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1 - DK1100A English Manual
1 - DK1100A English Manual
Operation Manual
All systems and supplies, whether considered hazardous or not, should be used in
accordance with principles of good manufacturing practice.
4. TROUBLE-SHOOTING4-20
9. MAINTENANCE CARD----------------------------------------------------------------------------------------------------9-1
1. GENERAL & SAFETY INFORMATION
This handbook aims to introduce how to install, operate and maintain the DK-1100A High-speed Ink
Roll Coder safely.
Thanks for choosing DIKAI as your supplier. Any problems, please contact the local office or
distributor that will provide you with instant and ideal service.
Labels
There is a label on the back panel of the Control Box (see below for label description).
Model Number
Factory Location
Serial Number
Electricity Requirements
Producing Year
DK Logo
Contact Information
CE Label
DK-1100A Ink Roll Coder Operation Manual
Before operating this unit, read this manual thoroughly. Pay particular attention to the WARNINGS
AND CAUTIONS to prevent possible injury to personnel.
DANGER: Automatic packaging machine start-up after a printer reset! Install the printer Fault Output
Signal for manual packaging machine reset. Automatic start-up of a packaging machine could kill or
seriously maim an operator.
The printer installer is responsible for implementing the Fault Output Signal in a way that requires
the operator to manually restart the packing machine after a printer condition has been cleared. Any
deviation from this method is unsafe and is not approved by DIKAI or applicable regulatory
agencies.
The DK-1100A printer has an optional feature which enables it to stop or prevent packaging
machine operation when printer conditions prevent marking the packages. These conditions include,
but are not limit to, FAULT, WARMUP PERIOD and PRINT DISABLED STATUS. Some of these
printer conditions are cleared manually by the operator, and some are cleared automatically. In
either case, if the printer has not been properly connected, the packaging machine can begin
cycling when the condition is cleared. Failure to observe this may result in personal injury.
There are various ways for an installer to use the DIKAI printer Fault Output Signal to control a
packaging machine. Only someone familiar with the packaging machine can determine the best way
to signal it with an external device like the DIKAI printer. If doubt, consult the manufacturer of the
packaging machine.
WARNING: line voltages. Remove the power line cord AND the fault cable from the control box
before repairing the DK-1100A printer. Failure to do so can result in serious injury from an electrical
shock.
NOTICE: Failure to install the ground wire may result in random machine shutdown. Make sure to
install the ground wire to the control box.
IMPORTANT: Never connect or disconnect the cables to the DK-1100 A control box with the power
on. Damage to the electronics may occur.
IMPORTANT: DO NOT operate the DK-1100A during the warm up period. It takes 15-20mins to
reach operating temperature.
IMPORTANT: DO NOT touch the Print Head during the heating status, it may result in injury.
IMPORTANT: DO NOT run the printer when any covers are taken off.
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DK-1100A Ink Roll Coder Operation Manual
Safety Labels
This label is located on the back panel of Control Box. This label warns the operator that the printer
should be well ground connected.
This label warns the operator to repair the printer after disconnecting the power.
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DK-1100A Ink Roll Coder Operation Manual
2. PRODUCT DESCRIPTION
DK-1100A is an electronic continuous motion coder designed to print an area as described in the
DK-1100A Machine Specifications. The DK-1100A will product imprint on all common packaging
materials at rates up to 300 prints per minute and at film speed up to 35meters per minute with
below features:
Stable Printing
Simple Installation
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DK-1100A Ink Roll Coder Operation Manual
Diagram 1
1. The Types contact the Hot Ink Roll and get the ink;
2. The Types are driven by the Rubber Wheel and Pressure Roller to continue moving, then touch the
packing film to produce imprint.
3. The Rubber Wheel and Rubber Roller must keep in good contact to ensure the clarity and
consistency of the printing.
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Diagram 2
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Diagram 3
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Radial = 45.5mm
≥75mm(2-up printer)
Left-hand (Counter-clockwise)
Electrical AC100-AC230V,50/60 Hz
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DK-1100A Ink Roll Coder Operation Manual
3.1 Installation
At the very beginning of the installation, manually check the home position, that is the Hot Ink Roll,
Rubber Roller and Pressure Roller should be in position as diagram 4. The rubber wheel can not
touch pressure roller or packing film. Otherwise, it will cause failed or missed printing.
Diagram 4
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Diagram 5
3.14 Installing the Control Box
IMPORTANT: Mount the control box away from potential sources of water spray or cleaning
solutions. The control box connectors are not sealed from harsh
environments.
Install the print head cable to the print head, as below diagram.
: This cable has 3-pin plug-in, can input print signal. Match the proximity sensor to
I/O cable:
the correct color wires. Refer to Diagram 6.
Drive cable: This cable has 7-pin plug-in, connecting the print head and the control box.
Power cable: This cable has plug-in and three wires, connecting the control box and power
supply. The cable can get the power supply from packaging machine.
IMPORTANT: Never connect or disconnect the cables to the DK-1100A control box with the
power on. Failure to do this may result in personal injury.
Diagram 6
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DK-1100A Ink Roll Coder Operation Manual
Proximity Sensor Use an inductive proximity switch to sense a rotating or moving metal
device such as a vane, bolt head, or cam lobe.
1. Connect the proximity switch with the I/O cable.
2. Mount the proximity switch in front of a lug or vane (around 15mm
wide) that will make one actuation for each product.
3. Position the mounting nuts on the proximity sensor so that the
switch end is not further 2mm from the vane or lug.
Photo Sensor Use a photo sensor to sense the marking in the packing film.
PLC Use a contact closure as the print go sensor. Connect the blue wire to
one terminal and black wire to the other terminal of a normally open
voltage free contact.
IMPORTANT: Keep the correct switch position (as Diagram 7) before installing the sensors or
getting print signal from PLC of packaging machine.
Refer to Table 1.
Diagram 7
SIGNAL POSITION
1 2 3 4 5
NPN Sensor ON OFF ON OFF ON
PNP Sensor OFF ON OFF ON ON
PLC Electrical Signal OFF ON OFF ON OFF
Table 1
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DK-1100A Ink Roll Coder Operation Manual
J1 J6 J3 J8 J7 J11
DK1100A SW1
J4
J5
W4
J5′
LED Board
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3.1.7 Interfaces for External Signal, Encoder and Fault Output Signal
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3.2 Relocation
Diagram 10 Diagram 11
3.2.2 Relocating the Pressure between Pressure Roller and Rubber Wheel
As diagram 12, the pressure and parallelism between pressure roller and rubber wheel can be
relocated by adjusting the screws and the horizontal position of adjusting wedges. This relocation makes
the correct position between pressure roller and rubber wheel, to get legible prints. When relocating, the
operator can press the test button in the control box to make type holder rotate and check whether the
pressure and position is correct.
Adjusting wedge
Diagram 12
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DK-1100A Ink Roll Coder Operation Manual
3.2.3 Relocating the Pressure between the Ink Roll and Types
IMPORTANT: Poor pressure between the ink roll and types can result in un-clear or missed prints.
1- Use the 6mm Allen wrench to take out the Allen screw in the body of print head.
2- Loose the inside M5 Allen screws.
3- Take the ink roll out, rotate the ink roll shaft manually to relocate the space between ink roll shaft and
ink roll (the ink roll shaft is eccentric).
4- Put in the ink roll to check whether the pressure is correct; if not, repeat step 3 & 4 till the pressure is
correct.
5- Tight the M5 Allen screw.
6- Reset the M8 Allen screw.
1- Install the type on the pins of the type holder. Secure the type to the type holder pins with the
type stoppers. Two type styles are available, depending on which way the print is oriented on
the web- radial (for printing with the web), and axial (for printing across the web).
2- Align the type holder to the type holder shaft. Push the type holder into the print head and
turn until it seats into place.
IMPORTANT: The PREHEATER is an optional part to preheat the ink roll and reduce the stand-by time
of the production line.
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DK-1100A Ink Roll Coder Operation Manual
Print indicator
Signal indicator
Heat Indicator
Print Position
Fix Delay Indicator
TMP Setting Button Test Button Print Button
Print delay position display In fix delay mode: delayed time ; the unit is ms
Heat Indicator light When the machine is heating, heat indicator light will be on
Fix delay indicator light The light will be on when it is in fix delay mode
Temperature setting button To set the operating temperature for the heater block
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DK-1100A Ink Roll Coder Operation Manual
Test button In standby mode, press the button and one print is completed
In Auto-track mode, printing position is adjusted by setting the percentage of delayed printing cycle, that
adjusting the percentage of the time of received two printing signals. The printing position could be the
same and accurate on the packages of the same packing length, even if the packing speed changes.
But the print of the first package is unable to be given the right order by the coder due to the failure of
coder's detecting the speed of packing machines. We integrated the domestic use of most of the
packaging machines and set a virtual speed (200 packs / min) in the program to control the printing
position of the first package. In this case, the printing position of the first package is not necessarily
correct.
When the packing speeds is less than 60 packages / minute, the interval time of received signals is over
1 second, then the state of packaging machine is default as downtime. When receiving another
printing signal, the coders print regarding it as the first package, with speed up to 200 packages / minute.
The range of printing position adjustment is 300ms only.
In fixed delay mode, the printing position adjustment is controlled by adjusting printing delayed time. The
Maximum delayed time is 4995ms. Adjusting it when its printing rate reaches 12 packs / minute to 60
packages / minute ensures print on the packages anywhere. In fixed delayed mode, the printing
position will result in displacement accordingly as per different linear velocities. And the displacement
range of printing position each time will be different unless the speed of packing machine is stable.
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4. TROUBLE-SHOOTING
Incorrect The type holder is Tight the tension of the belt wheel. Tight the screw in
Printing slipping. the main shaft.
Positions
Unstable print signals Adjust to get the stable print signals.
No display in the LED Check the power supply
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5. ROUTINE MAINTENANCE
Make sure to clean ink accumulations from the type holder and heater block at least
once a week. Use only a rag and blunt, non-metallic, non-marking scraper to prevent
damage to the anodized aluminum surface. Ink buildup on the heater block will
insulate the ink roll from reaching the correct operating temperature.
※ Do not use sc rewd rive rs , pliers or othe r tools to p ry types with ink
accumulations, which c ould do ha rm to type holder.
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Note: “***” is the PN of standard bracket indicates the length, shall be filled in when doing order. Take
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Item Qty. Part No. Description
bearing)
21 1 Y9900106 Eccentric Sheath
22 1 C9900052 Baffle Shaft
23 1 C9900001 Magnetic Solenoid
24 1 Y9900105 Back Board
25 1 Y9900055 Airframe
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26 1 Y9900032 Back Canopy Board
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DK-1100A Ink Roll Coder Operation Manual
Revision
Update Date Manual Edition Revision Content Description
Department
Technology
2010/12/21 V1.0 Stoppage of publication
department
Technology
2011/03/15 V2.0 Stoppage of publication
department
Technology
2011/04/1 V2.1 Official publishing edition
department
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DK-1100A Ink Roll Coder Operation Manual
Use for ink roll coding machines to print production date, batch NO and other related information on such
materials as plastic film, paper, etc. With the characters of easy-to-use and non-toxic, the ink roll is able to
produce at high speed with instant dry and highly legible printing that has a good adhesion for a longer usage
life.
( mm)
Standard Dimensions( ):36×
×10 ×16
36× ×32
36× ×35
36× ×40
36× ×45
36× ×40mm。
40× 。
1、Adopt the appropriate ink roll according to the packing materials and production requirements
2、Set temperature value of the coder according to temperature range. Generally,the setting temperature
should be the minimum temperature of the range values to ensure normal melting
3、The ink roll is unable to use until completely melted after being preheated for 5 to 10 minutes
4、Relocate the pressure between the types and ink roll when adopt the new ink roll.
5、The coder could fade gradually after a certain amount of prints,in which case, the temperature of the coder
could be increased to make the letters more legible .
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6、Keep continuous use as far as possible to get more printing times. Intermittent use will result in reduction in
its life
7、The ink roll will become softer when it turns cold after full use. Please improve the method of application if it
remains hard. Generally too low temperature would cause to insufficient use
8、Increase the working temperature of the ink roll accordingly when it is in the status of low temperature or
high speed coding.
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5. MAINTENANCE CARD
Maintenance Card
Vice Alliance(customer retention)
No.:
Customer: Tel:
Add: Fax:
Fault Description:
When contacting DIKAI for maintenance, please give the above card together with the printer.
Warranty Receipt
No.:
Customer: Tel:
Add: Fax:
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After being filled, this receipt should be submitted to DiKai workers or be faxed/emailed to DiKai
customer service center. Otherwise, DiKai consider user give up repair right voluntarily.
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