TN-0063-01-Ultra-Press-Packaging-Instructions-1

Scodix Technical Note
TN Number: TN-0063 Date: January, 2019
TN Revision: 01 Rev. description: New technical note
System: Scodix Ultra Press Series and Foil Station
Subject: Packaging Instructions for Scodix Ultra Press and Foil Station
Background
This document provides instructions for preparing the Press system for shipping and for packing
the Press.
Special tools
• Forklift with 5-ton capability
• Pallet jack
• Ratchet band tool
Prerequisites
See page 3
Estimated Time
2 Days (2 personnel)
Technical Note Distribution
Scodix and partners
TN-0063 Rev. 01 Packaging Instructions for Scodix Ultra Press and Foil Station Page 1 of 65
Contents
Overview ..................................................................................................................................... 3
Prerequisites .................................................................................................................................................... 3
Preparing the Press for Packing ................................................................................................... 5

Before You Begin .............................................................................................................................................. 5
Flushing the Ink System .................................................................................................................................... 5
Securing the Bridge........................................................................................................................................... 5
Preparing the Ink Tanks .................................................................................................................................... 7
Starting the Engine Packing............................................................................................................................. 10
Preparing the Feeder ...................................................................................................................................... 12
Preparing the Stacker ..................................................................................................................................... 18
Preparing the Foil Station ............................................................................................................................... 19
Preparing the HMI...................................................................................................................................... 28

Completing the Foil Station Preparations.................................................................................................... 31
Preparing the UV Conveyor ............................................................................................................................. 31
Continuing the Engine Preparation ................................................................................................................. 39
Preparing the ECU .......................................................................................................................................... 41
Completing Preparations for Packaging ........................................................................................................... 44
Loading the Press on the Shipping Pallets ................................................................................. 45

Packing the Accessories on the Pallet .............................................................................................................. 50
Packing Pallet BR-3000 ............................................................................................................................... 50

Packing Pallet BR-1000 ............................................................................................................................... 51
Installing Shipping Restraints and Labels ......................................................................................................... 52
Assembling the Crates .................................................................................................................................... 55
Appendix ................................................................................................................................... 60
Crate BR-1000 ................................................................................................................................................ 60
Crate BR-3000 ................................................................................................................................................ 61
Crates BR-8100 and BR-6000 .......................................................................................................................... 62
Ultra UV Lamp and Quartz Box........................................................................................................................ 63
Foil Unit Crate ................................................................................................................................................ 64
Overview
The Scodix Ultra Press is shipped on three pallets:
• BR-1000: Press Engine and Foil Station accessories
• BR-3000: UV Conveyor, accessories, and UV lamp
• BR-6000: Feeder and Stacker.
If you are packing the Foil Station, contact Scodix headquarters to order the pallet.
Prerequisites
• All relevant FCOs must be installed on the press.
(See the Ultra FCO page and the Foil Station FCO page in the Scodix Knowledge Center.)
• Memory stick
• Scodix Cleaning Fluid 2
• JG-3004-01: ULTRA PRINT TABLE TRANSPORTATION BRACKET
• JG-3000-53: PHS Shipment JIG Assy
• Pieces of cardboard (see page 16)
• Piece of Styrofoam (see page 48)
• KIT-0102-01: for Ultra Press (not including Foil Station), which contains the following:
Part number Part description Qty
HPK-0005-01 Bubble wrap roll 2
HPK-0006-01 Masking tape 4
HPK-0008-01 Blue shrink wrap roll l=100m, w=500mm t=23micron 4
HPK-0012-01 Ultra UV assy crate (BR-3000) 1
HPK-0013-01 Ultra loading system & stacker crate (BR-6000) 1
HPK-0015-01 Ultra engine crate (BR-1000) 1
HPK-0028-01 Ultra UV lamp & quartz packaging box 1
HPK-0029-01 Nylon roll (polyethylene nylon) 100 M x 4 M 2
HPK-0030-01 Dehydrator for 1.5 cubic feet (moisture absorbers) 28
HPK-0034-01 Tilt watch label 3
HPK-0035-01 Ratchet band 35 mm 6
HPK-0037-01 Red shock watch label 3
HPK-0050-01 Temperature measure & record label, 40-71 deg. 1
HPK-0071-01 Safety tag – Remove Before Operating 5
HPK-0073-01 2m strapping band + buckle 2
MBK-0460-41 Flat Philips cone head screw iso 7046 m4x60 150
Part number Part description Qty
Hard Styrofoam 12 x 12 x 12
Note:
If the configuration that you are packing includes the Foil System, contact Scodix
Headquarters to order a second crate (HPK-0028-01) for the UV lamp and quartz glass.
Preparing the Press for Packing
Important!
• Make sure to clean the press thorougly as you prepare it.
• Lubricate non-coated surfaces.
• Label ink hoses and other relevant connections.
Before You Begin

1. Print a signature/nozzle test. You will package it later with the press.
2. Perform a stability test: Run 190 CATP to verify that the press is in top condition.
3. Perform a software backup: Create a backup folder on the PC and backup the print modes,
site config, and log files. In addition, save the backed-up files on a memory stick.
4. Move the front table toward the Feeder.
5. Move the rear table toward the Stacker.
6. To enable connecting the yellow shipping brackets, in GShell, move both tables to the same
height: -12 Zpos.
Flushing the Ink System

• Ultra Pro with SIT type 1: Drain all of the ink tanks and flush the ink system according to
the instructions in TN-0083 Replacing Polymer with a Different Type of Polymer-SIT1.
Start on page 6, and continue through page 10 or 14, according to whether or not you
bypass the SIT.
Note that In step 6 on page 6, you will fill the ink tanks with only 5 kg of Cleaning Fluid 2
(not 10 kg).
• Ultra Pro with SIT type 2: Drain all of the ink tanks and flush the ink system according to
the instructions in TN-0084 Replacing Polymer with a Different Type-SIT2.
Start on page 6, and continue through page 11 or 16, according to whether or not you
bypass the SIT.
Note that in step 6 on page 7, you will fill the ink tanks with only 5 kg of Cleaning Fluid 2
(not 10 kg).
Securing the Bridge

1. In GShell, bring the rear OPA bridge as close as possible to the front bridge.
2. Exit the software and turn off the Press.
3. Wrap the OPA cameras to protect them.
4. Use tie-raps to secure the rear bridge to the front bridge.
5. Add a “Remove tie before operating” tag (P/N HPK-0071-01)
Preparing the Ink Tanks
1. After you have flushed the polymer system (see Flushing the Ink System on page 5), from the
ink cabinet, remove the ink tanks.
2. On each cover, open the 4 screws and remove the cover.
3. Drain the remaining Cleaning Fluid 2 into a suitable waste container.

4. Clean the tank with acetone, IPA, or ethanol (acetone is recommended), and clean room
wipes.
5. Remove the polymer hoses from the waste container. Then label and plug them.
From
separator From
output
manifold
6. Remove the waste container and dispose of it to an approved location (according to the
polymer MSDS).
Note:
The accessories kit contains a new waste container.
7. Disconnect each ink tank’s 2 electrical wires.
8. From each ink tank, disconnect, plug, and label the ink hoses “Tank [#], out/return”.
9. Remove the ink tanks from the press.
10. Clean the ink tanks externally.

11. In the ink cabinet, cut the tie wraps, and then bundle the cables together according to
function. Do not bundle the sensor cables at this time.
Starting the Engine Packing
1. Disconnect the main power cable from the wall outlet.
2. Remove the 2 OS side panels and the 2 NOS side panels.
Then wrap each panel separately in 2 layers of bubble wrap, followed by 2 layers of
corrugated cardboard.
3. Uninstall the monitor and pack it in bubble wrap, and pack it in a box.
4. Disconnect the mouse, wrap it in bubble wrap, and add it to the box.
(Later you will place the box on the pallet with the Engine.)
5. Disconnect the keyboard, place it inside the monitor holder tray, and wrap the holder and
tray in bubble wrap.
6. If the configuration includes a Foil Station, disconnect the following cabels:
• Foil Station main power cable (CBL-4216)
• Interface cable (CBL-4221)
• Main air hose (PIP-0008-01).
Pull the cables and hose out of the Engine, and through the UV Conveyor unit. Then wrap
and secure the them in the Foil Station.
Preparing the Feeder

1. Move the rear feeder assembly and the rear Bernoulli bridge together, lock them, and secure
them together with 2 tie wraps. Place a “Remove Before Operating” tag (HPK-0071-01).
2. On the NOS, disconnect the loader motor power and control cables. Secure the connections
together, wrap the ends in a plastic bag and secure the end of the bag.
3. To access the Feeder connection panel, use the pallet jack to pull out the Feeder slightly.
4. From the rear of the Feeder, disconnect the electrical and pneumatic connections.
5. Secure the connections together, wrap the ends of all of the cables and hoses in a plastic bag
and secure the end of the bag.
NOS
connections
OS
connections
6. To protect the reflector, place a “Remove before operating” tag (P/N HPK-0071-01) over the
reflector, and tape a piece of cardboard over the sticker.
7. Lock the front Bernoulli bridge and secure it with tie wraps.
8. To prevent the sheet separators from bending during shipment, place pieces of styrofoam or
similar, as shown.
9. Wrap the air hose in bubble wrap and secure it with a tie wrap to the front of the Feeder.
10. Wrap the Feeder door handle in bubble wrap.
11. Using the pallet jack, gently and slowly pull the Feeder further out, making sure that there
are no obstacles in the way.
12. When the Feeder is lifted, raise the legs.
Preparing the Stacker
1. To access the Stacker connection panel, use the pallet jack to pull the Stacker out slightly.
2. From the rear of the Stacker, disconnect the electrical and pneumatic connections.
(You will un-route them later.)
3. Lock the Stacker’s levers.
4. Use the pallet jack to raise the Stacker.
5. Gently and slowly, pull the Stacker further out, making sure that there are no obstacles in the
way.
6. When the Stacker is lifted, raise the legs.
Preparing the Foil Station

1. Before moving the Foil Station, disconnect the metal bands from the exhaust ducts. Save the
metal bands.
2. To access connections, use the pallet jack to slightly lift the Foil Station and move it about
50 cm from the UV Conveyor.
3. When the Foil Station is lifted, raise the legs.

4. Disconnect the W6 power cable.
5. Un-route the Stacker connections through and out of the Foil Station (the power,
communication, ground and air that you disconnected in step 2 on page 18).
6. In the UV Conveyor Unit, disconnect cables W2, W3, W4, and W5, route them back to the
Foil Station ECU, and wrap and secure them.
W4 W2, W3
W5
7. In the UV Conveyor Unit, from the blower, disconnect W8, route it to the Foil Station ECU,
and wrap and secure it.
8. Uninstall the electronic power supply (EPS):
a. Disconnect the cables (W7, W5, and grounding). Then route them to the ECU, and wrap
and secure them.
Ground
W5
W7
W7
b. Uninstall the electronic power supply (EPS), and wrap it in bubble wrap.
c. Uninstall the cable guide.
9. Disconnect the UV exhaust:
a. Disconnect the ducts and pack them in bubble wrap or a cardboard box to prevent
damage.
Note:
Remember to pack the metal rings that you opened earlier.
b. Uninstall and pack the UV exhaust cabinet.
10. In the UV Conveyor, uninstall the encoder:
a. On the encoder bracket, open the 4 screws and remove the encoder with its bracket.
b. Open the 2 screws, and then open the setscrew.
c. Remove the encoder with the cable, pull the encoder cable through to the Foil Station,
and wrap the encoder and encoder bracket inside the Foil Station’s ECU.
11. Pack the blower and transfer the metal elbow:
a. Disconnect the metal elbow from the secure UV housing.
Do not pack the metal elbow—you will install it in the UV Conveyor unit.
b. Disconnect the blower from the activate UV housing in the UV Conveyor unit. Pack the
blower with the Foil Station.
Note:
Make sure the pack the blower’s bracket along with the blower
c. In the UV Conveyor unit, mount the metal elbow in the activate UV housing.
12. On the Foil Station’s secure UV lamp housing, disconnect the 2 secure UV sensor cables,
route them to the UV Conveyor’s ink cabinet, and secure them with tie wraps.
13. Pack the UV lamp tray, lamp, and quartz glass.
a. Remove the lamp, mark it “Secure”, and remove the quartz glass.
b. Pack the UV lamp tray, lamp, and quartz glass in box HPK-0028-01.
Preparing the HMI
To enable the Foil Station to fit inside the crate, remove the HMI operator panel and bracket:
1. Open the 4 screws and remove the operator panel.
2. Place the operator panel upside down on bubble wrap or similar to protect it from scratches.
3. Disconnect the communication cable, the HMI power line, and the ground wire.
4. Disconnect the emergency stop (E-stop) switch from the emergency button.
5. Open the 4 screws and remove the metal box.
6. Open the black plastic nut to release the hose, and then pull the panel wires into the Foil
Station.
7. Secure the panel wires and the hose under the Foil Station conveyor with tie wraps.
8. Pack the HMI inside the Foil Station ECU.
Completing the Foil Station Preparations
1. On the OS, remove the Foil Station doors.
2. Install the yellow rectangular lifting brackets (marked B) and the 2 support brackets
(marked A).
Note:
You will reinstall the doors after placing the Foil Station on the shipping pallet.
B B
3. Make sure that all Foil Station cables are secured in the ECU or underneath the conveyor.
Preparing the UV Conveyor

1. Reinstall the ink tanks.
2. To access connections, use the pallet jack to slightly lift and move the UV Conveyor away
from the Engine.
UV Conveyor Engine
3. When the UV Conveyor is lifted, raise the legs.

4. Disconnect the sensors:
a. From the UV lamp housing, disconnect the activate UV sensors.
b. Unroute the sensors to the Foil Station, and secure them.
5. Unroute the Stacker connections through and out of the UV Conveyor toward the Engine.
Then wrap, mark, and secure in the Engine ECU.
Stacker
connections
6. From the UV Conveyor’s entrance side, disconnect the air and ground connections, and wrap
and secure them in the ECU.
7. On the NOS, in the UV Conveyor cabinet, disconnect the following electrical cables, and then
wrap and secure them in the ECU.
a. Disconnect the main UV power cable.
b. From the MUC, disconnect CBL-4031 SUB D1 and CBL-4210 SUB D2.
c. Disconnect the conveyor motor cable CBL-4038 (SK UV conveyor) Molex.
d. Disconnect grounding wires.
8. On the OS, in the ink cabinet, disconnect the following:
• 4133 Ink UV 24 VDC power
• 4037 UV/Ink cabinet JMB
9. Remove the UV lamp tray, lamp, and quartz glass.

a. Remove the UV lamp tray, mark it “Activate” or “Secure”, as relevant, and remove the
quartz glass.
b. Pack the UV lamp tray, lamp, and quartz glass in box HPK-0028-01.
10. Pack the ink bath:

a. Disconnect the ink bath waste hose, and drain the residual polymer from the waste hose.
b. Disconnect the 4 Allen screws that secure the ink bath, remove the ink bath, and
package it separately.
Note:
To avoid losing the screws, reinstall them underneath the conveyor.
c. Wrap the ink bath in 2 layers of bubble wrap, followed by 2 layers of corrugated
cardboard.
11. With the pallet jack, lift the UV Conveyor slightly and move it completely out of the Engine.
Continuing the Engine Preparation
1. Make sure that the gripper is in up position, and secure it with 2 large tie wraps to prevent
movement during shipment. Add a sign “Release Before Operating”.
Gripper in
up position
Gripper
secured and
marked
2. With the blue sponge underneath the bridge, install the print head protection cover and
bracket (JG-3000-53):
Print heads
protection
cover
Print heads
protection
bracket
3. Install the front and rear table protection brackets (JG-3004-01).
Front table Rear table

protection bracket protection bracket
Preparing the ECU
1. Wrap and secure the network cable.
2. Turn off all of the circuit breakers.
3. Verify that in the terminal blocks, all wiring is secure.
4. Pack and secure the PC:
• Use ratchet bands to secure the PC in place
or
• Disconnect the wiring from the PC, wrap and secure it in the ECU.
Then uninstall the PC and pack it in an appropriate box.
5. Lock the ECU front door.
6. Reinstall the ECU panel.
Completing Preparations for Packaging
1. Lift the Engine, remove the feet pads, (and spacer if relevant) and package them separately.
2. Using a 35-mm ratchet band, secure each Press unit (as shown following for the Stacker).
Loading the Press on the Shipping Pallets
The wooden boards on the pallets (see the diagrams in the Appendix) prevent the machine units
and systems from shifting during shipment. Make sure to position the press units correctly on
the pallets.
Note:
If “Front” and “Rear” are not printed on the pallet, use a marker to mark “Front” and “Rear” on
the outside of the pallet.
1. Place a large piece of polyethylene nylon centered on each shipping pallet.

It will be used to cover the Press units.
2. Move the Press units to the packing area.
3. Using a forklift, place the Feeder and Stacker on pallet BR-6000.
Note:
The existing wooden block supports the Feeder. The wooden block underneath the Stacker is
added after the Stacker is loaded.
Added Existing
a. Make sure that the Feeder handle is not too close to the edge of the pallet.
b. Attach brackets to the Feeder and Stacker feet. Under each bracket, insert a nut on the
foot and then secure each bracket to the pallet with 4 screws.
4. Using a forklift, place the Engine on pallet BR-1000.
a. Pallet BR-1000 for the Engine has 3 holes for the 3 5/8x400 bolts that secure the Engine’s
feet to the pallet. There is no bolt for the ECU, so position the Engine so that the ECU is
over the area without the opening.
Before lowering the Engine, make sure that the feet bolts are positioned over the
openings.
b. Secure each bolt with 2 nuts and 2 washers.
5. Using a forklift, place the UV Conveyor unit on pallet BR-3000. Make sure that the support
with the Styrofoam buffer supports the conveyor.
a. If necessary, add another piece of styrofoam between the styrofoam buffer and the
conveyor.
Add styrofoam
here, if necessary
b. Attach brackets to the UV Conveyor unit’s feet, secure each bracket to the pallet with 4
screws, and insert a nut on the foot underneath the bracket.
6. Using a forklift, place the Foil Station on the “Foil Unit” pallet.
7. Reinstall the Foil Station doors.

8. On each pallet, place 8–10 moisture absorbers (dehydrator - HPK-0030-01).
Packing the Accessories on the Pallet
Packing Pallet BR-3000
1. Place the accessories, substrate, and computer under the conveyor, and the UV lamp on the
other side of the conveyor support.
Added buffer
Buffer
Conveyor
Accessories support
Computer
Substrate
UV lamp box
2. Secure the UV lamp box to the pallet with 2 screws.
3. Secure the accessories to the UV Conveyor press unit with plastic wrap.
Packing Pallet BR-1000

1. On pallet BR-1000, pack the box with the computer monitor and mouse.
2. If you are packing the Foil Station, on pallet BR-1000, pack the Foil accessory kit, exhaust
ducts, and so on, with the Press Engine. (The Foil Station will be packed on a different pallet.)
Foil accessories
Foil UV lamp
Foil UV lamp
housing
3. Place the wrapped press panels and the ink bath on the pallet where space permits, either
together or separately.
4. Wrap all items on the pallet with plastic wrap.
Panel
Installing Shipping Restraints and Labels

1. On the ECU, affix the temperature label (HPK-0050-01) above the Scodix nameplate.
2. Secure each of the 2 Press Engine covers with a restraining belt.
3. Attach the "Caution: Remove tie before operating" tags (HPK-0071-01), as shown.
4. On the UV Conveyor, wrap the wheels with bubble wrap.
5. On the UV Conveyor, place a sample of the nozzle test.

6. Using two plastic bands, secure the UV Conveyor cover.
Band to
Band to
secure cover
secure cover
Nozzle test
Assembling the Crates
1. Attach the 2 narrow crate walls to the pallet base using 5/16*90 screws.
2. Attach the 2 wide crate walls to the pallet base and to the narrow crate walls using 4*70
screws.
3. Attach the support beams to the top of the crate, and then cover the crate with Polyethylene
nylon.
4. Attach the crate top to the walls.
5. Secure the crate with two 32-mm plastic bands.
6. On each crate, on one of the wide crate walls, stick center-of-gravity stickers in the relevant
location.
7. On each crate, on the right side of one of the wide crate walls, and on the left side of one of
the narrow crate walls, stick ShockWatch, TiltWatch (HPK-0034-01), and this-side-up stickers.
On each crate, mark on all walls: “UNPACK BY AUTHORIZED PERSONNEL ONLY
8. On each crate, affix a label to each crate with the name of the press unit and its serial
number.
9. With the forklift, lift the crates onto the truck, and secure the crates so that they will not
move.
Appendix
Crate BR-1000
Crate BR-3000
Crates BR-8100 and BR-6000
Ultra UV Lamp and Quartz Box
Foil Unit Crate
Document History
Rev Written / Date Approved by Remarks

updated by
01 Bar K., Nissim J., 10-01-2019 Yuval L. New Document
Patti S.

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Scodix Technical Note

TN Number: TN-0063 Date: January, 2019

TN Revision: 01 Rev. description: New technical note

System: Scodix Ultra Press Series and Foil Station

Preparing the Press for Packing ................................................................................................... 5

Preparing the HMI...................................................................................................................................... 28

Loading the Press on the Shipping Pallets ................................................................................. 45

Packing Pallet BR-3000 ............................................................................................................................... 50

Part number Part description Qty

HPK-0005-01 Bubble wrap roll 2

HPK-0006-01 Masking tape 4

HPK-0008-01 Blue shrink wrap roll l=100m, w=500mm t=23micron 4

HPK-0012-01 Ultra UV assy crate (BR-3000) 1

HPK-0013-01 Ultra loading system & stacker crate (BR-6000) 1

HPK-0015-01 Ultra engine crate (BR-1000) 1

HPK-0028-01 Ultra UV lamp & quartz packaging box 1

HPK-0029-01 Nylon roll (polyethylene nylon) 100 M x 4 M 2

HPK-0030-01 Dehydrator for 1.5 cubic feet (moisture absorbers) 28

HPK-0034-01 Tilt watch label 3

HPK-0035-01 Ratchet band 35 mm 6

HPK-0037-01 Red shock watch label 3

HPK-0050-01 Temperature measure & record label, 40-71 deg. 1

HPK-0071-01 Safety tag – Remove Before Operating 5

HPK-0073-01 2m strapping band + buckle 2

Before You Begin

Flushing the Ink System

Securing the Bridge

4. Use tie-raps to secure the rear bridge to the front bridge.

5. Add a “Remove tie before operating” tag (P/N HPK-0071-01)

3. Drain the remaining Cleaning Fluid 2 into a suitable waste container.

9. Remove the ink tanks from the press.

10. Clean the ink tanks externally.

Preparing the Feeder

10. Wrap the Feeder door handle in bubble wrap.

12. When the Feeder is lifted, raise the legs.

3. Lock the Stacker’s levers.

Preparing the Foil Station

3. When the Foil Station is lifted, raise the legs.

c. Uninstall the cable guide.

b. Uninstall and pack the UV exhaust cabinet.

b. Open the 2 screws, and then open the setscrew.

8. Pack the HMI inside the Foil Station ECU.

Preparing the UV Conveyor

3. When the UV Conveyor is lifted, raise the legs.

b. Unroute the sensors to the Foil Station, and secure them.

d. Disconnect grounding wires.

9. Remove the UV lamp tray, lamp, and quartz glass.

10. Pack the ink bath:

3. Install the front and rear table protection brackets (JG-3004-01).

Front table Rear table

2. Turn off all of the circuit breakers.

3. Verify that in the terminal blocks, all wiring is secure.

6. Reinstall the ECU panel.

1. Place a large piece of polyethylene nylon centered on each shipping pallet.

2. Move the Press units to the packing area.

b. Secure each bolt with 2 nuts and 2 washers.

7. Reinstall the Foil Station doors.

2. Secure the UV lamp box to the pallet with 2 screws.

Packing Pallet BR-1000

Installing Shipping Restraints and Labels

5. On the UV Conveyor, place a sample of the nozzle test.

4. Attach the crate top to the walls.

On each crate, mark on all walls: “UNPACK BY AUTHORIZED PERSONNEL ONLY

Rev Written / Date Approved by Remarks