Instruction manual

ES200i
ES500
ES500i
To the best of our knowledge, the information contained in this guide was correct at the time of
printing. However, continual enhancement of our products can result in some differences
between the instructions represented in this guide and your Markem-Imaje ES200i, ES500, and
ES500i fume extraction and air cooling units .

All rights reserved. Reproducing this publication in whole or in part without written permission
is expressly prohibited.

Owner’s Re cord

The model and serial numbers are located on the left side of the unit. Record the serial number in
the space provided below.

Model Number: ________________

Serial Number: ________________

Clean Air Filter Part Number

(ES500i Only) ________________

Pre Filter Part Number: ________________

Combined Filter Part Number: ________________

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 Table of Contents
Section Description Page
Section 1 General Information 5
1.1 Welcome to the Model ES200i, ES500, 5
and ES500i Fume Extraction and Air
Cooling Units
1.2 Before You Begin 5
1.3 Safety Information 5
1.4 Electrical Safety 6
1.5 Physical Safety 6
1.6 Warning and Information Labels 7
1.7 Specifications 8
1.8 Environmental Operating Range 8
1.9 Fuses 9

Section 2 Installation 10
2.1 Introduction 10
2.2 Fume Capture 10
2.2.1 Arm and Nozzle Extraction 10
2.2.2 Enclosures 11
2.3 Extractor Overview 12
2.4 Extractor Installation Procedure 13
2.4.1 Moving the Unit 13
2.4.2 Spacing 13
2.4.3 Hose Kit 13
2.4.4 Cooling Air Kit (Not Required for ES500) 13
2.4.5 Power Cable 14
2.4.6 Electrical Customisation 14
2.4.7 Misuse 16
Section 3 Operation 17
3.1 Powering the ES units 17
3.2 Filter Condition and System Failure Indicators 17
3.3 Setting the Airflow /Closed Loop Auto Flow Control 18
3.4 PVC Version 18
3.5 Cleaning 18

Section 4 Preventive Maintenance 19

4.1 Preventive Maintenance Procedures 19
4.2 Filter Change Procedure for Models ES500/i 19
4.2.1 Clean Air Filter,(ES500i only) 19
4.2.2 Pre-filter Replacement, 20
4.2.3 Combined Filter Replacement, 20
4.3 Filter Change Procedure for Model ES200i 21
4.3.1 Pre-filter Replacement, 21
4.3.2 Combined Filter Replacement, 22
4.4. Spare Filters 22
4.5 Filter Disposal 22
4.6 Filter Part Numbers 23

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Page 4
Section 1 General Information

1.1 Welcome to the Model ES200i, ES500, and ES500i Fume Extraction and Air
Cooling Units

What This Guide Covers

This manual covers the following:

Installation of the system

Operation of the system
Maintenance of the system

For assistance in troubleshooting the ES200i, ES500 or ES500i models, contact

your local Markem-Imaje representative

1.2 Before You Begin

Before you can begin printing, make sure the system is completely and correctly
installed and integrated with your production line.

1.3 Safety Information

Safety terms are provided to avoid hazards and provide understanding for safely
operating this system.

WARNING: A potentially hazardous situation which, if not avoided, will result in

death or serious injury.

CAUTION: A potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.

NOTE: Indicates an operating procedure that is essential but not known to cause
hazards as indicated by a warning or caution.

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1.4 Electrical Safety

The ES range of extraction units is designed to meet the safety requirements of

the Low Voltage Directive 2006/95/EC to meet CE requirements and is also UL
listed.

WARNING: When performing work with the pump/motor housing open, live
115/230 Volt components are accessible. Always observe safety rules and
regulations for work on live components.
WARNING: To reduce the risk of fire, electric shock, or injury, always:

1. Isolate the system from the main power supply before removing the
pump/motor panel.
2. Use the system only as described in this guide.
3. Connect only to a properly grounded outlet.

1.5 Physical Safety

Once the filters in the ES extraction units have been used, they contain a mixture
of particulates, some of which may be sub-micron in size.

1. EYES and RESPIRATORY SYSTEM – When the used filters are

moved, this movement may agitate some of these particulates, which
could get into the operator’s eyes and respiratory system.
2. SKIN – Also, depending on the materials being lased, the particulates
may be irritants to the operator’s skin.

CAUTION: When changing used filters, the operator should always wear
an appropriate mask, safety glasses, and gloves.

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1.6 Warning and Information Labels
Refer to the following labels:
Label/Symbol Position

ES500 & ES500i

Left side of internal front panel

ES500 & ES500i

Bottom Central on the internal front panel

ES200i
Rear of base above suction connection

ES500i
Clean air exhaust panel

ES500 & ES500i

Above pump/motor cooling louvers
DO NOT COVER

ES500 & ES500i

Below Cables on side of extractor

ES200i
Rear of unit below power connection

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1.7 Specifications

Unit ES500

Capacity 380m 3/hr

Size Height 905mm
Depth 430mm
Width 430mm
Weight 75kg
Exhauster Side Channel Blower
Output 1.1kW
Electrical Supply 115/230V 1Ph 50/60Hz
Noise Level Below 60dB(A) (at typical operating speed)
Filters Pre-filter Surface Area 12.0 m 2
Efficiency F8 85% @ 0.8µ
Hepa Filter Efficiency H13 99.997% @ 0.3µ
Gas Filter Activated Carbon 15kg
Unit ES500i

Same as ES500 above except:

Clean Air Fan 180m 3/hr

Fan Centrifugal Fan
Output 135W

Unit ES200i

Capacity 180m 3/hr

Size Height 560mm
Depth 380mm
Width 380mm
Weight 30kg
Exhauster Centrifugal Fan
Output 105W
Electrical Supply 115/230V 1Ph 50/60Hz
Noise Level Below 60dB(A)
Filters Pre-filter Surface Area 6.0 m 2
Efficiency F8 99% @ 0.8µ
Hepa Filter Efficiency H13 99.997% @ 0.3µ
Gas Filter Activated Carbon 10.0kg

1.8 Environmental Operating Range

Temperature +5°C to +40°C

Humidity Max 80% RH up to 31°C
To Max 50% RH up to 40°C

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 1.9 Fuses

The following table gives details of the internal fuses in the range of units:

Unit Item Protected Fuse Rating A FLC A Fuse Type Voltage

All units 12v Power Pack 1 <.1 230 or 110v
ES500i Cooling Fan 1 0.8 HBC Anti Surge 230v
100m ³/Hr 1 1.0 110v
ES200i Cooling Fan 2 0.8 HBC Anti Surge 230v
200m ³/Hr 2 1.0 110v

NOTE: All maintenance or minor work (except for filter changes) should be carried out
by Markem-Imaje appointed engineers/electricians.

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Section 2 Installation

2.1 Introduction

When a component is laser marked, an amount of the substrate surface is

thermally decomposed or ‘burnt off.” This thermal decomposition comprises a
mixture of particulate and gaseous compounds. The heat energy of the laser
causes the gases and surrounding air to quickly expand, moving away from the
surface at high velocity, and entraining any particulate matter with the gases.
This is the ‘fume.’

There are two main reasons for capturing the fume:

1. Operational – If ignored, the fume can settle on the laser optics,

causing damage to the lens and impairing the quality of the marking.
2. Health and Safety – The particulate generated from most materials is
sub-micron in size, which is a health hazard if inhaled, and some
materials give off harmful gases, which again, operators need
protection from.

The ES range of extraction units is suitable for extracting the fume from laser
marking applications, capturing it in the multistage filter system, and returning the
associated clean air back into the workplace. Please note the media in the gas
filters fitted in these units is capable of absorbing a wide range of organic
compounds. However it is the responsibility of the user to ensure it is suitable for
the particular application it is being used on.

2.2 Fume Capture

The fume is normally captured by one of two methods: either a flexible arm and
nozzle close to the marking point, or an enclosure around the marking area.

2.2.1 Arm and Nozzle Extraction

For most applications, the product to be marked on a conveyor will move past the stationary
laser. The nozzle should be positioned as close as possible to the marking area on the side of
the laser the product is moving toward (Figure 1).

Figure 1

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 Purge air should be kept to a minimum, where possible, to prevent the fume from
being blown away from the nozzle.

High speed bottling lines may need bigger scoops or nozzles for both sides of the
bottles, due to the turbulence caused by the speed of the bottles.

2.2.2 Enclosures

Extraction can be attached to an enclosure around the marking zone, provided the extraction
point is situated within 50-75mm of the marking point (Figure 2).

Figure 2

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 2.3 Extractor Overview

The ES500 and ES500i are units providing extraction and filtration of the fume generated by the
SmartLase or 7031 series lasers, the ES500i incorporating a clean air supply for cooling the
laser. The units are robustly designed, easy to use, and require minimal maintenance. The main
components are shown in Figure 3.

Figure 3

1. Unit/ Filter condition Display / Flow controller

2. On/Off Switch
3. Filter compartment Latch
4. Filter Compartment Door
5. Motor Cooling In/Out
6. Hose Inlet Connection
7. Signal/Interface Cable To Laser
8. Power Cable
9. Clean Air Connection (Model ES500i Only)
10. Cooling Air Inlet (Model ES500i Only)

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The ES200i is a similar unit to the ES500i but is designed for light to medium applications. The
main components are shown in Figure 4.

1. Unit/Filter Condition Dis play

2. On/Off S witch
3. Filter Compartment Latch
4. Clean Air Connection
5. Hose Inlet Connection
6. Signal Interface Cable to Laser
7. Power Cable

Figure 4

2.4 Extractor Installation Procedure

Use the following procedure to install the extractor:

2.4.1 Moving the Unit

Move the unit to the location where it is going to be installed, and remove the unit from its
packaging.

2.4.2 Spacing
A 0.5m space must be available around the louvered areas of the unit to ensure good air flow.
Lock the two castors with the brakes.

2.4.3 Hose Kit (Figure 5)

The ‘stay-put’ arm should be mounted as close as possible to the marking point using the horse
shoe clips. Unscrew the push fit connector from the other end of the flexible hose, and cut the
flexible hose to match the distance back to the extractor suction connection (back at the bottom
on the ES500 and ES500i; lower connection on the ES200i). Keep it as short as possible; then
refit the connector and push it onto the extractor suction connection.

Figure 5

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 2.4.4 Cooling Air Kit (Not Required for ES500)
Remove the fan grill from the rear of the laser and fit the appropriate elbow to the back of the
laser unit (larger flange on the SmartLase 110; smaller for the SmartLase 130), using the original
screws to retain it. Push one of the cuffs on the flexible hose onto the adapter. Unscrew the cuff
of the other end of the flexible hose and cut the hose so that it just reaches the higher of the two
connections on the side of the extractor unit. Refit the cuff and push fit it onto the extractor.

2.4.5 Power Cable

Check the integrity of the electrical power cable.

CAUTION: Test that the main input at the isolated supply is the same as the voltage on the
serial number label.

Connect the power cable to an isolated supply.

WARNING: Concerning the main voltage, dangerous voltages exist in this equipment.
Ensure all covers are fitted before operating this equipment.

2.4.6 Electrical customisation

ES200i and ES500i – Filter blocked signal.

The extraction unit is fitted with a pressure transducer to monitor the condition of the filters and to
indicate that the extractor is running. In addition to controlling the LEDs on the front of the unit,
this signal is available via the green and white core cable that exits the cabinet next to the power
cable. The signal is a ‘volt free’ contact. This is a closed circuit that will exist between the green
and white wires when the filter condition is good and the unit is running. It will change to an open
circuit on filter blockage or system failure.

This cable should be connected across the remote interlock (b) on standard SmartLase units, see
figure 5-1 and across connection 5 on washdown units, see figure 5-2.

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Figure 5-1

Figure 5-2:

ES500 – Filter blocked signal and remote Start/Stop.

The ES500 has a 5 pin connector, see figure 5-3, next to the power cable and should be
connected to the Markem-Imaje 7031 Laser, using connector cable, Part number A70148, as
detailed below

Connection to stop the laser when extractor is not producing any suction

Alarm output
3-5 open when filter is COM 5 J2/14 ou J2/15 : +24 V DC
clogged or filter unit NO 3
not running (no Fault
suction)
0 V DC

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Connection to synchronize the start and stop of extractor with laser Markem-Imaje 7031.

Extractor enable: dry

Extracteur 1 J2/28 : COM contact is closed when
2 J2/29 : NO laser starts (runs)

Connection

There is an override switch in the extractor, see figure 5-3, which can be accessed by
removing the front panel, which must be in the ‘OFF’ position to allow remote Stop/Start.

Figure 5-3

Remote Connection
5-pin connector (M12-male), Turck RS4.5T (Eurofast) or equivalent.

Figure 5-4

2.4.7 Misuse
WARNING: If this equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.

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 Section 3 Operation

3.1 Powering the ES Units

The ES500 and ES500i units are powered on by pushing the green button on the front of the
extractor. They are powered off by pressing the red button below the green button.

The ES200i unit is powered on and off by the illuminated red rocker switch at the back of the
extractor.

3.2 Filter Condition and System Failure Indicators

The LEDs on the front panel (Figure 6) indicate the following conditions:

Figure 6

The ES500i has a fourth LED labeled Cooling Filter Blocked which will illuminate when the
clean air filter needs replacing, “clean air filter” replacement is the correct action when the LED
illuminates.

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 3.3 Setting the Airflow /Closed Loop Auto Flow Control

With this fitted the unit features closed loop automatic flow control. This enables you to set the
required airflow rate. When filters start to block, the blowers in the extractor will increase in speed
compensating for any loss in performance. The extractor must be fully installed, with all pipe work
connected before setting the airflow.

Setting the Airflow

To set the airflow on your extractor, hold down the Up (+) and Down (-) arrows on the front panel
for 5 seconds. (See fig 8) The green LED will now start to flash, indicating that the machine is
now in set mode. You can now increase or decrease the flow by holding down either the up or
down arrow. The flow is indicated by a row of 6 blue LED’s on the panel, 6 being full speed and 1
being the lowest. Set the airflow on the lowest of the 6 LED’s but still ensure that all of the fume is
being removed. This will vary from application to application. Once you have set your speed,
leave the controls for 10-20 seconds and the machine will return to operation mode. (This setup
procedure should be carried out with all the ductwork connected and (if fitted) the stop/start signal
present)

3.4 PVC Version

Units for PVC applications are equipped with VOC/HCL sensors to detect the level of Volatile
Organic Compounds and/or Hydrogen Chloride in the exhausted air. If their presence exceeds a
preset level, an additional red light on the front of the unit will illuminate. This indicates that the
gas portion of the combined filter is saturated and the filter needs replacing.

NOTE: On initial start-up, the light will illuminate, and it may stay illuminated for up to 45
minutes while the sensor reaches its operating temperature. The sensor needs replacing
after approximately 18 months. This will be indicated by the red light staying illuminated,
even though the filter is known to be serviceable.

3.5 Cleaning

The units can be cleaned by using any good quality propriet ary stainless steel cleaner.

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Section 4 Preventive Maintenance

4.1 Preventive Maintenance Procedures

Maintenance consists of replacing filters only. Replace the filters annually or

when the filter change indicator is activated.

4.2 Filter Change Procedure for Models ES500 and ES500i

4.2.1 Clean Air Filter, See Chapter 4.6 for Part Number (ES500i only) (Figure 7)

When the fourth LED on the front of the unit comes on, it is time to change the filter.

1. Turn off the electrical supply to the extractor. Disconnect the power supply.
2. Open the front door of the extractor, by turning the door latches through 90°
3. The filter can be seen at the top of the extractor.
4. The filter is removed simply by pulling it from its frame.
5. A new clean filter can now be fitted.
6. Close the door and secure using the door latches.
7. Reconnect the electrical supply and turn on.

Figure 7

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 4.2.2 Pre-filter Replacement, see chapter 4.6 for part number (Figure 8)

The filter needs changing when the filter change signal is activated and/or the green, amber, and red
LEDs on the unit are illuminated. Isolate the electrical supply to the extractor.

CAUTION: When changing used filters, always wear the appropriate mask, safety glasses, and
gloves.

1. Turn off the electrical supply to the extractor. Disconnect the power supply.
2. Undo the two latches on the front of the unit by turning them through 90°, and then open the door.
3. The pre-filter is the lower of the two filters (Figure 8).
4. Slide the filter forwards to disengage it from the inlet connection, and then pull the cartridge out of the
unit.
5. Slide a new filter all the way inside the unit; make sure it is located onto the suction connection.
6. Close the door; fasten the two latches; and reconnect the power supply.

Figure 8

4.2.3 Combined Filter Replacement, see chapter 4.6 for part number
(Figure 8)

The filter needs changing annually or when the filter alarm signal and LEDs do not go off after
changing the pre-filter. Isolate the electrical supply to the extractor.

CAUTION: When changing used filters, always wear the appropriate mask, safety glasses, and
gloves.

1. Turn off the electrical supply to the extractor. Disconnect the power supply.
2. Undo the two latches on the front of the unit by turning them 90°, and then open the door.
3. The combined filter is the higher of the two filters (Figure 8).
4. Turn the handle through 180° Slide the filter out of the unit, holding tightly to the handle on the filter as
it is heavy and will tend to drop when it comes out of the unit.
5. Slide a new filter into position. Turn the handle through 180° to seal the filter.
6. Close the door; fasten the two latches; and reconnect the power supply.

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 4.3 Filter Change Procedure for Model ES200i

4.3.1 Pre-filter Replacement, see chapter 4.6 for part number (Figure 9)

The filter needs changing when the filter change signal is activated and/or the green, amber, and red
LEDs on the unit are illuminated. Isolate the electrical supply to the extractor.

CAUTION: When changing used filters, always wear the appropriate mask, safety glasses, and
gloves.

1. Turn off the electrical supply to the extractor. Disconnect the power supply.
2. Undo the latches on either side of the unit, and lift the motor section off.
3. Remove the filters from the base.
4. Vacuum out any dust in the base.
5. Remove the pre-filter from inside the combined filter, and replace it with a new pre-filter.
6. Locate the combined filter and the pre-filter onto the base.
7. Replace the motor section and fasten the latches.
8. Reconnect the power supply.

Figure 9

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 4.3.2 Combined Filter Replacement, see chapter 4.6 for part number

The filter needs changing annually or when the filter alarm signal and LEDs do not go off after
changing the pre-filter.

CAUTION: When changing used filters, always wear the appropriate mask, safety glasses, and
gloves.

1. Isolate the electrical supply to the extractor. Disconnect the power supply.
2. Undo the latches on either side of the unit, and lift the motor section off.
3. Remove the filters from the base.
4. Vacuum out any dust in the base.
5. Remove the pre-filter from inside the combined filter, and if it is still serviceable, fit it into a new
combined filter.
6. Locate the new combined filter and pre-filter onto the base.
7. Replace the motor section and fasten the latches.
8. Reconnect the power supply.

4.4 Spare filters (Figure 10)

ES500, ES500i
Pre-Filter
ES500, ES500i
Clean Cooling Air Filter

ES200i
Combined Filter

ES500, ES500i
Combined Filter
ES200i
Pre-Filter

Figure 10
4.5 Filter Disposal

Pre- and combined filters are manufactured from non-toxic materials. Filters are not reusable.
Cleaning used filters is not recommended. Disposal of the used filters depends on the material
deposited on them. Refer to the table below for more information:
Deposit EWC Listing* Comment
Non-hazardous 15 02 03 Can be disposed of as non-hazardous waste.
Hazardous 15 02 02 M The type of hazard needs to be identified and
the associated risks defined. The thresholds
for these risks can then be compared with the
amount of materials in the filters to see if they
fall into the hazardous category. If so, the
filters will need to be disposed of in line with
local/national regulations.

*European Waste Catalog

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4.6 Filter Part Numbers

Extractor Item Part Number

ES500i Clean / cooling air filter 10058220
ES500 & ES500i Pre-filter cartridge 10058218
ES500 & ES500i Combined filter 10058219
ES200i Pre-filter 10017601
ES200i Combined filter 10017602

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For Marking & Coding Equipment. Photographs and drawings are not binding in detail. This document
was originally written in English. The English text of this document shall alone be authentic and shall
prevail in the event of a dispute. Markem-Imaje reserves the right to modify the specifications of its
products without prior notice. Any reproduction, even partial, of this document is prohibited.
Translation of the original manual: the original manual (in English) is available on the DVD-ROM
supplied with the printer.
© 2011 Markem- Imaje All Rights Reserved. English version

en September 2011

A43808-A

www.markem-imaje.com
Markem-Imaje S.A.S.
9, rue Gaspard Monge – B.P. 110
26501 BOURG-LES-VALENCE
Cedex – France
Tel 33 (0)4 75 75 55 00
Fax 33 (0)4 75 82 98 32

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