F)
Storage and transport temperatures -25 / + 55 °C (-13 / 131 °F)
Operating altitude range 0 / 1000 m MSL
Humidity range 10-90 % relative without
condensation

Inputs:
Product sensor (photocell) 24 Vdc N.P.N./P.N.P. or
Normally Open contact (NO)
Encoder 24 Vdc N.P.N./P.N.P.
BCD device 2 bit

Data input/output:
From a Host Computer serial line RS232-RS485
Ethernet Port 1 Fast Ethernet 10/100 Mbit/s
USB Port USB HS 2.0 interface

Alarm output:
Outputs (relay free contact) max 500mA

Print specifications:
Number of lines: up to 4
Character height 2-14 mm
Character width adjustable
Minimum printing distance 2 mm
Maximum printing distance 90 mm
Recommended printing distance 5-20 mm

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3.7 MAINTENANCE

Maintenance personnel qualifications

To carry the hydraulic and eletrical maintenance the operator needs to be qualified and
trained through an approved practical and theorical training course consisting of:
• theoretical and functional training concerning the system main parts
• manufacturer’s engineers helping for the starting-up.

3.7.1 Maintenance safety conditions

Qualified personnel is required to service the system.

Every maintenance on the system not described on the manual or on the help on-line
affects the warranty and relieves the manufacturer of any responsability.
Carry out periodical checks and maintenance procedures on the system to keep it in good
working order and safety working conditions.
If the system operates in a harsh environment, the maintenance operations must be sche-
duled more frequently.
Before any maintenance, cleaning or repair procedure has been carried out by operators,
it is recommended to wear safety devices.

If any doubt concerning the correct way of maintenance carrying out arises (in spite of the
instructions in the manual and in the help on-line on the system), operators must ask the
manufacturer or Service Assistance for needed information.

Where it is necessary to perform an electrical maintenance, before opening the electronic

compartment turn off the system and be sure to unplug the power cable from the electri-
cal outlet. The power cable is only 3 meters long, then the operator is able to monitor its
effective disconnection from its working position in front of the system.

3.7.2 Technical instructions for correct maintenance

In order to obtain an optimal maintenance:

• use always original spare-parts, equipment suitable and in good working order.
• comply with the handbook instructions in order to carry out preventive and scheduled
maintenance (see paragraph 3.8).
• in order to carry out efficient maintenance, pay constant attention and closely watch
the system.

If the system has not being used for long periods of time you are strongly advised
to operate the system for at least 2 hours every 7 days. This is important to prevent
the ink from drying up in the hoses and pumps.

For this purpose, turn on the system and activate the inkjet (even in the not-printing mo-
dality, state “3”) for at least 2 hours.
At the end off the system and carefully clean the printhead with the solvent.

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3.8 MAINTENANCE SCHEDULE

Daily maintenance
1. Check for alarms or warnings.
2. Switch off the system and properly clean the printhead using the solvent.

Yearly ordinary maintenance or every 4000 hours (Service Maintenance)

(the first occurring)

The Service Maintenance consists of:

1. consumables replacement
2. ink stream alignment check-up
3. system cleaning (internal and external)
4. ink tank drainage and cleaning using the cleaning solvent
5. ink tank filling with new cartridges
6. setting and system parameters check-up

In case of larger utilization (more than 4000 hours) the yearly ordinary maintenance
must be defined with the Official Zanasi Service Centers.

The Service Maintenance has to be carried in the Official Zanasi Service Centers.

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TUBOLAR
DAMPER FILTER
FLUSH

MAIN
FILTER TUBOLAR
FILTER
TUBOL. FILTER MAKE-UP VISCO

TUBOL. TUBOL.
FILTER FILTER
INK GUTTER

Filters and Damper

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3.9 FILTERS AND DAMPER

The system features a main filter and five tubular secondary filters.
The filters must be replaced following the preventive maintenance schedule (see para-
graph 3.8).

3.9.1 Main filter

It has a nominal filtering capacity of 5µm (15µm for pigmented inks).

For the replacement of the main filter refer to the on-line help on the system.

3.9.2 Tubular filters

They are black (two), grey (two) and white according to their filtering capacity.
For the replacement of the tubolar filters refer to the on-line help on the system.

3.9.3 Damper

It keeps the ink pressure in the hydraulic manifold constant

For the replacement of the damper refer to the on-line help on the system.

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Manifold

Viscometer

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3.10 MANIFOLD

The manifold controls the ink flow in the circuit. The filtered ink enters into the manifold
and is delivered to the other components of the printing system.
The main components on the manifold are the electrovalves and the pressure transducer:
this has the function of detecting the value of the ink pressure and to keep it constant.

3.10.1 Electrovalve

On the manifold there are four electrovalves.

From left to right, they control:

• Ink suction from tubus (purge).
• Make-Up adding in the ink tank and tubus purging.
• Ink suction from gutter
• Ink suction from viscosimeter.

For the cleaning of the electrovalves refer to the on-line help on the system.
After cleaning, if the valve still does not work, must be replaced.
A new valve is available from the manufacturer or supplier.

3.11 VISCOMETER

It monitors and manages the viscosity of the ink.

For the cleaning of the viscometer refer to the on-line help on the system.

3.11.1 Viscometer replacement

After cleaning, if the viscometer does not work, it is needed to replace it. Remove hoses
and switch off the system.
These operations can be carried out only by trained technicians.

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Printhead

SUCTION
PUMP

FORCE
PUMP

Pumps

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3.12 PRINTHEAD

The printhead maintenance includes:

• Ink stream alignment
• Nozzle cleaning

For both the tasks refer to the on-line help on the system.

3.13 PUMPS

In the hydraulic compartment there are two pumps: - suction pump (a)
- force pump (b)

3.13.1 Suction Pump replacement

When there is no suction from the gutter, replace the suction pump referring to the on-line
help on the system.

3.13.2 Force Pump replacement

When there is no pressure in the hydraulic circuit, replace the force pump referring to the
on-line help on the system.

3.14 HYDRAULIC CIRCUIT CLEANING

It must be operated by the assistance service when a stop of at least 30 days is scheduled.

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A
B
C

L
D
M
L

G E

Logic board

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3.15 LOGIC BOARD

It is the main board in the system, equipped with a microprocessor that coordinates all the
functions and operations required for the correct functioning.

The main components are:

A - Connector power supply cable
B - Connector flat hydraulic board
C - Connector cable force pump (marked by the label with the F character)
D - Connector cable suction pump (marked by the label with the S character)
E - Connector flat Io/Int board
F - Connector cable printhead
G - H.V. wires
H - Connector flat keyboard
I - Switch for serial address
L - Connectors fans wires
M - Label indicating the release of the logic board
N - Buffer battery

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+5

+ 24

+ 12

- 12

Leds

Fuses

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3.16 POWER SUPPLY

3.16.1 Switching power supply

The system switching power supply generates and supplies constant voltages for circuits
and electrical components. They are verifiable by the active leds on the upper-left corner
on the main board.

3.16.2 Fuses

The alternating voltage in input is filtered by fuses in order to damp all electrical noises in
the circuit.

When there is no voltage, check the fuse in the electronic compartment. If they are broken,
replace them with new equivalent fuses:
• in case of 220V = 1.6A T with breaking capacity 1500A
• in case of 110V = 3.15A T with breaking capacity 1500A

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3.17 EXTERNAL CONNECTIONS

3.17.1 Encoder

Female connector

5 pin female connector pinout (front view):

1. +24 VDC
2. Encoder signal
3. Common
4.
5. GND

Connections for the encoder are:

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3.17.2 Photocell

Female connector

5 pin female connector pinout (front view):

1. +24 VDC
2. Photocell signal
3.
4. Common
5. GND

Connections for the product sensor are:

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3.17.3 Bcd

Male connector

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

18 pin male connector pinout (front view):

1. 10.
2. 11. GND
3. 12.
4. 13.
5. 14. +24 VDC
6. 15.
7. 16. Input 0
8. 17. Input 1
9. 18. Common

Connections for the external devices are:

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A minimum time is required between the BCD change and the print start to allow the sys-
tem to complete the coding. This time (few milliseconds) depends on the structure of the
message, such as the length, height or the number of variable fields inside it.

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3.17.4 Alarm output

Male connector

18 pin male connector pinout (front view):

1. CONTACT 1 COMMON (CM1) 10. GND

2. CONTACT 1 NORM. CLOSED (NC1) 11. GND
3. GND 12. CONTACT 2 COMMON (CM2)
4. CONTACT 2 NORM. OPENED (NO2) 13. +24 VDC
5. CONTACT 2 NORM. CLOSED (NC2) 14. +24 VDC
6. +24 VDC 15. CONTACT 3 NORM. OPENED (NO3)
7. CONTACT 3 NORM. CLOSED (NC3) 16.
7. CONTACT 3 COMMON (CM3) 17.
9. CONTACT 1 NORM. OPENED (NO1) 18.

Connections for the alarms are:

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

System System
off or off or
Warning System
of the Input-Output module

not active Ready

according to the settings

not active
Logic to be defined

Warning System
active Ready
activ

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3.17.5 Serial connections

Male connector

A serial line allows the connection of PC or other devices to the system.

It can be set by keyboard, by means of the following electrical standards:

RS232 allows point-point connection up to 15 metres.

RS485 allows a multi-drop connection (up to 32 systems on the same cable) up

to 1,300 metres.

For both standards, the typology set is:

• data bit: 8
• parity bit: none
• stop bit: 1

9 pin male connector pinout (front view):

1. 6.
2. RX232 7.
3. TX232 8. RX- (485)
4. 9. RX+ (485)
5. GND

Connection to a PC through serial line RS232:

Z4700 SIDE PC SIDE

pin 2 --> pin 3 (TX)
pin 3 --> pin 2 (RX)
pin 5 --> pin 5 (GND)

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3.17.6 Ethernet connection

Through the Ethernet comunication, it’s possible to connect the console to the company
network for the exchange of data or the management of shared folders.

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3.17.7 USB connection

The USB port is used to load on the system the logos previously realized.

The official Zanasi USB key is the only guaranteed for the service and it may be
used only for this purpose. It’s therefore forbidden the user to save personal files
on it in order not to compromise the proper functioning.

WARNING:
Low quality USB keys may cause irreparable damage to the system, making the
warranty of the pc board inside the system null and void.

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3.18 HYDRAULIC CIRCUIT

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3.19 PACKING FOR THE SHIPMENT

In order to ship or transport the system, it is essential to pack it with the appropriate pro-
tections.
For this purpose, refer to the help on-line on the system.

Packing

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4 Communication
Protocols

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4 COMMUNICATION PROTOCOLS

4.1 TCP/IP PROTOCOL

The Orkestra architecture on which the Z4700 system is based, provides a “plain text” TCP/
IP protocol, whose representation of the content is in human-readable format.
This protocol allows to remotely manage and control the status of the system, properly
connected to the network through the ethernet cable.

Communication between the printer and a remote PC via the TCP/IP protocol takes place
using proprietary ports; in order to establish a connection, open a socket to the indicated
address and port.

Default IP address
IP: 192.168.210.101
Mask: 255.255.255.0

Proprietary port
TCP/IP 0xA866 (43110 in decimal notation)

The port number assigned to the protocol can be consulted on the release page
in the help on-line on the system.

The example shows the settings using the telnet protocol with the client emulator Putty (but
they are similar for all other methods of accessing the TCP/IP protocol)

4.1.1 Rules

Some parameters are read-only, then simply for consultable, other also in writing, then
possibly modifiable.

Some rules listed below contain an example of how the communication as pure
data packet occurs and an equivalent example using a telnet protocol with the
client emulator Putty.

• Commands are case-sensitive, so pay attention to correctly use uppercase or lower-

case letters.

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• Each TCP command (either sent to the printer or received from the printer) must be
closed by an LF line feed character [x0A]. Then:
- in case of command sent to the printer, the string must end with [x0A]
- in case of reply received from the printer, the string will correspond to [x20][x0A]
if the command was a setting command, or to {required content}[x0A] if the com-
mand was a read-only command.

For example, in order to set the “test” content to the external field 0 of string type, the
command to compose is: external_field string 0 “test”, that is, in hexadecimal:

COMMAND [x65][x78][x74][x65][x72][x6E][x61][x6C][x5F][x66][x69][x65][x6C]
[x64][x20][x73][x74][x72][x69][x6E][x67][x20][x30][x20][x22][x74]
[x65][x73][x74][x22][x0A]
external_field string 0 “test”
REPLY [x20][x0A]
˽

By using Putty, the closing character command is supplied to the system throught
the Enter key (corresponding to CR LF)

• Consult the list of categories

By sending only the closing character of the command, the system will reply the list
of the accessible categories.

COMMAND [x0A]

REPLY [x76][x61][x72][x69][x61][x62][x6C][x65][x20][x65][x78][x74][x65]
[x72][x6E][x61][x6C][x5F][x66][x69][x65][x6C][x64][x20][x6D][x65]
[x73][x73][x61][x67][x65][x20][x63][x6F][x6D][x6D][x61][x6E][x64]
[x20][x69][x6E][x66][x6F][x20][x70][x65][x72][x69][x70][x68][x65]
[x72][x61][x6C][x20][x73][x79][x73][x74][x65][x6D][x0A]
variable externale_field message command info peripheral system

Instead by using Putty, pressing “Enter” (without having entered anything before),
the system will show:

• Consult the list of sub-items

By sending the name of a category, followed by the closing character, the system will
reply all the accessible sub-entries of the requested category.
For example, by composing the command: variable

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COMMAND [x76][x61][x72][x69][x61][x62][x6C][x65][x0A]
variable
REPLY [x73][x70][x65][x65][x64][x20][x61][x73][x][x70][x65][x63][x74][x20]
[x73][x65][x74][x75][x70][x20][x63][x6F][x70][x79][x20][x][x70][x68]
[x79][x73][x69][x63][x61][x6C][x20][x61][x6C][x61][x72][x6D][x73]
[x20][x][x63][x6F][x6E][x6E][x65][x63][x74][x69][x6F][x6E][x73][x20]
[x73][x65][x72][x76][x][x69][x63][x65][x20][x72][x65][x70][x6F][x72]
[x74][x0A]
speed aspect setup copy physical alarms connections service
report

Instead by using Putty, typing “variable” followed by “Enter” the system will show:

• Read the value of a parameter

In order to read the value of a parameter, compose a command formed by the list
of categories and sub-entries necessary to reach the parameter, followed by the
closing character. The system will reply by providing the content of the requested
parameter.
For example, by composing the command: variable aspect Intensity

COMMAND [x76][x61][x72][x69][x61][x62][x6C][x65][x20][x61][x73][x70][x65]
[x63][x74][x20][x49][x6E][x74][x65][x6E][x73][x69][x74][x79][x0A]
variable aspect Intensity
REPLY [x31][x0A]
1

Instead by using Putty, typing “variable aspect Intensity” followed by “Enter” the sy-
stem will show:

Another example, by composing the command: message index.

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COMMAND [x6D][x65][x73][x73][x61][x67][x65][x20][x69][x6E][x64][x65][x78]
[x0A]
message index
REPLY [x31][x30][x0A]
10

Instead by using Putty, typing “message index” seguito da “Enter” followed by “Enter”
the system will show:

• Read the value of all parameters of a sub-entry

In order to read the value of a parameter of a sub-item, compose a command formed
by the list of categories and sub-entries necessary to reach the required sub-entry,
followed by the closing character. The system will reply by providing the name of the
required sub-entry followed by the “:” character and the list of all the parameters it
contains ({parameter name}={content}).
For example, by composing the command: variable aspect

COMMAND [x76][x61][x72][x69][x61][x62][x6C][x65][x20][x61][x73][x70][x65]
[x63][x74][x20][x0A]
variable aspect
REPLY [x61][x73][x70][x65][x63][x74][x3A][x20][x][x49][x6E][x74][x65][x6E]
[x73][x69][x74][x79][x3D][x30][x20][x43][x6F][x6E][x74][x][x72][x61]
[x73][x74][x3D][x31][x20][x51][x75][x61][x6C][x69][x74][x79][x3D]
[x30][x0A]
aspect: Intensity=0 Contrast=1 Quality=0

Instead by using Putty, typing “variable aspect” followed by “Enter” the system will
show:

For convenience, it’s possible to type only portion of the command; for example
the command “variable” can be invoked simply by typing “var” o “v”.
In case multiple commands begin with the characters entered, the system will
consider the first of the list of the sub-entries; for example “var se“ will invoke the
command “setup” as placed before, in the list than the command “service”.

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Some parameters return a value difficult to understand, as not in the unit we

would expect to see (it’s an hexadecimal or a value used by the system).
In these cases, add the letter “v” (=verbose) at the end of the command in order
to display the value in the correct way.
Example: “info measure board_temp v“

Read-only parameters are identified by a name starting with a lowercase character;

parameters also accessible in writing (therefore also possible to set) are
identified by a name starting with a uppercase character.

• Set a parameter
In order to set the value of a parameter, compose a command formed by the list of
categories and sub-entries necessary to reach the parameter, followed by the “=”
character, by the value to be set and by the closing character. The system will reply
by providing a space and the closing character ([x20][x0A]).
For example, by composing the command: variable aspect Intensity=4

COMMAND [x76][x61][x72][x69][x61][x62][x6C][x65][x][x20][x61][x73][x70][x65]
[x63][x74][x20][x49][x6E][x74][x65][x6E][x73][x69][x74][x][x79][x3D]
[x34][x0A]
variable aspect Intensity=4
REPLY [x20][x0A]
˽

Instead by using Putty, typing “variable aspect Intensity=4” followed by “Enter” the
system will show:

The name of the parameter value must be typed completely; in the previous
example, the string “var asp Intensity=4“ is correct, while the string
“var asp Int=4“ is not correctly recognized.

In giving value to the parameters that can be assigned a hexadecimal value,

specify the value preceded by the string 0x.

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4.1.2 List of parameters

Below is listed the complete tree of the parameters that can be accessed from the release of
firmware 3.2.c. In order to know the release of firmware of the system, type the command:
“peripheral all” and check the voice FWversion.

variable
speed
Type
Var1
Var2
Factor
aspect
Intensity
Quality
setup
LeftOn
UpOn
ExternalStartOn
PrintDistance
IndexedOn
SyncIndexOn
copy
Length
Number
Function (not used)
physical
Pressure
Suction
HighVoltageValue
AmplitudeOscillator
InkTypeName
InkCoefX2
InkCoefX1
InkCoefK
InkPigmentOn
SetPointViscosimeter
InkThreshold
MakeupThreshold
TankThreshold
GutterThreshold
NozzleDiameter
alarms
PressureOn
HighVoltageOn
GutterOn
PumpOn

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connections
RS232Enable
RS232Address
RS232BaudRate
RS485Enable
RS485Address
RS485BaudRate
service
WorkTimeFromReset
WorkTimeThreshold
DateThreshold
GlobalCounterFromReset
GlobalCounterThreshold
report
MessageNumber (not used)
external_field
string
bitmap
table
message
number
count
index
names
all_counts
command
purge
print
visco
makeup
ink
keycode
retcode
key_params (not used)
disable_print
enable_print
counter
msg_counts_reset
all_msg_counts_reset
set_count_value
info
x_resolution
y_resolution
BCDin

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state
alarms
warnings
errors
valves
hw_indicators
state
message
proto_func
active_outputs
all_states
measure
board_temp
ink_temp
ink_level
full_level
mek_level
gutter_level
phase_peak
high_voltage
fly_time
pump_rpm
pressure
viscosity
set_point
all_measures
time_count
sys_time
abs_time
work_time
reset_time
count_abs
all_time
lock
mek_lock
to_mek_lock
ink_lock
to_ink_lock
purge_time
all_lock
peripheral
peripheral_ide
serial_number
proto_version
all
system
date_time
logs
level
proto_prog_version

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4.1.3 Reading and writing of the parameters

To consult and eventually modify, the current value of the variables in the system, type the
respective string.
Commands that can be valorized remotely contain the = symbol followed by the value to
assign (for example “variable speed Type=0”); the same command without the valorization
(for example “variable speed Type”) is read-only, to know the current status of the parameter.

4.1.3.1 Encoder Enabling

variable speed Type=0/1 0=encoder disabled

1=encoder enabled

4.1.3.2 Speed line

Only with the encoder disabled (variable speed Type=0)

variable speed Var1=xx (xx=speed expressed in m/sec)

4.1.3.3 Encoder settings

Only with the encoder enabled (variable speed Type=1)

variable speed Var1=xxxx (xxxx=resolution expressed in ppr)
variable speed Var2=y.yy (y.yy=pulley diameter expressed in m)

4.1.3.4 Stretch

variable speed Factor=x.xx (x.xx=stretch of labels expressed in decimals

compared to the size of the layout of the
messages (1.00=100%))

4.1.3.5 Bold

variable aspect Intensity=x (x=1...8 expressed in columns of thickness)

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4.1.3.6 Codify

variable aspect Quality=0/../13 0=17-S

1=16-HS
2=3L-9x7
3=24-S
4=24-HQ
7=4L-7x5
8=4L-5x5
9=1L-7x5
10=2L-7x5
11=3L-7x5
12=3L-5x5
13=4L-5x5HQ

4.1.3.7 Reverse Print

variable setup LeftOn=true/false true=reverse print enabled

false=reverse print disabled

4.1.3.8 Inverted Print

variable setup UpOn=true/false true=inverted print enabled

false=inverted print disabled

4.1.3.9 Photocell enabling

variable setup ExternalStartOn=true/false true=photocell enabled

false=photocell disabled

4.1.3.10 Print delay

variable setup PrintDistance=xxx (xxx=delay expressed in mm)

4.1.3.11 Indexed message

variable setup IndexedOn=true/false true=use of indexed messages

false=not use of indexed messages

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4.1.3.12 Synchronization or BCD for indexed messages

Only with the Indexed Message modality enabled (variable setup IndexedOn=true)
variable setup SyncIndexOn=true/false true=synchronized modality
false=BCD modality

4.1.3.13 Repeater

variable copy Number=0/1/N 0=repeater enabled and continuos

1=repeater disabled
N=repeater enabled for N times

4.1.3.14 Distance between printings

Only with the Repeater modality enabled (variable copy Number=0 or =N)
variable copy Length=x.xx (x.xx=distance between the printings
expressed in m)

4.1.3.15 Pressure set

variable physical Pressure=xxxxx (xxxxx=pressure set expressed in KPa)

4.1.3.16 Suction set

variable physical Suction=xxxx (xxxx=suction set expressed in rpm)

4.1.3.17 Deflection Plates

variable physical HighVoltageValue=xx (xx=deflection plates value)

4.1.3.18 Oscillator Amplitude

variable physical AmplitudeOscillator=xxx (xxx=oscillator amplitude value)

4.1.3.19 Pressure Alarm

variable alarms PressureOn=true/false true=Pressure alarm enabled

false=Pressure alarm disabled

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4.1.3.20 High Voltage Alarm

variable alarms HighVoltageOn=true/false true=High Voltage alarm enabled

false=High Voltage alarm disabled

4.1.3.21 Gutter Alarm

variable alarms GutterOn=true/false true=Gutter alarm enabled

false=Gutter alarm disabled

4.1.3.22 Force Pump Alarm

variable alarms PumpOn=true/false true=Force Pump Alarm enable

false=Force Pump Alarm disable

4.1.3.23 RS232 Serial Connection

variable connections RS232Enable=true/false true=RS232 serial line enabled

false=RS232 serial line enabled

4.1.3.24 Buadrate RS232 Serial Connection

variable connections RS232BaudRate=0/../4 0=4800

1=9600
2=19200
3=38400
4=56800

4.1.3.25 RS485 Serial Connection

variable connections RS485Enable=true/false true=RS485 serial line enabled

false=RS485 serial line enabled

4.1.3.26 Buadrate RS485 Serial Connection

variable connections RS485BaudRate=0/../4 0=4800

1=9600
2=19200
3=38400
4=56800

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4.1.3.27 Ink used into the System

variable physical InkType=xxx (xxx=number of ink)

4.1.3.28 Set Point Viscometer

variable physical SetPointViscosimeter=xxx (xxx=set point)

4.1.3.29 Nozzle Diameter

variable physical NozzleDiameter=50/70 (50=diameter 50µ

70= diameter 70µ)

4.1.3.30 Threshold Warning Ink Level Low

variable physical InkThreshold=xxxx (xxxx=threshold)

4.1.3.31 Threshold Warning Make Up Missing

variable physical MakeupThreshold=xxxx (xxxx=threshold)

4.1.3.32 Threshold Warning Tank Too Full

variable physical TankThreshold=xxxx (xxxx=threshold)

4.1.3.33 Threshold Gutter Alarm

variable physical GutterThreshold=xxxx (xxxx=threshold)

4.1.3.34 Time of use (read-only)

variable service WorkTimeFromReset=xxxxxx (xxxx=time of use expressed in

minutes)

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4.1.3.35 Time to next maintenance (read-only)

variable service WorkTimeThreshold=xxxx (xxxxxxx=time to next maintenance

expressed in minutes)

4.1.3.36 Maximum date next maintenance (read-only)

variable service DateThreshold=xxxxxxxxxx (xxxxxxxxxx=date next maintenance

expressed in Unix time)

4.1.3.37 Number of printings since last reset (read-only)

variable service GlobalCounterFromReset=xxxx (xxxxxxx=number of printings)

4.1.3.38 Number of printings to next maintenance (read-only)

variable service GlobalCounterThreshold=xxxx (xxxxxxx=number of printings)

4.1.3.39 Valorization of the String external field

external_field string x “yyyyyyyyy“ (x=index external field [0,...,19];

yyyyyyyyy=string to print (max 100
characters))

4.1.3.40 Valorization of the Bitmap external field

external_field bitmap x yyyyyyyy (x=index external field [0,...,4];

yyyyyyyy=bytes corresponding to the bitmap
expressed in hexadecimal (max 200 byte)
(attention: bytes, not string))

4.1.3.41 Valorization of the Table external field

external_field table x yyyyyyyy (x=index external field [0,...,9];

yyyyyyyyy=bytes corresponding to the indi-
ces of table to print the contents
expressed in hexadecimal (max 60 byte)
(attention: bytes, not string))

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4.1.3.42 Opening/Closing Purge Valve

command purge (switches the current state)

4.1.3.43 Opening/Closing Visco Valve

command visco (switches the current state)

4.1.3.44 Opening/Closing Makeup Valve

command makeup (switches the current state)

4.1.3.45 Opening/Closing Ink Valve

command ink (switches the current state)

4.1.3.46 Simulation of one printing start

command print

4.1.3.47 Execution of the function xxx

command keycode xxxx (xxxx=0110 Print

=0111 Start/Stop
=0108 System shutdown
=0109 Ink Jet turning off
=010A Ink Jet turning on
=010B System flushing
=010C Stop System flushing)

4.1.3.48 Last function executed (read-only)

command retcode

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4.1.3.49 Printing disabling

command disable_print (note: after each reboot, the system will always
have the printing enabled; in printing disabled
condition, if the system receives a print
command, a warning on the display will warn
the user)

4.1.3.50 Printing enabling

command enable_print (note: after each reboot, the system will always
have the printing enabled)

4.1.3.51 Back to the starting value of counters-batches of the current message

command counter msg_counts_reset

4.1.3.52 Back to the starting value of counters-batches of all the messages

command counter all_msg_counts_reset

4.1.3.53 Setting the starting value of a counter or batch

command counter set_count_value xxx yyyyy (xxx=ID Reference counter/batch

yyyyy=actual value to set)

4.1.3.54 Number of messages loaded into the Bcd list (read-only)

message number

4.1.3.55 Report of the printing message (read-only)

message count

4.1.3.56 Report of the all the 64 possible indexed messages (read-only)

message all_counts

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4.1.3.57 Index of the printing message

message index

4.1.3.58 Names of messages loaded into the Bcd list (read-only)

message names (the system also displays the number of loaded messages)

4.1.3.59 Horizontal resolution of the printing message (read-only)

info x_resolution (expressed in dpi)

4.1.3.60 Vertical resolution of the printing message (read-only)

info y_resolution (expressed in dpi)

4.1.3.61 Bcd input of the printing message (read-only)

info BCDin

4.1.3.62 Current state of the system (read-only)

info state state v

4.1.3.63 Alarms in the system (read-only)

info state alarms v (alarms currently present)

4.1.3.64 Warnings in the system (read-only)

info state warnings v (warnings currently present)

4.1.3.65 Valves opened in the system (read-only)

info state valves v (valves currently opened)

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4.1.3.66 Errors in the system (read-only)

info state errors v (errors currently present)

4.1.3.67 Hardware devices working (read-only)

info state hw_indicators v (hardware currently working)

4.1.3.68 Index and total report of the printing message (read-only)

info state message (expressed as “index;total report of the message;

value of the report from the last reset”)

4.1.3.69 Last functions executed (read-only)

info state proto_func v

4.1.3.70 Active auxiliary outputs (read-only)

info state active_outputs (useful for the management of the auxiliary outputs)

4.1.3.71 All the states (read-only)

info state all_states (the system returns all the current states (the
sub-items of “info state”) expressed in hexadecimal)

4.1.3.72 Temperature Logic Board (read-only)

info measure board_temp v (temperature expressed in °C)

4.1.3.73 Temperature Ink (read-only)

info measure ink_temp v (temperature expressed in °C)

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4.1.3.74 Level Missing Ink (read-only)

info measure ink_level (current level)

4.1.3.75 Level Full Ink (read-only)

info measure full_level (current level)

4.1.3.76 Level Missing Make-Up (read-only)

info measure mek_level (current level)

4.1.3.77 Level ink into the Gutter (read-only)

info measure gutter_level (current level)

4.1.3.78 Phase Peak (read-only)

info measure phase_peak (last value)

4.1.3.79 High Voltage between the Deflection Plates (read-only)

info measure high_voltage (current voltage expressed in V)

4.1.3.80 Fly Time (read-only)

info measure fly_time (last value expressed in µsec)

4.1.3.81 Force Pump revolutions (read-only)

info measure pump_rpm (current revolutions expressed in rpm)

4.1.3.82 Current Pressure (read-only)

info measure pressure current pressure expressed in KPa)

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4.1.3.83 Current Set Point (read-only)

info measure viscosity

4.1.3.84 Reference Set Point (read-only)

info measure set_point (reference set point for the current temperature)

4.1.3.85 All the measures (read-only)

info measure all_measures (the system returns all the measurement parameters
(the sub-items of “info measure”); temperatures are
not expressed in °C)

4.1.3.86 Current date and time (read-only)

info time_count sys_time (date expressed in Unix Time)

4.1.3.87 System locked for Make-Up missing (read-only)

info lock mek_lock 0=system not locked

1=system locked

4.1.3.88 Time to system locking for Make-Up missing (read-only)

info lock to_mek_lock

4.1.3.89 System locked for Ink missing (read-only)

info lock ink_lock 0=system not locked

1=system locked

4.1.3.90 Time to system locking for Ink missing (read-only)

info lock to_ink_lock

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4.1.3.91 Length manual purge (read-only)

info lock purge_time (expressed in s)

4.1.3.92 All the info on the system locking (read-only)

info lock all_lock (the system returns all the sub-items of “info lock”)

4.1.3.93 ID Peripheral (read-only)

peripheral peripheral_ide

4.1.3.94 Serial Number (read-only)

peripheral serial_number

4.1.3.95 Communication Protocol Version (read-only)

peripheral proto_version

4.1.3.96 All the info about Peripheral (read-only)

peripheral all (the system returns all the sub-items of “peripheral”)

4.1.3.97 Date and Time (read-only)

system date_time (currently set on the system)

4.1.3.98 Events on the system (read-only)

system logs (expressed as date_event; time_event;N;type_task;task;content;

id_peripheral;serial_number_peripheral;connection-channel;
type_protocol)

4.1.3.99 Proto Version (read-only)

system proto_prog_version

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4.2 SERIAL PROTOCOL

The serial communication protocol allows to valorize an external field of the Z4700 system
from a PC (or PLC) connected via serial cable and to check its content, in addition to decide
the message to print and to send the printing start.

For the connection between the PC (or PLC) and the Z4700 via serial cable, refer to pa-
ragraph 3.17.5.

Note: regardless of the command sent, if the message has been sent correctly, the
system Z4700 will return the ‘=’ (equal) symbol, otherwise it will return the ‘!’ (excla-
mation mark) symbol.

4.2.1 Valorization of an external field

After having created and sent to the printhead directly on the console the message con-
taining variable fields (refer to the Help On-Line on the system), open a Serial Terminal
application (as “Protocol Simulator”) and send the command with the following structure:

#
+ 1 byte [ ] indicating the index of the function: 163 in order to set the external field “string”
166 in order to set the external field “string”
with the return of the ($) character after every
printing
164 in order to set the external field “bitmap”
165 in order to set the external field “table”
+ 1 byte [ ] indicating the index of the external field already inserted in the message
+ 2 bytes [ ] [ ] indicating the length of the message
+ the message, containing a maximum of 100 characters

Note: in case of using a PLC instead of a PC, as every PLC uses a specific
language, refer to its Instruction Manual in order to set the right communication
with the Z4700 system

Example with string

In order to send the string ZANASI (then of length 6 characters = 6 bytes) to the external
field “string” with index 4 previously created, send the command:

# [163] [4] [0] [6] ZANASI

In order to receive the ($) character after every printing, (as confirmation of printing), send the
command:

# [166] [4] [0] [6] ZANASI

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Example with bitmap

In order to send a 16x16 (then of length 32 bytes) bitmap with the image (an isosceles
right triangle of size 15x15 dots) to the external field “bitmap” with index 7 previously created,
send the command:

# [164] [7] [0] [32] [x0] [x1] [x0] [x3] [x0] [x7] [x0] [xF] [x0] [x1F] [x0] [x3F] [x0] [x7F] [x0]
[xFF] [x1] [xFF] [x3] [xFF] [x7] [xFF] [xF] [xFF] [x1F] [xFF] [x3F] [xFF] [x7F] [xFF] [xFF]
[xFF]

where the last 32 bytes correspond to the dots to print: every printable column is divided into
groups of 8 dots each. Every group corresponds to one byte (so, in the example, there are 2
bytes for each column).
Through the bytes it is possible to indicate which dots to print and which not: every byte identifies
a value between [00000000,11111111] in binary (where 0=dot to print and 1=dot not to print, in
negative logic), that is [0,F] in hexadecimal.
The first byte considered is the bottom one.
1
0
0
0
00000001 = x1 0
binary hexadecimal 0
0
0
0
0
0
0
00000000 = x0 0
binary hexadecimal 0
0
0

So the first two bytes are [x0] and [x1].

1
1
0
00000011 = x3 0
binary hexadecimal 0
0
0
0
0
0
0
0
00000000 = x0 0
binary hexadecimal 0
0
0

So the following two bytes are [x0] and [x3].

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1
1
1
00000111 = x7 0
binary hexadecimal 0
0
0
0
0
0
0
00000000 = x0 0
0
binary hexadecimal
0
0
0

So the following two bytes are [x0] and [x7].

And so on until the last column:
1
1
11111111 = xFF 1
binary hexadecimal 1
1
1
1
1
1
1
1
11111111 = xFF
1
binary hexadecimal 1
1
1
1

So the last two bytes are [xFF] and [xFF].

In this way, the the sequence of bytes to send is: [x0] [x1] [x0] [x3] [x0] [x7] [x0] [xF] [x0] [x1F]
[x0] [x3F] [x0] [x7F] [x0] [xFF] [x1] [xFF] [x3] [xFF] [x7] [xFF] [xF] [xFF] [x1F] [xFF] [x3F] [xFF]
[x7F] [xFF] [xFF] [xFF]

Example with table

In order to send a table containing 5 elements (then of length 5 bytes) to the external field
“table” with index 6 previously created, the command to send is:

# [5] [6] [0] [5] [1] [7] [4] [1] [5]

where the last 5 bytes correspond to the indices of the 5 symbols in the table

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4.2.2 Query about the content of an external field

In order to check the contents of an external field, open a Serial Terminal application (as
“Protocol Simulator”) and send the command with the following structure:

#
+ 1 byte [ ] indicating the index of the function: 160 in order to check the external field “string”
161 in order to check the external field “bitmap”
162 in order to check the external field “table”
+ 1 byte [ ] indicating the index of the external field to check

The system will respond with a string with the following structure:

2 bytes [ ][ ] indicating the length of the message

+ 2 bytes [ ][ ] indicating the width of the message (only in case of bitmap)
+ the message
+ the checksum character

Example with string

In order to check the contents of the external field “string” with index 4 (valorised in paragraph
4.2.1), send the command:

# [160] [4]

The system will respond:

[0] [6] ZANASI [CK]

Example with bitmap

In order to check the contents of the external field “bitmap” with index 7 (valorised in paragraph
4.2.1), send the command:

# [161] [7]

The system will respond:

[0] [32] [0] [16] [x0] [x1] [x0] [x3] [x0] [x7] [x0] [xF] [x0] [x1F] [x0] [x3F] [x0] [x7F] [x0]
[xFF] [x1] [xFF] [x3] [xFF] [x7] [xFF] [xF] [xFF] [x1F] [xFF] [x3F] [xFF] [x7F] [xFF] [xFF]
[xFF] [CK]

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Example with table

In order to check the contents of the external field “table” with index 6 (valorised in paragraph
4.2.1), send the command:

# [162] [6]

The system will respond:

[0] [5] [1] [7] [4] [1] [5] [CK]

4.2.3 Printing start

In order to print the current message (to check it), send the command:

# [168]

4.2.4 Choosing the message to print

In order to print the message of index X (with X in binary code) in case of an indexed synchro-
nized list, send the command

# [167] [X]

4.2.5 Enable/Disable the character of printing succesfully

After every printing, it’s possible to receive a character (“$”) as confirmation of printing; in
order to enable this feature send the command:
# [169]

Conversely, in order to disable this feature send the command:

# [170]

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4.2.6 Serial commands of termination

For any serial command sent to the Z4700 system, it’s possible to set one or more termi-
nators to receive in reply, in addition to the ‘=’ (equal) symbol; in order to enable this feature
send the command:

# [171]
+ 1 byte [ ] indicating the number n (between 1 and 6) of closing characters used
(ie how many bytes will follow)
+ n bytes [ ] [ ] [ ] containing the closing characters

Example
After the command:

#[171][2][13][10]

to any serial command sent to the Z4700 system, the system will add to the end of the
reply message

[13][10] (corresponding to “CR” and line feed)

In order to disable this function and reset the terminators (coming back to reply only with
the ‘=’ (equal) symbol), send the command:

# [172]

4.2.7 Outcome action commands of the external device

In order to inform the system if the action performed by an external device connected to
it is successful or not, set the device so that it sends to the system the command:

# [173] [ACK] (if the action is successful), or

# [173] [NACK] (if the action is not successful)

This is particularly useful in the Input/Output module, to bond the result of an action per-
formed by an external device to a possible event to trigger as Output (for example, after
some NACK received, to trigger the siren connected to the Aux Relais)

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4.2.8 Enable/Disable the printing

In order to enable the printing, if it has been previously disabled, send the command:

# [175]

Instead, in order to disable the printing, send the command:

# [176]

If, when the printing is disabled, the system receives a print command (eg from photocell
or repeater), a warning on the display will alert the user.

Note: after each reboot, the system will always have the printing enabled

4.2.9 Set counter or batch value

In order to set the current value of a counter or batch of the message currently printed,
send the command:

# [177]
+ 1 byte [ ] indicating the ID which identifies the counter or batch
+ 4 bytes [ ] [ ] [ ] [ ] containing the value to set

Example
In order to set the value 10 to the counter (or batch) with ID=24 of the message currently
printed, send the command:

# [177] [24] [0] [0] [0] [10]

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