Z3000 Training Manual PDF

Training Manual
Z 3000
REL 1.00
Z3000
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Training Manual
Z 3000
Procedures in this manual should be performed only
by trained people
Head Oce: Branch Oces:
Zanasi ITALIA Zanasi, Milano

via Marche, 10 - Sassuolo (MO) - Italy via Newton, 9 - Pero (MI) - Italy
Tel: (+39) 0536 999711 Tel: (+39) 02 35.36.593
Fax: (+39) 0536 999765 Fax: (+39) 02 35.39.942
www.zanasi.it - info@zanasi.it www.zanasi.it - filialemilano@zanasi.it
Zanasi USA
8601 73rd Ave. N. Ste. 38 Brooklyn Park, Mn 55428
Tel: (001) 763.593.1907
Fax: (001) 763.593.1907
www.zanasiusa.com - info@zanasiusa.com
Zanasi CHINA
Zhongcun KaiFaQu A Qu, 511495 Panyu - GZ
Tel: (+86) 20 61.96.20.01
Fax: (+86) 20 23.83.32.11
www.zanasichina.com - info@zanasichina.com
Z3000
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Addi onal copies of this manual or other Zanasi literature may be obtained from:
Zanasi s.r.l
via Marche, 10
41049 Sassuolo
Modena Italy
Zanasi has the policy of con nuos product improvement, the company therefore retains the right to modify the
specifica ons contained in this manual at any me without no ce. Contact Zanasi or your local sales oce to
obtain the latest specifica on before placing your order.
Zanasi assumes no responsability for any errors that may appear in this document. Zanasi makes no commit-
ment to update or to keep current the informa on contained in this document.
Z3000
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UPDATING CHART
Release Date
1.00 November 2010

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Index
Chapter 0 - Introduc on
Equipment Descrip on
Introduc on
Graphic Operator Interface
Hydraulic system overview
Electrical and Power Supply System Overview
Print Head Overview
Character Composi on
Prin ng Features
Technical Specifica ons
Chapter 1 - Hydraulic Compartment

Overview of the Hydraulic Compartment
General Informa on
Turning the System ON
Turning the System OFF

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Hydraulic Circuit Flowchart
Force Circuit Flowchart
Suc on Circuit Flowchart
Viscometer Circuit Flowchart
Make Up Circuit Flowchart
Purge Circuit Flowchart
Flush Circuit Flowchart
Chapter 2 - Hydraulic Maintenance

Filters Maintenance
Tubolar Filters
Tubolar Filters Replacement Procedure
Main Filter
Main FIlter Replacement Procedure
Damper
Damper Replacement Procedure
Manifold
Solenoid Valve Cleaning Procedure
Viscometer
Viscometer Cleaning Procedure
Viscometer Replacement Procedure

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Force Pump
Force Pump replacement procedure
Connec ons Tank-Pipe

Automa c Flushing Procedure
Note of the Flushing System Procedure
Start-up procedure a er flushing
Suggested Maintenance Schedule
Chapter 3 - Alarms of the System

Alarms of the System
How to see the Specific Alarm
*Low Priority Alarms*
*High Priority Alarms*
Tank Alarms
Make-Up Missing
Ink Level Low
Tank Too Full
Print Head Alarms
Print Head Cover Missing
Gu er Alarm
High Voltage Alarm

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Hydraulic Alarms
Viscometer Alarm
Pressure Alarm
Maintenance Warning
Chapter 4 - Electronic Compartment

Overview of the Electronic Compartment
Power Supply
Main Switch
Switching Power Supply
Ven la on Fan
Main Logic Board
General Informa on
Main Components
Hydraulic Signals
Main Signals
Test Point Checking Procedure
Hydraulic Board
Motors
External Connec ons
Photocell
Encoder
Print Direc on Input
Serial Line (connec on to the pc or to the scanner)

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Alarms Output
Connec ons Main Board - Print Head
Connec ons on the Print Head
Print Head Cover Sensor
Pacar Card
Print Head Micro Valve Card
Chapter 5 - Print Head

Print Head
General Informa on
Print Head Working Principle
Break Point
Print Head Layout
Chapter 6 - First Start Up Of The System

Unpack the Printer
Removing the Printer from the Carton
Supplemental Parts
Printer Stand
Power Supply
Preparing the Printer for Use
Ink Filling
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Make-Up Filling
Printer Start-Up
Print Head Set-Up
Wizard Procedure
Failed Star ng Procedure
Chapter 7 - Programming So ware Release 1.02
Keyboard Descrip on
How To Verify The So ware Release
Main Page
Alarms Page
**High Priority Alarms**
Menu Set
Manual Commands Page
Edit Page
Brief Coding Types Guide
System Password
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Logo Editor
Distributor Page
Maintenance Warning
Automa c Viscosity Control
How to Reset the System
Communica on Protocol
Chapter 8 - Print Head Prac ce
Troubleshoo ng Flowchart
Basic Configura on
Self-Cleaning
How to Verify if the Nozzle is Cleaned
Global View of the Print Head
To Adjust the Ink Stream in the Middle of the Charge Electrode
How to Disassemble the Nozzle
How to Clean the Nozzle
How to Assemble the Nozzle
How to Adjust the Ink Stream into the Gu er
How to Replace the Oscillator
How to Replace the Tubus
How to Find the Prin ng Range
Prin ng Quality Depending on the Lod Road Amplitude Range
Examples of Prin ng Errors
General Errors
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Phase Errors
H.V. Errors
Low Viscosity Errors
Electrosta c Charge Errors
Chapter 9 - System Installa on
Unit Posi oning
Print Head Posi oning
System Checking
Electrical Connec ons
Dangerous Working Environments
Temperature
Distributor Page
Customer Training
Shipping
Troubleshoo ng Form
Installa on Form
Introduc on 0
Introduc on
Graphic Operator Interface
Electronic and Power Supply System Overview
Print Head Overview
Character Composi on
Prin ng Features

Z 3000
INTRODUCT ON C APTER
0
Introduc on
The Z3000 printer is composed of two basic assemblies: the CONTROL UNIT and the PRINT HEAD connect-
ed by an umbilical cable (a flexible conduit containing electrical and fluid lines). The Control Unit consists
of the HYDRAULIC and ELECTRICAL SECTION, as well as the keyboard.
3
1. Armoured umbilical
5 2. Print Head
3. Electronic and power supply sec on
4 4. Hydraulic sec on
5. Graphic operator interface
1 2
Graphic operator interface

The keyboard is located on the front of the printer cabinet and it is organized into many sec ons, each of
which contains keys dedicated to perform a specific printer func on
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0
C APTER INTRODUCT ON

The Hydraulic compartment is located behind the keyboard front door. This is where the Ink and the
Make-up fluid are stored, monitored and maintained to ensure proper fluid viscosity (thickness). This is
also where the pressure is applied to the ink in order to create the ink stream on the print head.
The ink circuit management system is used to:
1. Deliver the filtered ink to the tubus always at the same pressure
2. Ac vate or deac vate the ink stream with just a minimum operators interven on
3. Control the ink working parameters and automa cally add make-up when needed
4. Control the suc on from the gu er
5. Transimit the ink and make-up level signals to the electronic system
10
3 1 4
1. Valves: Purge, Viscometer, Make-Up and Gu er
2. Viscometer 2
3. Main Filter 8
4. Manifold
5. Force Pump 5
6. Ink Tank
7. Make-Up Tank 6
8. Damper 9
9. Venturi
10. Pressure Transducer
7
The ink circuit management system is composed of:
Ink Tank and Make-Up Tank: there are two dierent tanks: the ink one is the big on the le ; the make-up
one is the small on the right. The level of the liquid inside is detected by sensors. There are special fi ngs
to accept the cartridges. Inside the cap there is a pointed metal bar that pierces the alluminium seal of
the cartridge inserted. The top of the outer plas c cap of the cartridge must be cut before inser ng it.
Pump: the force (pressure) pump draws ink from the tank to the print head with a constant pressure.
Main Filter: it protects the Hydraulic Circuit to prevent debris from entering and damaging the devices
present. It has a 5m filtering element. It is situated in the le top side of the hydraulic compartment.
Venturi: the venturi draws ink from the gu er, from the viscometer and, during the purge opera ons,
from the tubus to the tank. It also sucks make-up from the make-up tank. The Venturi eect is the reduc-
on in fluid pressure that results when a fluid flows through a constricted sec on of pipe.
Pressure Transducer: the pressure transducer con nuosly checks the ink pressure stability. It automa -
cally adjusts the revolu on of pressure pump to always keep the pressure stable on the print head.
Moreover the pressure transducer verifies the inner ink temperature during the system running.
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Damper: it increases the ink pressure stability assuring perfect prin ng quality.
It avoids also fluctua ons when the force pump reduces its performances during its life me.
Ink filter: it has a 10m filtering element and it is black. This filter prevents any material that entered the
system during filter replacement from clogging any parts of the ink system. The ink flows through this
filter before reaching the print-head.
Gu er filter: it has a 40m filtering element and it is grey. It filters the ink coming from the gu er to
prevent any dust in the environment to enter the tank.
Make-Up filter: it has a 40m filtering element and it is grey. It filters the Make-Up coming from the
Make-Up tank to prevent any dust to enter the Hydraulic circuit.
Viscometer filter: it has a 160um filtering element and it is white. It filters the Ink coming from the Ink
tank to prevent any dust to enter into Viscometer circuit.
Manifold: it controls the ink flow in the ink system. It is composed of a series of channels that connect
dierent uses, from three valves and a pressure transducer. The filtered ink enters the manifold and is
distribuited to the other components of the system like the print head. The pressure is maintained con-
stant by the pressure transducer.
Viscometer: this device meters the viscosity of the ink and sends this data to the electronic system. The
viscometer is composed of a glass pipe, a sensor and a metal sphere. The ink and the sphere are sucked
up into the pipe. When the sphere reaches the top of the pipe, the suc on process stops and the sphere
begins to fall down. The viscosity of the ink is propor onal to the me that the sphere takes to reach the
sensor.
Ink valve: the ink valve is normally closed, but it opens to allow the ink to flow through the tubus. This
valve is located on the print-head.
Flush valve: the flush valve is normally closed, but it opens to allow the Make Up to flow through the
tubus during the start up and shutdown. This valve is located on the print-head.
Purge valve: the purge valve operates for a number of seconds during the start up and for 2 minutes
during the shut-down of the system to purge all the air trapped into the tubus. It is used also during the
print head flushing.
Make-Up valve: it opens when some make-up is needed in the Ink Tank. This opera on is automa cally
carried out even when the system is in full opera on and the ink stream is running.
Viscometer valve: when it opens, the ink pass through the viscometer allowing the sensor to read its
viscosity. This opera on is automa cally carried out even when the system is in full opera on and the
ink stream is running.
Gu er valve: the gu er valve operates for a number of seconds during the start-up and during the shut-
down of the system to increase the performance and eciency of the flushing procedure on the print
head.
0.19
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0
Electrical and Power Supply system overview

The Electronic compartment is located behind the Hydraulic Compartment. This is where all the electrical
and electronic signal are generated and controlled.
2
1. CPU Main Logic Board
2. Switching Power Supply
3. Fan with air Filter
4. Force Motor
5. Hydraulic Board
6. GCU with Keyboard
1
3
4
The electronic system is composed of:
Main Logic Board: the CPU microprocessor board coordinates all the various func on required for the
correct opera on of the system. All the calcula on and control processes are made inside this board,
that also prepares the data to be printed. Moreover, the CPU board performs the following tasks:
1. stores the next messages, logo, etc...

2. controls the parameters that have been set
3. verifies if any alarms are ac vated and send the warning to the GCU board
4. manages the alarms
5. manages the internal clock and counters
6. manages the interface with the field signal such as photocell or encoder signals
7. monitors the hydraulic system
8. generates the modula ng signal to the tubus
9. generates the charge signal for the droplets during the prin ng process
10. syncronizes the droplets charge signals with the droplets
11. generates and controls the 300 Vdc voltage for the droplets charge
12. generates and controls the +4000 and -4000 Vdc high voltage for the deflec on plates
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Switching Power Supply: generates and supplies the direct voltages required by the electronic circuits
and all the other electrical devices. It supplies direct voltages +-12V, +24V and +5V, star ng from an al-
terna ng voltage ranging between 90 and 276 Vac (50-60 Hz).
The incoming alterna ng voltage is previously filtered by a connector filter (that also contains the fuses)
in order to damp all electrical noises and it is then transferred to the switching power supply, to the mo-
tors and to the fan.
Fan with Air filter: a 24Vdc fan to cool down the Electronic sec on. The air filter is necessary to prevent
dust into the electronic parts.
Hydraulic Board: it connects the electronic system to the electrovalves and shows their status with
LEDS.
Motor: the motor to drive the Force Pump
Graphic Control Unit (GCU board): the microprocessor logic board that performs the following tasks:
1. operators interface management

2. management and programming of the CPU board for messages,logo, etc...
3. CPU board parameter programming
4. alarms and warning signals ac va on
On the GCU is fi ed a liquid crystal graphic display with 240x64 dots with LED back
ligh ng to guarantee readability even in poor light condi ons. The board also
manages 53 keys keyboard for programming and text inser on purposes.
0.21
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Print head overview

The print head is connected to the control unit by the umbilical assembly. The print head receives pres-
surized ink through the umbilical, and turns the ink stream into the ny electrically charged ink droplets
which are deflected on the surface to form a printed code. Here follow we describe the rela onship be-
tween the various components of the print-head.
1
2 3
1. Cover sensor 4
5
2. Tubus
3. Nozzle
4. Charge electrode 6
5. Phase detector electrode
6. Deflec on plates 7
7. Gu er
1. The pressurized ink enters to the tubus and comes out through the nozzle. The tubus receives a
modula on signal that makes the ink stream vibrate. The induced vibra on generates 64,000 equally
sized droplets each second.
2. The charge electrode surrounds the ink stream at the point where it breaks up forming the droplets.
The electrode supplies an electrical charge to the droplets. The system sends high amplitude voltage
pulses to the electrode during the prin ng process and low amplitude voltage pulses during phase
control.
3. During the phase control the phase detector electrode measures the charge of the passing droplets
and sends the signal back to the electronic control system .
4. Between the two deflec on plates there is an electrosta c field. The charged droplets are deflected
when they pass through this field. The field is generated by a high voltage generator that is switched
on only when the ink stream is running and the print head protec ve cover is in place.
5. The ink droplets that have not been used for prin ng enter into the gu er and return to the ink
tank.
0.22
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1. Tubus with nozzle 1

2. Charge electrode
2
3. Phase detect electrode 3
4. Deflec on plate (- 4000 Vdc) 4
5. Deflec on plate (+ 4000 Vdc)
6. Gu er 6
N.B. The print head cover must always be in

place during the prin ng opera ons.
Character composi on
Characters are formed by columns of dots and are printed in a dot matrix format which is made up of a
number of rows. For example, the 5x5 font matrix prints a character as follows:
Row 5
Row 4
Row 3
Row 2
Row 1
Column s 1 2 3 4 5 6
A 5x5 matrix is composed of 5 rows and 5 columns of dots. An empty column is then added (#6) to sepa-
rate one character from the following. When you are prin ng more than one line, they are separated by
one or more empty rows. The space between two printed lines is called interline.
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Prin ng Features
The following font matrixes are available:
5x5 7x5 9x7 10x8 16x10
You can print up to 16 dot per column
one line (16X10,10x8,9X7,7X5 OR 5x5 font matrix)
two lines (7x5, 5x5 font matrix)
two lines mixed
You can use lower cases:
abcdefghilmnopqrstuvz
You can set the height and the width of the character:
height: ABC ABC ABC
width: ABC ABC ABC
You can print bold characters up to 8 mes:
Using the internal counters, you can print numbers that are authoma cally increased or decreased:
increment: 0001 0002 0003 0004
decrement: 9999 9998 9997 9996
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The date and/or me can be printed using the internal system clock
22 / 06 / 2007 9:15
The system can print logo that have been previously loaded from a PC or created on the keyboard
The system can also print various barcodes with or without bo om text
Code Industrial 2/5:
Code UPC-A:
Code 39:
Code EAN-13:
A message can be printed upside down (reversed print) or backwards (inverted print) to allow for dier-
ent product orienta on. With the backwards prin ng, the system starts prin ng from right to le , e.g.
the word INVERTED will be printed star ng with the D and ending with the I.
0.25
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Electrical specifica ons
AC supply - 85-130 Vac, 90-240 Vac, 50-60 Hz, single phase

Power ra ng - around 120 VA
CAUTION: the system must be grounded
Mechanical specifica ons
Complete system Weigth: 18 kgs (with full tank)

Cabinet Heigth: 375 mm (14.8 in.)
Width: 370 mm (14.6 in.)
Length: 332 mm (13.0 in.)
370
375
395
330
Print head Heigth: 49 mm (1.9 in.)

Width: 42 mm (1.6 in.)
Length: 227 mm (8.9 in.)
42 227
49
Print head to cabinet umbilical length: 1,8 m (5.9 .)

Power cable length: 1.7 m (5.6 .)
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Environmental specifica ons
Op mum opera ng temperature 20 C (68 F)

Opera ng temperature range 5-45 C (41-104 F)
Storage temperature 5-50 C (41-122 F)
Humidity 10-90 % (no-condensing)
Sensor input
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.
Data input
From a Host Computer serial line RS232
Relay alarm output
Digital Output Max 500 mA
Ink and Make-up specifica ons
Ink type ketone - or alcohol based

Colors black, red, blue, green,
transparent
Ink cartridge capacity 415/800 ml
Make-up type ketone - or alcohol based
Make-up cartridge capacity 800 ml
CAUTION: refer to the relevant Material Safety Data Sheets for informa on
on inks and make-up.
Print specifica ons (depending on so ware and nozzle types)
Number of prin ng lines up to 2

Character heigth 0.9-12 mm (0.03-0.47 in.)
Character width adjustable
Minimum prin ng distance 2 mm (0.08 in.)
Maximum prin ng distance (depending on pressure and coding type) 90 mm (3.54 in.)
Recommended prin ng distance 7-10 mm (0.27-0.39 in.)
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Ink consump on
The consump on of Ink depends on: the nozzle dimensions (50m or 70 m),
the selected matrix and from the level of boldfaced (print width) programmed in the text.
By using a double wide character, the number of the reproducible characters it is half.
The following charts show the number of characters that can be printed with 1 liter of Ink and with a
standard cartridge (800 ml) based to the selected matrix.
In the charts the consump on is considered for prin ng real characters. For example: matrix 5x5 is com-
posed from 25 dots; concretely however for the prin ng of a real character, on average, only the 50%
of the dots are used.
NOZZLE DIAMETER 70m
Number Number Number of printable

Selected Number of printable
of dots per of dots per characters per 800 ml
matrix characters per 1 lt.
matrix character cartridge
5x5 25 12 94.492.964 75.594.369
7x5 35 17 66.700.916 53.360.731
9x7 63 31 36.577.922 29.262.336
16x10 160 80 14.173.945 11.339.155
Number of droplets per liter 1.133.915.568
NOZZLE DIAMETER 50m
Number Number Number of printable

Selected Number of printable
of dots per of dots per characters per 800 ml
matrix characters per 1 lt.
matrix character cartridge
5x5 25 12 259.288.693 207.430.951
7x5 35 17 183.027.313 146.421.847
9x7 63 31 100.369.817 80.295.852
16x10 160 80 38.893.304 31.114.642
Number of droplets per liter 3.111.464.320
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Make-up consump on
The Make-up consump on depends on room temperature.
The Make-up consump on depends mainly on the temperature of the environment. Insignificant influence
has the size of the Tubus nozzle.
Min. duration Max. duration

Quantity Environment temperature
(hours) (hours)
20 C 115 130
Cartridge 800 ml. 25 C 95 110
30 C 75 90
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Speed Capability
Coding Type: 17-S Coding Type: 16-HS
128 mt/m
256 mt/m
160 mt/m
320 mt/m
192 mt/m
384 mt/m
2mm 2.5mm 3mm
5x5 5x5 5x5 2mm 2.5mm 3mm
Character Width 5x5 5x5 5x5
Character Width
91 mt/m
182 mt/m
114 mt/m
228 mt/m
137 mt/m
2mm 2.5mm 3mm 274 mt/m
7x5 7x5 7x5 2mm 2.5mm 3mm
75 mt/m
Character Width
144 mt/m
101 mt/m
192 mt/m
126 mt/m
3mm 4mm 5mm 240 mt/m
9x7 9x7 9x7
Character Width 3mm 4mm 5mm
9x7 9x7 9x7
81 mt/m Character Width
101 mt/m 131 mt/m
121 mt/m 164 mt/m

4mm 5mm 6mm
10x8 10x8 10x8 196 mt/m
Character Width
4mm 5mm 6mm
58 mt/m 10x8 10x8 10x8
Character Width
67 mt/m
89 mt/m
75 mt/m
102 mt/m
7mm 8mm 9mm
16x10 16x10 16x10 Character Width 115 mt/m
55 mt/m 7mm 8mm 9mm
16x10 16x10 16x10 Character Width
69 mt/m
83 mt/m 85 mt/m
2mm 2.5mm 3mm 106 mt/m
5x5 5x5 5x5
41 mt/m 2mm 2.5mm 3mm
5x5 5x5 5x5
51 mt/m 5x5 5x5 5x5
Character Width
61 mt/m 55 mt/m
2mm 2.5mm 3mm
7x5 7x5 7x5 69 mt/m
35 mt/m 2mm 2.5mm 3mm
7x5 7x5 7x5
44 mt/m 7x5 7x5 7x5 Character Width
53 mt/m
2mm 2.5mm 3mm
5x5 5x5 5x5
5x5 5x5 5x5
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Coding Type: 1L 7x5 Coding Type: 2L 7x5
256 mt/m 42 mt/m
320 mt/m 53 mt/m
384 mt/m 64 mt/m
2mm 2mm 2.5mm 3mm

2.5mm 3mm
5x5 5x5 5x5 5x5 5x5 5x5
Character Width 5x5 5x5 5x5 Character Width
182 mt/m
30 mt/m
228 mt/m
38 mt/m
274 mt/m
45 mt/m
2mm 2.5mm 3mm
7x5 7x5 7x5 2mm 2.5mm 3mm
Z 3000 MINIMUM SPEEDS

MINIMUM MINIMUM
SPEED SPEED
CODING MATRIX INTERLINE
USABLE USABLE
TYPE USED USED
WITHOUT WITH
ENCODER ENCODER
5X5 Not used 25 1*

1L-7X5
7X5 Not used 33 1*
5X5 3
140 1*
5X5 To SET UP
2L-7X5
7X5
1 (DEFAULT) 195 1*
7X5
5X5 Not used 25 1*
7X5 Not used 33 1*
9X7 Not used 46 1*
10X8 Not used 64 1*

16-HS
5X5
2 (DEFAULT) 62 1*
5X5
7X5
2 (DEFAULT) 105 1*
7X5
16x10 Not used 114 1*
5X5 Not used 46 1*
7X5 Not used 64 1*
9X7 Not used 87 1*
16-S 10x8 Not used 110 1*
5X5
2 (DEFAULT) 110 1*
5X5
7X5
2 (DEFAULT) 145 1*
7X5
16x10 Not used 172 1*
* = the minimum speed with the encoder depends on the encoder frequency Max Speed = 80 KHz
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NOTES
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0.32
Hydraulic Compartment 1
General Informa on
Force Circuit Flowchart
Suc on Circuit Flowchart
Viscometer Circuit Flowchart
Make Up Circuit Flowchart
Purge Circuit Flowchart
Flush Circuit Flowchart

Z 3000
HYDRAULIC COMPARTMENT C APTER
1
General Informa on
The ink circuit management system is used to:
1. Deliver the filtered ink to the tubus always at the same pressure.
2. Ac vate or deac vate the ink stream with just a minimum operators interven on.
3. Control the ink working parameters and automa cally add make-up when needed .
4. Control the suc on from the gu er.
5. Transmit the ink and make-up level signals to the electronic system.
6
1. Main Filter
3
2. Damper 1
3. Valves 14 5
4. Venturi
13
5. Viscometer
6. Pressure Transducer 2
7. Manifold
8. Force Pump
11 7
9. Ink Tank
10. Make-Up Tank 4
11. Ink Cap
12. Make-Up Cap 12
13. Ink Cartridge Slot
9 10
14. Make-Up Cartridge Slot 8
Ink Tank and Make-Up Tank: the tank is composed of two sec ons: one for the ink (the big one) and one
for the make-up (the small one). The level of the liquid inside is detacted by sensors. There are special
fi ngs to accept the cartridges. Inside the cap there is a pointed metal bar that pierces the alluminium
seal of the cartridge upon inser on. The top of the outer plas c cap of the cartridge must be cut before
inser ng it.
Pump: the force (pressure) pump draws ink from the tank to the print-head.
Manifold: it controls the ink flow in the ink system. It is composed of a series of channels that connect
dierent uses, from three valves and a pressure transducer. The filtered ink enters the manifold and is dis-
tribuited to the other components of the system like the print head. The pressure is maintained constant
by the pressure transducer.
Venturi: the venturi draws ink from the gu er, from the viscometer and, during the purge opera ons,
from the tubus to the tank. It also sucks make up from the make up tank. The Venturi eect is the reduc-
on in fluid pressure that results when a fluid flows through a constricted sec on of pipe.
1.35
Z 3000
1
C APTER HYDRAULIC COMPARTMENT
Viscometer: this device meters the viscosity of the ink and sends this data to the electronic system. The
viscometer is composed of a glass pipe, a sensor and a metal sphere. The ink and the sphere are sucked
up into the pipe. When the sphere reaches the top of the pipe, the suc on process stops and the sphere
begins to fall down. The viscosity of the ink is propor onal to the me that the sphere takes to reach the
sensor.
Damper: it increases the ink pressure stability assuring perfect prin ng quality. It avoids also fluctua ons
when the force pump reduces its performances during its life me.
Filters
Main filter: it protects the Hydraulic Circuit to prevent debris from entering and damaging the devices
present. It has a 5um filtering element. It is situated in the le top side of the hydraulic compartment.
Ink filter: it has a 10um filtering element and it is black. This filter prevents any material that entered the
system during filter replacement from clogging any parts of the ink system. The ink flows through this
filter before reaching the print-head.
Gu er filter: it has a 40um filtering element and it is grey. It filters the ink coming from the gu er to pre-
vent any dust in the environment to enter into the tank.
Make-Up filter: it has a 40um filtering element and it is grey. It filters the Make-Up coming from the
Make-Up tank to prevent any dust to enter into Hydraulic circuit.
Valves into the Cabinet
Purge valve: the purge valve operates for a number of seconds during the start-up and for 2 minutes
during the shut-down of the system to purge all the air trapped into the tubus. It is used also during the
print-head flushing.
Make-Up valve: it opens open when some make-up is needed in the Ink Tank. This opera on is automa -
cally carried out even when the system is in full opera on and the ink stream is running.
Viscometer valve: the viscometer valve is normally closed: when it opens, the ink pass through the vis-
cometer allowing the sensor to read its viscosity.
Gu er valve: the gu er valve operates for a number of seconds during the start-up and during the shut-
down of the system to increase the performance and eciency of the flushing procedure on the print
head.
1.36
Z 3000
1
Valves on the Print Head
Ink valve: the ink valve is normally closed, but it opens to allow the ink to flow through the tubus.
Flush valve: the flush valve is normally closed, but it opens to allow the make-up to flow through the
tubus during the start up and shutdown (Tubus Flushing).
Micro Manifold: it controls the ink and solvent flow in the head. It is composed of a series of channels
that connect dierent uses, from two solenoid valves
1. Flush Valve
2. Ink Valve
3. Micro Manifold
3
1.37
Z 3000
1
Turning system on
Press START/STOP
(The motors start to run; the ink
pressure goes up to the value set)
0 seconds
START FLUSHING TUBUS
5 seconds
(EV FLUSH ON; EV PURGE ON)
STOP FLUSHING TUBUS
15 seconds (EV FLUSH OFF; EV PURGE OFF)
INCREASING PRESSURE
(The system increase the revolutions of
the force motor in order to reach the pres-
sure of 4 bar)
35 seconds INK STREAM ON
(EV INK ON)
40 seconds
PURGE ON & DECREASE PRESSURE
45 seconds
(EV PURGE ON; EV INK ON)
50 seconds (The system decrease the revolutions of
the force motor in order to set up the pres-
55 seconds
sure at PRESSURES SET value)
PURGE OFF & H.V. ON
(EV PURGE OFF; EV INK ON)
SYSTEM READY
(The green LEDS on the keys turn
ON and the system is ready to print)
1.38
Z 3000
1
Standard turning system o
Press START/STOP bu on
press SYSTEM OFF

0 seconds (EV INK OFF; EV PURGE OFF)
5 seconds START FLUSHING TUBUS
STOP FLUSHING TUBUS

15 seconds
(EV FLUSH OFF; EV PURGE ON)
(The flushing procedure lasts 10 seconds)
STOP
(EV PURGE OFF; MOTORS OFF)
75 seconds (The system switches OFF the motors
automa cally and the led on the key
START/STOP turns o)
1.39
Z 3000
1
Extended turning system o
Press START/STOP bu on
0 seconds press + EXTENDED SHUT DOWN

(EV INK OFF; EV PURGE OFF)
5 seconds
START FLUSHING TUBUS

35 seconds
STOP FLUSHING TUBUS
(EV FLUSH OFF; EV PURGE ON)
(The flushing procedure lasts 30 seconds)
STOP
(EV PURGE OFF; MOTORS OFF)
120 seconds
(The system switches OFF the motors
automa cally and the led on the key
START/STOP turns o)
1.40
Z 3000
1
SUCTION CIRCUIT
FORCE CIRCUIT
INK TANK MAKE-UP

TANK
FORCE
PUMP VENTURI
MANIFOLD
BY-PASS VISCO
VALVE
INK MAKE-UP
VALVE ON VALVE
PRINTHEAD
PURGE
VALVE
FLUSH
VALVE ON
GUTTER
PRINTHEAD
VALVE
TUBUS GUTTER
1.41
TPT04
1.42
1
GUTTER MAKE UP VISCO PURGE
VENTURI VALVE VALVE VALVE VALVE
TRANSDUCER
(0.73mm) MANIFOLD
MANIFOLD
C APTER
PRINT HEAD
MAIN FILTER
(5 Micron)
IN
OUT
OUT
BLACK (10 MICRON)
IN
DAMPER INK FILTER

HYDRAULIC COMPARTMENT
PURGE INK FLUSH

FORCE PUMP
IN
OUT
Z 3000
FORCE CIRCUIT
SUCTION CIRCUIT PIPE 6 x 4
FLUSH CIRCUIT PIPE 4 x 1.5
PURGE CIRCUIT
PIPE 4 x 2
INK TANK MAKE UP TANK
(black color) (gray color)
TPT04

VENTURI VALVE VALVE VALVE VALVE
TRANSDUCER
(0.73mm)
MANIFOLD MANIFOLD
PRINT HEAD
MAIN FILTER
(5 Micron)
IN
OUT
OUT GRAY (40 MICRON)

BLACK (10 MICRON)
IN
Z 3000
GUTTER FILTER
DAMPER INK FILTER
PURGE INK GUTTER FLUSH

FORCE PUMP
IN
OUT
FORCE CIRCUIT
SUCTION CIRCUIT PIPE 6 x 4
C APTER
FLUSH CIRCUIT PIPE 4 x 1.5

PURGE CIRCUIT PIPE 4 x 2
1

1.43
TPT04
1.44
VALVE VALVE VALVE VALVE
1
VENTURI
MANIFOLD
(0.73mm)
TRANSDUCER
OUT
MANIFOLD
C APTER
PRINT HEAD
MAIN FILTER
VISCOMETER
(5 Micron)
IN
IN
OUT

IN
BLACK (10 MICRON)
GUTTER FILTER
DAMPER INK FILTER
WHITE (160 MICRON)
VISCOMETER FILTER

FORCE PUMP
IN
OUT
Z 3000
MAKE UP FILTER
GRAY (40 MICRON)
FORCE CIRCUIT
SUCTION CIRCUIT
FLUSH CIRCUIT PIPE 6 x 4
PURGE CIRCUIT
PIPE 4 x 1.5
VISCOMETER CIRCUIT
PIPE 4 x 2
MAKE UP CIRCUIT
TPT04
VENTURI
MANIFOLD
(0.73mm)
TRANSDUCER
OUT
MANIFOLD
PRINT HEAD
MAIN FILTER
VISCOMETER
(5 Micron)
IN
IN
OUT

BLACK (10 MICRON)
Z 3000
IN
GUTTER FILTER
DAMPER INK FILTER
WHITE (160 MICRON)
VISCOMETER FILTER

FORCE PUMP
IN
OUT
MAKE UP FILTER
GRAY (40 MICRON)
VAPORS
EXIT
VAPORS CIRCUIT
FORCE CIRCUIT
SUCTION CIRCUIT
PIPE 6 x 4
FLUSH CIRCUIT
C APTER
PURGE CIRCUIT
PIPE 4 x 1.5
VISCOMETER CIRCUIT PIPE 4 x 2
1
MAKE UP CIRCUIT INK TANK PIPE 4 x 2.5

(black color)
MAKE UP TANK
(gray color)
1.45
TPT04
1.46
1
VENTURI
MANIFOLD
(0.73mm)
TRANSDUCER
OUT
MANIFOLD
C APTER
PRINT HEAD
MAIN FILTER
VISCOMETER
(5 Micron)
IN
IN
OUT

IN
BLACK (10 MICRON)
GUTTER FILTER
DAMPER INK FILTER
WHITE (160 MICRON)
VISCOMETER FILTER

FORCE PUMP
IN
OUT
Z 3000
MAKE UP FILTER
GRAY (40 MICRON)
VAPORS
EXIT
VAPORS CIRCUIT
FORCE CIRCUIT
SUCTION CIRCUIT
FLUSH CIRCUIT PIPE 6 x 4
PURGE CIRCUIT PIPE 4 x 1.5
VISCOMETER CIRCUIT PIPE 4 x 2
MAKE UP CIRCUIT INK TANK PIPE 4 x 2.5
(black color)
MAKE UP TANK
(gray color)
Z 3000
1
NOTES
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1.47
Z 3000
1
NOTES
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1.48
Hydraulic Maintenance 2
Filters Maintenance
Tubolar Filters
Tubolar Filters Replacement Procedure
Main Filter
Main Filter Replacement Procedure
Damper
Damper Replacement Procedure
Manifold
Solenoid Valve Cleaning Procedure
Viscometer
Viscometer Cleaning Procedure
Viscometer Replacement Procedure
Force Pump
Force Pump Cleaning Procedure
Force Pump Replacement procedure
Connec ons Tank-Pipe
Automa c Flushing Procedure
Note of the Flushing System Procedure
Start-up Procedure a er Flushing
Suggested Maintenance Schedule

Z 3000
HYDRAULIC MAINTENANCE C APTER
2
Filters Maintenance
Tubular Filters
The tubolar filters are composed of an external container and a filtering element fi ed inside the con-
tainer. The filters are connected to the hoses with two locknuts
CAUTION: during the filter installing, make sure that you do so in the correct direc on of
ink flow. An arrow on the filter indicates the direc on from which the ink flows
into the filter (inlet side).
Black filter
Ink filter: it has a 10um filtering element. This filter prevents any material that may entered to the print-
head. The ink flows through this filter before reaching the print-head.
Grey filter
The grey filters are fi ed along the suc on hoses of the hydraulic circuit in the hydraulic compartment.
These filters have a nominal filtering capacity of 40m.
Gu er filter: It filters the ink coming from the gu er to prevent any dust in the ambient air to enter the
into tank.
Make-Up filter: It filters the make-up coming from the make-up tank on the ink tank.
White filter
2.51
Z 3000
2
C APTER HYDRAULIC MAINTENANCE
Tubolar filters replacement procedure
Cau on: during the filter replacement, make sure to use a new filter with the same color.
Cut o the pipe next to the old filter, use face of nut as guide
to clean square cut. Discard filter and nuts. Do not forget to
check the direc on of the flow.
Remove the two nuts from the new filter.
Push the tube through the nuts up to stop it inside the filter.
Keep pipe in place and ghten nut by fingers.
2.52
Z 3000
2
Main filter
The main filter has a nominal filtering capacity of 5m. It is located inside the Hydraulic compartment.
Main filter replacement procedure

To replace the main filter, observe the following procedure:
1. Loosen locknuts (IN and OUT) with a 16mm wrench.

2. Disconnect pipes
3. Replace the old filter with a new one, checking the direc on of the ink flow
4. Tighten two locknuts (IN and OUT) with a 16mm wrench.
INLET
(from the pressure pump)
OUTLET
(to the manifold)
OUTLET
INLET
Main filter removal Main filter replaced
2.53
Z 3000
2
Damper
The damper increases the ink pressure stability assuring perfect prin ng quality. This parts also avoid pres-
sure fluctua ons when the force pump reduces its performances during the its life me. It is located inside
hydraulic compartment.
Damper replacement procedure

To replace the damper, observe the following procedure:
1. Loosen two locknuts (IN and OUT) with a 11mm wrench.

2. Disconnect pipes
3. Replace the old damper with a new one, checking the direc on of the ink flow
4. Tighten two locknuts (IN and OUT) with a 11mm wrench.
OUTLET
(to the tubolar black filter)
INLET
(from the pressure transducer)
OUTLET
INLET
Damper removal Damper replaced
2.54
Z 3000
2
Manifold
The Manifold controls the ink flow in the ink system. It includes three valves. The filtered ink enters the
manifold and is distribuited to the other component of the system like the print-head. The pressure is
maintained constant automa cally by the Pressure Transducer.
On the Manifold are present three electrvalves:
1. Purge valve: the purge valve operates for 10

seconds during the start-up and for 2 minutes
during the shut down of the system for the Au- E.V. MAKE-UP
E.V. GUTTER E.V. VISCO E.V. PURGE
toma c flushing procedure.
2. Make-up adding valve: when make-up is

needed in the main tank (which con tains the
ink/make-up mixture), this valve opens. This
opera on is automa cally carried out when
the system is i full opera on, the stream of ink
is running and the motors is running.
3. Viscometer valve: this is the valve through

which the ink flows to the viscometer.
4. Gu er valve: the gu er valve operates for

a number of seconds during the start-up and
during the shut-down of the system to increase
the performance and eciency of the flushing
procedure on the print head.
2.55
Z 3000
2
Solenoid valve cleaning procedure
Open the hydraulic compartment.
Unscrew and disconnect the electrical contacts on solenoids.
Unscrew the locking nuts, and remove the magnets from the so-
lenoids.
Loosen the moun ng screws and remove valves. Pay a en-

on to the o rings located on valves.
2.56
Z 3000
Remove the metal plate and all the components inside the
valve.
Flush the components with cleaned solvent in the ultrasonic
cleaning bath and dry each component with cleaned com-
pressed air.
Clean with solvent the place where the valve is connected to

the manifold.
Reassemble each component, making sure to do not forget

any part and pay a e on to the o-ring.
2.57
Z 3000
2
Viscometer
This device measures the viscosity of the ink and sends this data to the the electronic system. The vis-
cometer is composed of a glass pipe, a sensor and a metal sphere. The ink and sphere are sucked up into
the pipe. When the sphere reaches the top of the pipe, the suc on process stops and the sphere begins
to fall down. The viscosity of the ink is propor onal to the me it takes for the sphere to reach the sen-
sor.
Viscometer cleaning procedure

The viscometer is connected to two pipes (1) fixed by two locknuts (2). Use the follwing procedure to
clen the viscometer:
3
ET
(25 CO S
)
C
VIS
2
1
1. Turn the System OFF

2. Loosen the locknuts (Ref 2) with a 12mm wrench
3. Gently disconnect the pipes (Ref. 1)
4. Clean the viscometer as shown in the second figure
5. In order to verify the correct running of the viscometer sensor, turn the power on by pressing the
Main Power Switch (ONLY MAIN POWER SWITCH DONT PRESS START/STOP) and move the viscometer
in order to move the sphere in front of the sensor. When the sphere passes in front of the sensor the
LED (Ref 3) turns on.
4. If the sensor works fine, reinstall the viscometer checking the direc on of the ink flow
CAUTION: do not open the viscometer
2.58
Z 3000
2
Viscometer replacement procedure
CAUTION: Turn power o before doing these opera on!!!
Open the electronic compartment and disconnect the viscom-

eter connector from the hydraulic eletrical board
Remove the connector AMP 6x1 from the viscometer cable
Pool the viscometer (5) cable throught the plas c connector

(4) and remove the viscometer..
2.59
Z 3000
2
Loosen the locknuts with a 12mm wrench and gently remove the
pipes from the locknuts
ET
(25 CO S
)
C
VIS
Replace the Viscometer with a new one, ATTENTION: Connect again

the viscometer pipes checking the correct direc on of the ink
ET
(25 CO S
)
C
VIS
CAUTION: NEW VISCO SET (25C)
Place into the system the new viscometer (1)
2.60
Z 3000
Connect the viscometer cable on the hydraulic electrical

board.
Press and to go into the DISTRIBUTOR PAGE and the system shows the following page:
Digit the password: _____________ (uppercase)
Press to confirm and to enter in the DISTRIBUTOR PAGE
2.61
Z 3000
2
Place the cursor at the VISCO SET (25C) posi on and insert the same printed value on the new viscom-
eter label:
NEW VISCOMETER SET POINT VALUE TO

BE INSERTED
ET
(25 CO S
)
C
VIS
Important: the VISCO SET (25 C) values must be changed ONLY when it is necessary to replace the vis-
cometer, otherwise this value will be the same for all the life of the system
Press to confirm the new VISCO SET (25C) value
Press to go back to the MAIN DISPLAY
2.62
Z 3000
2
Force Pump and Venturi
The Force Pump takes the ink from the tank and force it through the main ink filter and supplies it to the
print head. The Venturi draws ink from the gu er, from the viscometer and, during purge opera ons,
from the tubus. It also sucks make-up from the cartridge for the automa c print head flushing and to
adjust the viscosity.
Force Pump replacing procedure
Remove 3 screws (4x8) from the hydraulic compartment.
Gently pull out the pump/motor block from the electricl compart-
ment.
Insert the new pump/motor block into the cabinet place.
Fix 3 screws (4x8) of the new pump/motor block into the hydrau-
lic compartment.
2.63
Z 3000
2
Venturi cleaning/replacing procedure
Remove the locknut with venturi pipe from the manifold
Unscrew the drain junc on of venturi from the manifold using the
wrench key (13mm). Pay a e on to the o-ring.
Carefully clean the junc on hole of venturi drain and blow it up

with compressed cleaned air.
2.64
Z 3000
Get wet the junc on with the proper solvent before inser ng it back
and screw the junc on into the manifold. Pay a e on to the o-ring.
Connect the pipe again to the manifold.
2.65
2.66
2
C APTER
to the Force Pump
return from the Venturi
to the Viscometer
Vapors exit
Bridge - Ink
HYDRAULIC MAINTENANCE
to the Make-Up Valve on the Manifold

Z 3000
Tank Connec ons Overview
Vapors exit
to the Flush Valve on the Print-Head

Z 3000
2
AUTOMATIC FLUSHING PROCEDURE
Basic opera on before star ng the flushing procedure
- Remove the main filter and joint the two pipes (inlet/outlet) using the specific fi ng for 6x4 pipe.
- Remove the damper and joint the two pipes (inlet/outlet) using the specific fi ng for 4x1,5 pipe.
- Remove ink/make-up cartridges and remove the two caps.
- Flush the caps and the tanks carefully (ink/make-up sec ons).
- Refill the ink/make-up tanks with proper cleaned solvent.
- Disconnet the venturi outlet pipe from the black tank-cap side and be sure that this pipe goes to
waste tank during the flushing procedure
- Prepare a squeeze bo le with the proper solvent
- Place the Print Head inside a beaker
Start the flushing procedure

Press and to go into DISTRIBUTOR PAGE, the system shows the following page:
2.67
Z 3000
2
Press (flushing system start) to start up the automa c flushing procedure. This procedure
totally lasts 11 minutes with the following stepts:
STEP 1 General and Viscometer flushing (approx. 1:20 min.)

- During this first phase, flush the gu er conduit with the squeeze bo le un l the gu er pipe in the hy-
draulic circuit is perfectly cleaned.
STEP 2 Print Head flushing (approx. 2:20 min.)

- The system automa cally switches the motors o for 30 seconds and during this me disconnet the
flush pipe from the gray cap, and make certain that the flush pipe goes to waste tank.
STEP 3 Print Head Electrovalve flushing (approx. 6:50 min.)

- The system lets out a sound to indicate that the print head has to be posi oned upside down to improve
the electrovalve flushing eciency. During this last phase, flush the gu er conduit un l the gu er pipe in
the hydraulic circuit is perfectly cleaned and wait that the system finishes the flushing procedure.
Total hydraulic flushing me = approx. 11 min.
CAUTION: During the flushing procedure always control the level of the solvent inside the
tank. This procedure normally make use of 4800/5000 ml of solvent for the tank filling.
2.68
Z 3000
2
NOTE OF THE SYSTEM FLUSHING PROCEDURE
(training course)
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2.69
Z 3000
2
START-UP PROCEDURE AFTER FLUSHING
Push the main power to switch the system ON.
In the main page appears LOW PRIORITY ALARM cause INK

and MAKE UP missing.
Press bu on to visualize each specific alarm:
MAKE UP MISSING and INK LEVEL LOW
2.70
Z 3000
2
Ink Filling
CAUTION: FOR THE START UP PROCEDURE AFTER FLUSHING USE JUST 1 INK CARTRIDGE
Cut the top of the plas c seal from the ink cap car-
INK
tridge.
Shake vigorously the cartridge.

INK
Using the correct cleaned solvent to get wet the seal-

ing lip washer.
2.71
Z 3000
2
INK INK
Gently push the ink cartridge inside the ink housing (the
le one). Be sure the black cap of the cartridge is com-
pletely inserted. The seal membrane will be punctured
by the plas c puncher.
Wait a few minutes un l the INK LEVEL LOW alarm has

turned o.
2.72
Z 3000
2
Make-Up Filling
CAUTION: FOR THE START-UP PROCEDURE AFTER FLUSHING USE JUST 1 MAKE UP CARTRIDGE
MAKE-UP
Cut the top of the plas c seal from the make up cap
cartridge.
INK
Using the correct cleaned solvent to get wet the seal-
ing lip washer.
MAKE UP MAKE UP
Gently push the make-up cartridge inside the make-
INK up housing, (the right one). Be sure the black cap of
the cartridge is completely inserted. The seal mem-
brane will be punctured by the plas c puncher.
Wait a few minutes un l the MAKE-UP MISSING

alarm has turned o.
NOTE: the make-up cartridge will not be completely
empty.
2.73
Z 3000
2
Put the printhead inside the beaker

without the cover.
Press to enter into the MENU SET. The display will show the following page:
Press un l the display shows the following page:
2.74
Z 3000
2
Set the GUTTER ALARM..........(Y/N)= N in order to disable the Gu er Alarm
Set the START UP FLUSHING..........(Y/N)= N in order to disable the Start Up Flushing
Press : the green LED is on and the system is flushing the Tubus. In the mean me
the display shows the following page:
A er 40 seconds the system automa cally switches the ink stream on and the display shows the fol-
lowing page:
2.75
Z 3000
2
If the ink stream does not go straight

into the gu er do not take care about it be-
cause the system is removing air from hy-
draulic circuit.
A er 50 seconds the green LED on the key turns ON. The display shows the following
page:
CAUTION: High Priority Alarm turns on because the cover is missing; at this me
do not take care about it.
2.76
Z 3000
2
When the message >> INK STREAM ON << appears, press to enter into the COMMAND PAGE
and the display will show the following page:
Press to enable the Purge Valve for 30 seconds. The system will automa cally shows
the MAIN PAGE.
CAUTION: During the PURGING SYSTEM shake the Main Filter, Damper
and Black Filter to help the system in order to remove air from
hydraulic circuit.
When the message PURGING THE SYSTEM........... will disappear, press again to repeat the
purging procedure. ATTENTION: Repeat 5 mes this procedure
2.77
Z 3000
2
A er 5 purging procedures, press bu on and the display will show the following page:
Press to switch the ink stream o.
DO NOT CLEAN HERE

Clean the printhead only in the cleanable area
CLEAN ONLY HERE
with the squeeze bo le.
A er printhead cleaning press and than to switch the ink stream on as the
following page shows you:
CAUTION: The system flushing can aect the viscosity so before proceeding with the
following process be sure that the VISCOSITY READ is correct. (reference
chapter 7 page 197)
2.78
Z 3000
Check the ink stream align-

ment and stability.
If the ink stream is not stable, clean the nozzle

following the instruc on described in the chap-
ter 8 pages 239-241.
If the ink stream is not adjusted properly pro-

ceed with the correct aligment following the in-
struc ons described in the chapter 8 page 242.
Enable the GUTTER ALARM

Control the prin ng range following
the instruc ons described in the chapter 8 page
250.
Set the new SERVICE HOURS and SERVICE DATE

values present into DISTRIBUTOR PAGE 2 fol-
lowing the instruc ons described in the chapter
7 page 194.
<F3> START UP PROCEDURE
2.79
Z 3000
2
SUGGESTED MAINTENANCE SCHEDULE

This sec on provides the preven ve maintenance schedules and procedures, in addi on to infor-
ma on on periodic cleaning and replacement of components .
It is strongly recommended to set up the SERVICE HOURS and SERVICE DATE values present into
DISTRIBUTOR PAGE 2 as described in the following table:
PREVENTIVE MAINTENANCE SCHEDULE FOR

Standard inks
Working Hours Maintenance Schedule Procedure
Hydraulic Flushing, replace Filters(all), Ink,
Hours: 2000 Fan filters. A er Hydraulic Flushing, start
8 Hours per Day up the system and verify all parameters
Date: 12 Months and print head adjustments. So ware Up-
da ng *
Hours: 2000 Replace the Main filter (5m), verify all
system parameters and print head adjust-
Date: 6 Months ments. Fan Filter cleaning and check the
expira on date
16 Hours per Day
up the system and verify all parameters
da ng *
Hours: 2000 Verify all system parameters and print

head adjustments. Fan Filter cleaning and
Date: 3 Months check the expira on date

24 Hours per Day system parameters and print head adjust-
expira on date

da ng *
* verify on www.zanasi-coding.com (reserved area) for new available so ware
CAUTION: It is strongly recommanded in the dusty environments to pressurize the print head
in order to increase the ink life- me.
2.80
Z 3000
2
NOTES
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2.81
Z 3000
2
NOTES
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2.82
Alarms of the System 3
Maintenance Warning
Tank Alarms
Make-Up Missing
Ink Level Low
Tank Too Full
Print Head Alarms
Print Head Cover Missing
Gu er Alarm
High Voltage Alarm
Hydraulic Alarms
Viscometer Alarm
Pressure Alarm
Z 3000
ALARMS OF THE SYSTEM C APTER
3
The alarm are visualized by LEDS and on the MAIN DISPLAY:
Press bu on to go into the ALARM PAGE to see the specific alarm:
In the system are present 2 dierent alarm levels:
* LOW PRIORITY ALARMS * : The system is able to print

** HIGH PRIORITY ALARMS** : The system is not able to print
3.85
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CHAPTER ALARMS OF THE SYSTEM
Press and/or to visualize the General Status of Alarms
Press to EXIT and to go back to the Main Display
* Low Priority Alarm *
MAKE-UP MISSING: When this alarm triggers (STATUS =ON), it means that the make-up cartridge in the
hydraulic tank has run out. Replace the used cartridge with a new one as soon as possible. If the alarm
is ignored for a 2 hours, the system will switch o automa cally.
INK LEVEL LOW: When this alarm triggers (STATUS =ON), it means that the ink-solvent mix in the hy-
draulic tank is below the minimum level admi ed for the correct opera on of the printer. Replace the
used ink cartridge as soon as possible. If the alarm is ignored for 4 hours, the system will switch o
automa cally.
TANK TOO FULL: When this alarm triggers (STATUS=ON), it means that the ink-solvent mix in the hydrau-
lic tank is above the maximum level admi ed for the correct opera on of the printer. Drain the excess
ink as soon as possible.
VISCOMETER FAULT: When this alarm triggers (STATUS=ON), it means that the viscometer is blocked or
is not working correctly. Restore correct opera on of the viscometer as soon as possible or if the alarm
is ignored for more than 30 minutes, the system will start to work abnormally.
3.86
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ALARMS OF THE SYSTEM CHAPTER
3
** High Priority Alarm **
HIGH VOLTAGE ALARM: When this alarm triggers (STATUS =ON), it means that a spark between the high
voltage plates has occurred. It is possible to enable or disable this alarm from MENU SET at ENABLE
PAGE .
GUTTER ALARM: When this alarm triggers (STATUS =ON), it means that the ink is not draining into the
gu er. Check the posi on and alignment of the ink stream and clean the tubus nozzle and the gu er. It
is possible to enable or disable this alarm from MENU SET at ENABLE PAGE .
PRINT-HEAD COVER MISSING: When this alarm triggers (STATUS=ON), it means that the print head
cover on head has been removed. Fit the cover back in place or check if it is fi ed correctly in place. It
is possible to enable or disable this alarm from MENU SET at ENABLE PAGE .
PRESSURE ALARM: When this alarm triggers (STATUS=ON), it means that the pressure in the hydraulic
circuit is not stable or is inexistent. It is possible to enable or disable this alarm from MENU SET at
ENABLE PAGE .
PRESSURE REV. ALARM: When this alarm triggers (STATUS=ON), it means that the motor
overruns the maximum number of revolu ons admi ed. During the system start up this alarm verifies
the ink pressure stability in order to avaid pressure peak.
It is possible to enable or disable this alarm from the DISTRIBUTOR PAGE + .
Maintenance Warning
MAINTENANCE WARNING: When this alarm triggers (STATUS=ON), it means that the
system advises the user to call the service department for a regular maintenance pro-
cedure. (refer to chapter 7 page 194)
3.87
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3
Tank Alarms
The ink and the make-up tanks are provided with three sensors that check the levels of the ink and
make-up inside. These sensors can detect three dierent alarms:
1 - Make-Up Missing
2 - Ink Level Low
3 - Tank Too Full
Tank Full Sensor

(white wire) Ink Level Low
Sensor (black
wire)
GND Make-Up Sen- GND Ink sensor

sor (blue wire) Make-Up Missing (blue wire)
Sensor (red wire)
3.88
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3
1 - Make-Up Missing
The Make-Up cartridge is empty. The system stops sucking from the make-up cartridge but the printer
s ll works. Replace the Make-up cartridge with a new one.
REPLACE THE USED CARTRIDGE WITH A NEW ONE AS SOON AS POSSIBLE.
If the Make-Up Missing Alarm is ignored for 1 hour, the system shows the following message:
PLACE IN A NEW MAKE-UP

CARTRIDGE OTHERWISE THE SYSTEM
WILL STOP IN 1 HOUR!
Then, if also this warning is ignored for 1 hour more, (total 2 hours) the system will be shut OFF auto-
ma cally and it shows the following message:
SYSTEM HAS TURNED OFF DUE TO

EXTENDED MAKE-UP MISSING
PLACE A NEW MAKE-UP CARTRIDGE
CAUTION: REPLACE THE USED MAKE- UP CARTRIDGE WITH A NEW ONE ONLY WHEN THE
MAKE-UP MISSING ALARM IS ON. FOR USED MAKE-UP CARTRIDGE REPLACE-
MENT USE JUST 1 MAKE UP CARTRIDGE
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3
2 - Ink Level Low

The ink level in the mixing tank is too low but the system s ll works. Replace the empty ink cartridge
with a new one (very important: only one cartridge). If the alarm will be ignored for 2 hours, the sys-
tem shows the following message:
THE TANK IS EMPTY

PLACE IN A NEW INK CARTRIDGE
OTHERWISE THE SYSTEM WILL STOP
IN 2 HOURS
Then, if also this warning is ignored for 2 hours more, (total 4 hours) the system will be shut OFF
automa cally and it shows the following message:
SYSTEM HAS TURNED OFF DUE TO

INK LEVEL TOO LOW.
PLACE IN A NEW CARTRIDGE
AND TURN THE SYSTEM ON.
CAUTION: REPLACE THE USED INK CARTRIDGE WITH A NEW ONE ONLY WHEN THE INK LEV
EL LOW ALARM IS ON. FOR USED INK CARTRIDGE REPLACEMENT USE JUST 1
INK CARTRIDGE
3- Tank Too Full

The ink level in the mixing tank is too high but the system s ll works. Switch o the system unscrew the
tank cap and remove the excess ink from the tank manually.
3.90
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Print Head Alarms
The system check the status of the print head and advises the user of three possible alarms:
1 - Print Head Cover Missing

2 - Gu er Alarm
3 - High Voltage Alarm
1 - Print Head Cover Missing

The print head cover has been removed. The system switches the H.V. on the plates o. Fit the Print Head
Cover or make sure it is correctly installed.
cover sensor
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2 - Gu er Alarm
The gu er sensor detects when the ink stream does not flow into the gu er and shut the ink stream o
automa cally. Check the alignment of the ink stream and clean the nozzle.
GUTTER
GND
GUTTER
SENSOR
GUTTER
SIGNAL
CAUTION: the short gu er pipe (figured into below picture) must be always 4x2 diameter
and 19 mm long for a proper gu er alarm running. The inner distance between
the gu er and gu er sensor is 9 mm.
9 mm
19 mm
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3 - High voltage Alarm
Spark on H.V. Plates
The system detected electrical sparks between the

H.V. plates.
Causes: impurity (ink, dust, moisture, pieces of pa-

pers etc.) or incorrect working of H.V. black plugs.
Solu ons: H.V. plates

- Clean the printhead and verify the correct
working
- Check for humidity and/or dust
- Check the H.V. values, using the H.V. PROBE,
directy into the H.V. plates
- Check the H.V. generator disconnec on of the
H.V. cable on the logic board side
Hydraulic Alarms
The two alarms present in the hydraulic compartment are:
1 - Viscometer Alarm
2 - Pressure Alarm
1 - Viscometer Alarm
Viscometer Fault
This alarm switches on when the Viscometer is not

able to read the viscosity value for 3 consecu ve
mes.
Causes: sphere blocking due to dirty, air

bubbles, high viscosity, blocked viscometer
circuit and clogged visco valve.
If the alarm is ON, the viscometer s ll tries to mea-

sure the viscosity.
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2 - Pressure Alarm
This alarm switches on when the system is not able to reach

the pressure set-up on the SETTING PAGE. The pressure is
measured by the Pressure Transducer.
Causes:
- Incorrect working of the Force Motor
- Incorrect working of the Force Pump Pressure Transducer
- Main Filter clogging
- Ink level low
- High viscosity
- Incorrect working of the Pressure Transducer.
3 - Pressure Revolu ons Alarm
PRESSURE REV. ALARM: When this alarm triggers (STATUS=ON), it means that the motor overruns the
maximum number of revolu ons admi ed.
During the system start up this alarm verifies the ink pressure stability in order to avaid pressure peak.
It is possible to enable or disable this alarm from the DISTRIBUTOR PAGE + .
Causes:
- Incorrect working of the Force Motor
- Incorrect working of the Force Pump
- Hydraulic Circuit clogging
- Hydraulic Circuit leaking
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NOTES
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NOTES
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3.96
Electronic Compartment 4
Power Supply
Main Switch
Switching Power Supply
Ven la on Fan
Main Logic Board
General Informa on
Main Components
Hydraulic Signals
Main Signals
Test Point Checking Procedure
Hydraulic Board
Motors
External Connec ons
Photocell
Encoder
Serial Line (connec on to the pc or to the scanner)
Alarms Output
Print Head Cover Sensor
Pacar Card
Print Head Micro Valve Card

Z 3000
ELECTRONIC COMPARTMENT CHAPTER
4
The Electronic Compartment is composed of the following components:
4
7
2
1. CPU Main Board
3 2. Switching Power Supply
3. Fan
4. EV Hydraulic Board
5 5. Force Motor
6. Keydis board
7. Liquid crystal graphic display
1. Main Logic board: The CPU microprocessor board coordinates all the various required func ons for the
correct opera on of the system. All the calcula ons and control processes are made inside this board, that
also prepares the data to be printed. More over, the CPU board performs the following tasks:
1. stores the text messages, logo etc.

2. controls the parameters that have been set and acts accordingly,
3. verifies if any alarms are enabled and sends the warning to the GCU board,
4. manages the alarm,
5. manages the internal clock and counters,
6. manages the interface with the field signal such as photocell or encoder signals,
7. monitors the hydraulic system,
8. generates the modula ng signal to the tubus,
9. generates the charge signal for the droplets during the prin ng process,
10. syncronizes the droplets charge signals with the droplets,
11. generates and controls the 300 Vdc voltage for the droplets charge,
12. generates anc controls the 4kVdc high voltage for the deflec on plates.
4.99
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CHAPTER ELECTRONIC COMPARTMENT
2. Switching power supply: generates and supplies the direct voltages required by the electronic circuits
and all the other electrical devices. It supplies direct voltages 12 V, +24 V and + 5V, star ng from an al-
The incoming alterna ng voltage is previously filtered by a line trap (that also contains the fuses) in order
to damp all electrical noises and is then transferred to the switching power supply, to the motor and to
the fan.
3. Fan: 24Vdc fan to cool down the electronic sec on.
4. Hydraulic board: it connects the electronic system to the electrovalves and it shows their status with
LEDS
5. Motor: the motor drives the force pump.
6/7. Graphic Control Unit (GCU board): microprocessor logic board that performs the following tasks:
1. Operators interface management.

2. Management and programming of the CPU board messages, logo, etc.
3. CPU board parameter programming.
4. Alarms and warning signals ac va on.
On the GCU is fi ed a liquid crystal graphic display with 240x64 dots with LED back
ligh ng to guarantee readability even in poor light condi ons. The board also manages
a 53 keys keyboard for programming and text inser on purposes.
4.100
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4
220/110 VAC Main Switch
Power
Switching
Pressure
Transducer
Viscometer
5Vdc; 12Vdc; 24Vdc
24Vdc Ink/Make-Up
Hydraulic Level Signals
Board
Ventilation
Fan
Force Pump/Motor
Logic
Board
Keyboard
IO/Int
Board
PrintHead
4.101
Z 3000
4
Power Supply
power cable
Before connec ng to the mains, make sure that your voltage and frequency are compat-
ible with the system
The power supply must be: 85-240 Vac, 50-60 Hz single phase, grounded
In any case, make reference to the model plate on the rear of the unit.
The power supply must be free from cuts or varia ons in power. We strongly recommend the use of a
Uninterrup ble Power System (UPS) to protect the unit against high varia ons in frequency and/or volt-
age.
UPSS are available from your supplier and must be choosen according to the power ra ng of the sys-
tem.
The system must be properly grounded. Failure to do so will aect the system and safety
protec on to users. A stranded copper conductor with an area of 0.75 mm2 minimum
(0.0012 sq. in.) must be used to connect the unit to the mains and to the ground system.
The power cord should be installed in a protec ve conduit or a cable trunking system.
All the electrical works must be performed in accordance with your local regula ons.
4.102
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4
DO and DO NOT
DO NOT allow sudden cuts in the power supply.

DO NOT allow nearby machines or devices to aect or disturb the system.
DO NOT plug the power cord of the system to a panel that supplies other machineries.
If there is not other way than this, install an UPS between the unit and the panel.
DO periodically check that the plugs, sockets and cords are in good working order.
DO contact your supplier if you have any doubts about your electrical connec ons.
Grounding the System
It is very important to properly ground the system (between Neutral and Ground must be present
0.6V/2V). The print head and every other devices must be grounded through the system itself.
Failure to do so may create ground loops and aect the noise immunity of the system.
4.103
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4
Main Switch
(90-134 Vac or 186-276 Vac, 48-65 Hz)
main switch
Main power switch with filter
The AC voltage is filtered to reduce electrical noise and then reaches the switching power supply.
If no AC voltage reaches the power supply, check the connec ons and, if necessary, replace the fuses
located on the bo om of the I/O card with fuses of the same rate.
4.104
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4
Switching Power Supply FZ03
(90-134 Vac or 186-276 Vac, 48-65 Hz)
connector 1
(Input)
connector 2
(Output)
Switching power supply: generates and supplies the direct voltages required by the electronic circuits
and all the other electrical devices. It supplies direct voltages 12 V, +24 V and + 5V, star ng from an al-
Connector 1 (Input)
4 GND (yellow/green wire)

3
2 Neutral (brown wire)
1 Phase (blue wire)
Connector 2 (Output)
-12Vdc (YELLOW) 1 2 +5Vdc (WHITE)

GND (ORANGE) 3 4 NOT USED
GND (BLUE) 5 6 NOTUSED
NOT USED 7 8 NOT USED
NOT USED 9 10 +12Vdc (GRAY)
NOT USED 11 12 NOT USED
+24 Vdc (BROWN) 13 14 NOT USED
15 16
NOT USED NOT USED
4.105
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4
Ven la on Fan
It is located under the unit; its fuc on is to cool down the electronic compartment.
Fan
Fan Filter
Fan Cover
Technical Characteris c:
Dimension: 80x80x25 (millimeter)

Power Supply: 24 Vdc
This table provides the preven ve FAN MAINTENANCE SCHEDULE, in addi on to inform on periodic
cleaning and replacement of components.
Fan Maintenance Schedule
HOW OFTEN TO PERFORM PROCEDURE

Every week (dusty enviroment) Clean the fan filter
Every month (normal enviroment) Clean the fan filter
Every year (once per year) Change the fan filter
CAUTION: Depending on the type of environment, it is necessary to clean the fan filter
periodically in order to avoid the over hea ng of the Electronic sec on.
4.106
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4
Main Logic Board (Release 0308)
General Informa on
2 4
3
1
7
5
6
1) Power Supply Area

2) Hydraulic Area
3) Logic Area
4) Keyboard Area
5) Alarm and I/O signals
6) Head signals
7) Logic Board Version
4.107
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4
Main Components
Logic Board (Release 0308)
4.108
Z 3000
4
1) U22: Microcontroller HD2632683 MD2 with frequency 18,342 MHz, an internal buer on
32 bits, an extenal buer on 16 bits and an internal flash memory by 256 KBytes.
2) J8: Connector to download the program into the Microcontroller.
3) U28 and U29: Systems RAM HM628512. They have one inner ability to 1 MBytes.
4) U27: Flash Memory EPROM and it has one inner ability to 512 KBytes.
5) U16: EPLD to support the Microcontroller and Keyboard.
6) J6: Connector to download the program into the EPLD.
7) U44: EPLD to support the Charge and Nozzle Signal.
8) J3: Connector to download the program into the EPLD.
9) J14: Connector for the HYDRAULIC BOARD.
10) J7: Connector for the Force Motor.
11) J12: Print Head connec ons.
12) J9: Power Supply connec ons.
13) J4: Keyboard connec ons.
14) J2: I/O Card connec ons.
15) BOARD RELEASE: To state the Main Logic Board Release.
Switches Se ng:
SWITCH 1:
Always 1-2
SWITCH 3:
SERIAL M IN ID IP S W 2
ADDRESS = 0 4 3 2 1
0 O FF O FF O FF O FF
1 O FF O FF O FF ON
2 O FF O FF ON O FF
Serial Address
3 O FF O FF ON ON
4 O FF ON O FF O FF
ON = 1 OFF = 0 5 O FF ON O FF ON
6 O FF ON ON O FF
7 O FF ON ON ON
SERIAL 8 ON O FF O FF O FF
9 ON O FF O FF ON
ADDRESS = 15 10 ON O FF ON O FF
11 ON O FF ON ON
12 ON ON O FF O FF
13 ON ON O FF ON
14 ON ON ON O FF
ON = 1 OFF = 0 15 ON ON ON ON
4.109
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4
Main Signals
Logic Board (Release 0308)
NOZZLE
CHARGE
PHASE
4.110
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4
Test Points checking procedure
Connect the probe of the oscilloscope to the desired test point of the Logic Board to be controlled and its
correspondent ground point (GND):
- Test Point Nozzle for the Nozzle checking:the wave form must be as follows
oscilloscope se ng
- Test Point Charge for the Charge checking:the wave form must be as follows
oscilloscope se ng
4.111
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4
- Test Point Phase for the Phase checking:the wave form must be as follows
oscilloscope se ng
CAUTION: For an easier and faster checking, it is possible to check the Nozzle and
the Charge signal on the Head
Connect the probe of the oscilloscope to the desired test point of the CPU to be controlled and its cor-
respondent ground point (GND):
NOZZLE SIGNAL
CHARGE SIGNAL
GND (tubus)
Charge Signal: located on the Charge Electrode

Nozzle Signal: located on the Oscillator wire
4.112
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4
Hydraulic Board (Version Idra 3000 0608)
Electrovalve Connec on Board: it connects the electronic system to the electrovalves and shows their
status with Leds.
TRANSDUCER LEVELS
1 Brown 1 Red (Make Up)
2 Blue 2 Blue (Gnd)
3 White 3 Black (Ink)
4 Black 4 White (Tank Full
5 Not Used 5 Not Used
6 Not Used 6 Not Used
VISCOMETER
VALVES
1 Brown
2 Black 1 Not Used
3 Not Used 2 White
4 Blue 3 Blue
5 Not Used 4 Brown
6 Not Used
4.113
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4
Motor
(motor/pump assembly)
CAUTION: into Z3000 system there is a unic block concerning the motor assembly which is
composed of driver motor and the force pump. The integrated assembly guarantees an easier
set up (the motor is connected directly to the main logic board) and higher performances.
White
Green
Not Used
Yellow
Brown
Brown
White
Green
Not Used
Yellow
4.114
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4
External Connec ons
IO_INT board (External connec ons panel): this panel contains all the connectors to interface the system
with various field devices: serial line to a PC or a scanner, encoder, product sensor (addi onal photocell),
external alarm.
On the IO_INT board there are two dierent connectors:
1. the 15 pin connector used for: Alarms Output

Serial Line RS232
Encoder
2. the 9 pin connector used for: Product Sensor Input (Photocell)
CAUTION: If mul ple sensors are connected to the I/O connector (Product Sensor, Speed
Sensor) they must be of the same kind (all set to N.P.N. or all set to P.N.P.). Moreover, if a
free contact connec on is used in addi on to another sensor, the COMMON contact must
be of the same kind too.
CAUTION: Sensors must always be plugged or unplugged when system is turned OFF!
4.115
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4
Photocell
The product sensor must be installed in such a way that it does not get
dirty or splashed with ink. The later might arise when the sensor is in-
stalled right in front of the print head.
Various types of product sensors can be used:
- Direct reflec on photocell (standard)

- Photocell with reflector
- Op cal fiber photocell
- Induc ve sensor
The sensor should always be posi oned as much near to the print head as possible, whether it is in
front of it or on the same side.
The connec ons to the 9 pin female connector are the following: 5 4 3 2 1
1. +24 VDC (square pin)

2. Photocell signal
3. not used
4. Common signal for photocell
5. GND
6-9 not used
9 8 7 6
CAUTION: If mul ple sensors are connected to the I/O connector (Encoder, Print direc on
input), they MUST be of the same kind (all set to N.P.N. or all set to P.N.P.). Moreover, if a free
contact connec on is used in addi on to another sensor, the COMMON contact MUST be of
the same kind too.
Connec ons are the following:
4.116
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4
Encoder
When the speed of the produc on line is variable it is necessary to install an

encoder in order to synchronize the prin ng with the speed of the product.
Here below the encoder characteris c :
- The encoder must be of the N.P.N. or P.N.P. OPEN COLLECTOR 24

VDC type.
- MAX Encoder Frequency = 90KHz
The connec ons to the 15 pin female connector are the following:
1. Common signal (square pin)

2. TX 232
3. RX 232
4. Direc on 8 7 6 5 4 3 2 1
5. GND
6. +24 VDC
7. not used
8. not used
9. +24 VDC
10. Low alarm
11. High alarm
12. System ready 15 14 13 12 11 10 9
13. GND
14. Encoder signal
15. not used
the same kind too.
SUGGESTED ENCODER TYPE: - 2500/5000 pulse/revolu on (mostly used)

- NPN
- PUSH/PULL EXIT
- BIDIRECTIONAL
4.117
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4
When the operator sets the Print Direc on parameter, the pin correspon-
ding to the bit direc on on the 15 pin inputs connector is enable in order
to invert the prin ng message using a external input.
NOTE: to enable this func on it is necessary set up the parameters PRINT

DIRECTION=Y present into SET MENU at ENABLE PAGE

2. TX 232
3. RX 232
4. Direc on
5. GND
6. +24 VDC 8 7 6 5 4 3 2 1
7. not used
8. not used
9. +24 VDC
10. Low alarm
11. High alarm
12. System ready
13. GND
14. Encoder signal
15. not used 15 14 13 12 11 10 9
the same kind too.
NOTE: It is not possible to connect the Print Direc on Input with the N.P.N. logic.
4.118
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4
Serial Line (connec on to the PC or to the scanner)
Typically a serial line allows the connec on of a PC or a scanner to the

system. The serial line available is the RS232 that allows a connec on
up to 15 metres in a point-to-point configura on, i.e. only one system
for every serial line

2. TX 232
3. RX 232
4. Direc on
5. GND 8 7 6 5 4 3 2 1
6. +24 VDC
7. not used
8. not used
9. +24 VDC
10. Low alarm
11. High alarm
12. System ready
13. GND
14. Encoder signal 15 14 13 12 11 10 9
15. not used
Depending on the PC connector type (9 or 25 pins) the connec ons are the following:
4.119
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4
Alarms Output
On the 18 pin male connector on the side of the cabinet have been set 3
Digital Output (Low Priority Alarm, High Priority Alarm and System Ready)
8 7 6 5 4 3 2 1
2. TX 232 9. +24 VDC
3. RX 232 10. Low alarm
4. Direc on 11. High alarm
5. GND 12. System ready
6. +24 VDC 13. GND
7. not used 14. Encoder signal
8. not used 15. not used
15 14 13 12 11 10 9
The Outputs connected to the Alarm board must absorbe less than 500 mA
4.120
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4
All signals between the Main Board and the Printhead passes through the connector J12.
J12
Here following the Table with all the connec ons.
Connections on MAIN LOGIC BOARD (J12)

Pin number Signal Function Pin number Signal Function
1 Charge Signal to the Charge Electrode 13 not used not used
2 not used not used 14 Gnd Gnd Charge Cable Shielding
3 Nozzle Signal to the Oscillator 15 Gnd Gnd Oscillator Shielding
4 +12 Vdc Pacar Card 16 Gnd Gnd Print-Head Frame
5 -12 Vdc Pacar Card 17 Gnd Gnd Pacar Card
6 not used Gnd 18 Phase Signal Phase Signal, Pacar Card
7 +24 Vdc Cover Sensor 19 not used not used
8 Cover Sensor Signal Cover Sensor 20 Gnd Gnd Cover Sensor
9 not used Gnd 21 Gutter Signal Gutter Signal to Gutter Sensor
10 not used not used 22 Gnd Cable Shielding
11 EV Flush Signal EV Flush 23 EV Ink Signal EV Ink
12 not used not used 24 +12/24 Vdc EV Com
25 not used not used
4.121
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4
On the Print-Head are placed two small boards: the Microvalve Card and Pacar card.
1. Cover Sensor
3
2. Pacar Card
3. Microvalve Card
1 - Print Head Cover Sensor
This Sensor detects if the print head cover has been removed or fit correctly. Here below the connec-
ons:
+24 Brown wire

Gnd Blue wire
Signal Black wire
Cable wires from Logic Board Cover Sensor wires

Function / Signal Wire color Wire color
+24 Vdc Brown connected to Brown
Gnd Black connected to Blue
Signal Violet connected to Black
4.122
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4
2 - Pacar Card
This board amplifies the signal from the Phase electrode to the logic board. Here below the connec-
ons:
component side
+12 Vdc (Gray/Pink)
Gnd (White)
Input Phase Phase Signal

Signal Output (Blue)
Shielding -12 Vdc (Red/Blue)
Connection on Pacar Card

Wire Color Function / Signal
Gray/Pink +12 Vdc
White Gnd
Blue Phase Signal Output
Red/Blue -12 Vdc
3 - Print Head Micro Valve Card
On this board are connected the two print head microvalve. Here below the connec ons:
component side
EV2 flush (pink)

flush valve
+24 Vdc (red)
ink valve
EV1 ink (gray)
Connection on Microvalve Card

Wire Color Function / Signal
Pink Signal EV2 (flush)
Red +12/24 Vdc,EV common
Gray Signal EV1 (ink)
4.123
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4
NOTES
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4.124
Print Head 5
Print Head
General Informa on
Break Point
Print Head Layout

Z 3000
5
PRINT HEAD CHAPTER
Print Head
General Informa on
The Print Head is connected to the control unit by umbilical black cable (2 meters), and receiving pres-
surized ink, the print head turns the ink stream into the ny electrically charged ink droplets which are
deflected onto a substrate to form a printed code. Following we describe the rela onship between the
various components of the print head.
1. Cover Sensor
2. Tubus 3
3. Nozzle 4 5
6 8
4. Charge Electrode
5. Phase Electrode
6. Deflec on Plate Nega ve 1
(-4000 Vdc)
7. Deflec on Plate Posi ve
(+4000 Vdc) 2
8. Gu er 7
The pressurized ink enters into the tubus and comes out through the nozzle. The tubus receives a modu-
la on signal and it produces the ink stream vibra on.The induced vibra on generates
64,000 equally sized droplets each second.
The charge electrode surrounds the ink stream at the point where it breaks up forming the droplets. The
electrode supplies an electrical charge to the droplets. The system sends high amplitude voltage pulses
to the electrode during the prin ng process and low amplitude voltage pulses during phase control.
During the phase control the phase detector electrode measures the charge of the passing droplets and
it sends the signal back to the electronic control system.
Between the two deflec on plates there is an electrosta c field. The charged droplets are deflected
when they pass through this field. The field is generated by a high voltage generator that it is switched
on only when the ink stream is running and the print head protec ve cover is in place.
The ink droplets that have not been used for prin ng, they enter into the gu er and return back into the
ink tank.
NOTE: The print head cover must be always in place during prin ng opera ons.
5.127
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CHAPTER PRINT HEAD

- The oscillator transmits to the ink stream a vibra on with a fixed frequency of 64kHz and variable ampli-
tude.
- The ink stream comes out from the nozzle (50 or 70 micron) and, when it breaks, originates 64.000 drop-
lets per second.
- The correct break point must be set in the middle of the Charge Electrode: only in that way
the drop is charged in the correct way to be correctly posi oned.
- The droplets pass through the 2 deflec on plates, where they are deflected by an electric field propor-
onally to the received charge:
-each charged droplets is placed on the substrate in a correct defined posi on (deter-
mined by electrical charge received from the charge electrode).
-the neutral droplets are collected into the Gu er and they are sucked back to the ink
tank.
5.128
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5
PRINT HEAD CHAPTER
Gu er
Phase Electrode
Charge Electrode
Oscillator
5.129
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5
CHAPTER PRINT HEAD
Break Point
In order to have a good prin ng quality it is necessary to respect the following points:
TIME: only during the breaking point it is possible to charge the droplets
POSITION: only if the break point is in between of the charge electrode it is possible
to charge the droplets
The elements that can change the break point are:
- Pressure: PRESSURE REF e READ

- Ink viscosity: VISCOSITY READ
VISCOSITY REF: INK TYPE
VISCO SET (25 C)
TEMPERATURE
- Temperature: the ink temperature range is from 5C to 45C
- Nozzle: 50m, 70m or dirty
- Oscillator
- Ink: Expired, Contaminated or Ink changing
- Head Adjustments : Ink stream in the middle of the charge electrode
Ink stream adjustment (gu er)
- Oscillator Amplitude (Load Rod Amplitude)
Target:
- PRINTING RANGE
Breack Point Fly Time Picture (next page)

Viscosity increases Toward Tubus Increases 2
Viscosity decreases Toward Phase Electrode Decreases 3
Pressure increases Toward Phase Electrode Decreases 3
Pressure decreases Toward Tubus Increases 2
Amp. Osc. increases Toward Tubus Increases 2
Amp. Osc. decreases Toward Phase Electrode Decreases 3
- FLIGHT TIME: distance between the break point and the phase electrode. Typical value from 350 to
580
5.130
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5
PRINT HEAD CHAPTER
Picture 1
correct break point (Flight Time correct)
Picture 2
wrong break point (Flight Time high)
Picture 3
wrong break point (Flight Time low)
5.131
Z 3000
5
CHAPTER PRINT HEAD
Print Head Layout
1. Rear cover 12. Tubus cap o-ring

2. Magne c sensor M8 13. Oscillator
3. Micro valves connector 14. Oscillator o-ring
4. Micro valve manifold 15. Tubus body
5. Micro valve manifold o-ring 16. Nozzle o-ring
6. Micro valve o-ring 17. Nozzle
7. Ink micro valve 18. Span tool for removable nozzle
8. Flush micro valve 19. Deflec on plates
9. Pacar card 20. Tubus support
10. Print Head cover 21. Print Head bracket
11. Tubus cap 22. Gu er
5.132
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5
PRINT HEAD CHAPTER
NOTES
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5.133
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CHAPTER PRINT HEAD
NOTES
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5.134
First Start Up Of The System 6
Unpack the Printer
Removing the Printer from the Carton
Supplemental Parts
Printer Stand
Power Supply
Preparing the Printer for Use (Manual Start Up Procedure)
Ink Filling
Make-Up Filling
Printer Start-Up
Print Head Set-Up
Wizard Procedure

Z 3000
6
FIRST START UP OF THE SYSTEM CHAPTER
Unpack the Printer
Removing the printer from the carton

Remove the printer from its carton and visually inspect it for damaging. Examine the control unit, the um-
bilical black cable and the print head closely. The printer is packed carefully at the ZANASI manufacturing
facility. If any damage is noted, file damage claims with the carrier.
Supplemental Parts
Inside the carton, the bag of supplemental parts included with packed printer contains the following
items:
SUPPLEMENTAL PARTS
Quantity Description
1 Supply Cable
1 Photocell
1 Photocell Bracket
1 Mini Screwdriver
1 Squeeze Bottle
1 Beaker
1 Instruction Manual
6.137
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CHAPTER FIRST START UP OF THE SYSTEM
Printer Stand
The Z3000 printer is a free-standing unit, however

it should be secured to a printer stand for stability
and prac cality. The printer stand is available from
your supplier, so set up unit and print head on it like
showed into the following picture:
Power Supply
Before connec ng to the mains, make sure that your
voltage and frequency are compa ble with the system.
The power supply shall be: power cable
85-240 Vac, 50-60 Hz single phase, grounded
In any case, make reference to the model plate on the

rear of the unit.The power supply must be free from cuts
or varia ons in power. We strongly recommend the use
of a Uninterrup ble Power System (UPS) to protect the
unit against high varia ons in frequency and/or voltage.
The UPS is available from your supplier and must be
choosen according to the power ra ng of the system.
CAUTION: It is very important to properly ground the system. The print head
and every other device must be grounded through the system itself.
Failure to do so may create ground loops and aect the noise
immunity of the system.
6.138
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6
Preparing the Printer for Use

(manual start up procedure)
Push the main power to switch the system ON.
In the main page appears LOW PRIORITY ALARM

cause INK and MAKE-UP missing.
Press bu on to visualize each specific alarm:
MAKE-UP MISSING and INK LEVEL LOW
Remove the metal cover on the printhead.
6.139
Z 3000
6
Remove the cloth which protects the

nozzle and do not remove the black cov-
er from the gu er.
Remove the empty cartridges from the

ink and make-up tank.
6.140
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6
Ink Filling
CAUTION: FOR THE START-UP PROCEDURE AFTER FLUSHING USE JUST 1 INK CARTRIDGE
INK
Cut the top of the plas c seal from the

ink cap cartridge
INK Shake vigorously the cartridge.
Using the correct cleaned solvent to get

wet the sealing lip washer
6.141
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6
INK INK
Gently push the ink cartridge inside the
ink housing (the le one). Be sure the
black cap of the cartridge is completely
inserted. The seal membrane will be
punctured by the plas c puncher.
Wait a few minutes un l the INK LEVEL

LOW alarm has turned o.
INK
6.142
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6
Make-Up Filling
CAUTION: FOR THE START-UP PROCEDURE AFTER FLUSHING USE JUST 1 MAKE-UP CAR-
TRIDGE
MAKE-UP
Cut the top of the plas c seal from the

make-up cap cartridge
Using the correct cleaned solvent to get

wet the sealing lip washer
MAKE-UP MAKE-UP
Gently push the make-up cartridge inside

the make-up housing, (the right one). Be
sure the black cap of the cartridge is com-
pletely inserted. The seal membrane will
be punctured by the plas c puncher.
Wait a few minutes un l the MAKE-UP

MISSING alarm has turned o. NOTE:
the make-up cartridge will not be com-
pletely empty.
6.143
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6
Printer Start-Up
Press to enter into the MENU SET. The display will show the following page:
Press un l the display shows the following page:
6.144
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6
Set the GUTTER ALARM..........(Y/N)= N in order to disable the Gu er Alarm
Set the START UP FLUSHING..........(Y/N)= N in order to disable the Start Up Flushing
Press : the green LED is on and the system is flushing the Printhead. In the mean me
A er 40 seconds the system automa cally switches the ink stream on, the display shows the following
page:
6.145
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6
A er 50 seconds the green LED on the key turns ON. The display shows the following page:
CAUTION: High Priority Alarm turns on because the cover is missing; at this me
do not take care about it.
When the message >> INK STREAM ON << appears, press to enter into the COMMAND PAGE
and the display will show the following page:
6.146
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6
Press to enable the Purge Valve for 30 seconds. The system will automa cally shows
the MAIN PAGE
CAUTION: During the PURGING SYSTEM shake the Main Filter, Damper
and Black Filter to help the system in order to remove air from
hydraulic circuit.
When the message PURGING THE SYSTEM........... will disappear, press again to repeat
the purging procedure. ATTENTION: Repeat 5 mes this procedure
A er 5 purging procedures, press bu on and the display will show the following page:
Press to enable the standard automa c cleaning shut down procedure.
6.147
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6
The display will show the following page:
A er 100 seconds the system finishes the automa c cleaning shut-o procedure and the display shows
the following page:
When the massage >>SYSTEM OFF<< will appear, set up the printhead as following described
6.148
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6
Print Head Set Up
Remove the black cover from the gu er.
Remove the tube connected to the tubus

A en on: This pipe is 4x2
Cut the tube connected to the head in order to

obtain two pipes with the follow measure:
1- Ink line: 37 mm (1,46)

2- Purge line: 54 mm (2,12)
Connect the two pipes to the tubus.
6.149
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6
DO NOT CLEAN HERE Clean the print head only in the cleanable area
CLEAN ONLY HERE and use a lint free cloth to dry the head
black
knob
washer
Put a metal washer or a coin on the cover sensor

and hold it by the black knob
6.150
Z 3000
6
Wizard Procedure
The wizard procedure leads the operator during the FIRST SYSTEM START UP to properly arrange
the system. Thi procedure can be enabled by pressing <F3> START UP PROCEDURE into the
DISTRIBUTOR PAGE 2.
It is possible for the first start up of the system to enable this procedure in order to have a com-
plete system check up.
1 2
REMOVE THE EMPTY CARTRIDGES
OF INK AND MAKE-UP BY TURNING INSERT THE INK AND MAKE-UP
AND LIFTING UP THEM FROM THE CARTRIDGES BY WETTING THE
CAP.WET THE CAP WITH SOLVENT CAPS WITH SOLVENT BEFORE
BEFORE CARTRIDGES REMOVING INSERTING THEM
3 4
WAITING FOR CHECKING INK FALL DOWN ERROR !!!
INK AND MAKE-UP LEVELS INK AND MAKE-UP LEVELS CORRECT
INTO THE TANK... PRESS F4 TO CONTINUE
6.151
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6
6 7
REMOVE THE MAIN FILTER AND REMOVE THE METAL COVER
THE DAMPER TO SHAKE THEM FROM THE PRINT HEAD AND WET
DURING THE SYSTEM START-UP THE NOZZLE PROTECTION LINT
WITH THE SOLVENT
8 9
MAKE-UP ELECTROVALVE VISCOMETER ELECTROVALVE
TEST TEST
CHECK THE ELECTROVALVE CHECK THE ELECTROVALVE

CLICK EACH HALF A SECOND CLICK EACH HALF A SECOND
10 11
PURGE ELECTROVALVE INK ELECTROVALVE
TEST TEST
CHECK THE ELECTROVALVE CHECK THE ELECTROVALVE

CLICK EACH HALF A SECOND CLICK EACH HALF A SECOND
6.152
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6
12 13
FLUSHING ELECTROVALVE
TEST FORCE AND SUNCTION PUMPS
TURNING ON
CHECK THE ELECTROVALVE SHAKE THE MAIN FILTER AND
CLICK EACH HALF A SECOND THE DAMPER
14 15
VISCOMETER RUNNING
TEST
**** CORRECT PRESSION ****
-----------------------------------
WAIT FOR THE BEEP CONFIRM
VISCOMETER READING
16 17
CORRECT VISCOSITY READING! VISCOMETER READING ERROR!

SWITCH THE SYSTEM OFF
6.153
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6
18 19
WAIT FOR THE INK CIRCUIT
FILLING WAITING FOR THE FILLING
OF THE FLUSH CIRCUIT
SHAKE THE DAMPER AND THE
INK FILTER
20 21
REMOVE THE BY-PASS BETWEEN THE REMOVE THE NOZZLE PROTECTION,

PURGE AND INK PIPES ON THE LINT AND FLUSH THE NOZZLE
TUBUS AND CUT AND CONNECT UNTIL THE SOLVENT COMPLETELY
THE LONG PIPE TO THE TUBUS FLOWS THROUGH THE PURGE PIPE
ENTRANCE (RIGHT PIPE)
22 23
REPLACE MAIN FILTER AND DAMPER

REMOVE THE GUTTER PROTECTION IN THE CORRECT POSITION AND
AND DRY THE PRINT HEAD PERFECTLY PLACE THE BEAKER IN FRONT OF THE
PRINT HEAD
6.154
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24 25
*******************************************
**************************************
TEST INTERRUPTED BY THE USER
* TEST REGULARLY FINISHED *
*******************************************
***************************************
SWITCH THE SYSTEM OFF AND
CORRECT THE ERROR!
6.155
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6
Turning the System On

Press : the green LED is on and the system is flushing the tubus. In the mean me
A er 40 seconds the system automa cally switches the ink stream on, and the display shows the
following page:
A er 50 seconds the green LEDS (on the keys and ) turn ON and the system is ready to
print. The display shows the following page:
6.156
Z 3000
6
Check the ink stream

alignment
Remove the washer and install the cover on the

head.
Note: removing the washer the system disables
the H.V. on the plates and the
bu on will turn o
Enable the gu er alarm, and then enable the H.V.

pressing bu on
Note: check the chapter 4 for the photocell connec on and programming
6.157
Z 3000
6
CAUTION: If the Start Up procedure has not been successfully concluded,

the LED on bu on will turn to red and the system displays
the alarm message on the main page:
Press bu on to display the specific alarm
Press the display shows the following page:
Self Cleaning. (following the instruc ons described in the chapter 8 page 235)
6.158
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6
Turning the System O
CAUTION: do not switch the system o by turning the main power switch o directly.
Press START/STOP bu on which allows the system to complete the automa c shut down
procedure.
Press : the display shows the following page
Press to enable for 100 seconds the standard automa c shut down procedure.
Press + to enable for 120 seconds the extended automa c shut down procedure.
The display shows the following page:
6.159
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6
A er the automa c shut down procedure the LED on bu on will switch OFF and the display shows
the following page:
When the display shows >> SYSTEM OFF << , push

the main power to switch the system OFF.
Several regular maintenance func ons to ensure op mum printer opera on
do not clean the nozzle during the shut down procedure.The dry ink makes a protec on cap
over the nozzle hole to keep out air and dust from entering into the nozzle, because they can
cause unstable ink stream. During the automa c shut down procedure, only clean the gu er
conduit by flushing the gu er on the printhead with proper solvent (8 seconds). Clean the
printhead, specially the nozzle, at the start of every shi or work period.
in case you do not use the system for an extended period of me (more than 4-5 days) it is
strongly recommended to switch the system o by pressing
+ doing the extended shut down.
6.160
Z 3000
6
NOTES
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6.161
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NOTES
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6.162
Programming So ware Release 1.02 7
Keyboard Descrip on
Main Page
Alarms Page
Menu Set
Edit Page
Brief Coding Types Guide
System Password
Logo Editor
Distributor Page
Maintenance Warning
Communica on Protocol
Z 3000
7
PROGRAMMING CHAPTER
Keyboard Descrip on
This sec on describes the keys on the keyboard. The keyboard is located on the front of the printer cabi-
net and it is organized into many sec on, each of which contains keys dedicated to perform a specific
printer fuc on.
6 4 3 4 7
1 2
9 10
The keyboard contains the following components:
Control Key ................................... corresponding items number: 1-2

Display Screen............................... corresponding items number: 3
Status Lights................................. corresponding items number: 4
Func on Keys................................ corresponding items number: 5
Programming Keys......................... corresponding items number: 6
Arrow Keys.................................... corresponding items number: 7
Alpha and Numeric Keypad............. corresponding items number: 8
Special Characters.......................... corresponding items number: 9-10
7.165
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CHAPTER PROGRAMMING
Control keys
The control keys are the keys most o en used to operate the printer. The following keys considered
to be control keys
The START/STOP key is used to turn the printer ON/OFF. Remember that you
can use this control key only if the main power switch (located on the right side
of the printer) is ON, otherwise it can not be used.
NOTE: Once you will have pressed the START/STOP key, the system will auto-
ma cally turn on and it will be ready to print. Remember that the headcover
has to be correctly placed.
The PRINT key is used to make the system ready to print a message. Re-
member that it is possible to enable the PRINT key only if the light on the
START/STOP key is GREEN.
Screen display
The screen display shows messages, fault and warning informa on, so ware frames, and opera onal
commands for printer. The screen display is ON only if the main power switch (located on the right side
of the printer) is in the ON posi on.
Liquid crystal graphic display with 240x64 dots with LED bakligh ng to
guarantee readability even in poor light condi ons
Light Status
Light Status indicates the current status of the printer, and it is ac ve only when the printer is ON (
main power switch is in the ON posi on). The lights status indicates two status showed on the screen
display:

7.166
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PROGRAMMING CHAPTER
Func on keys
The func on keys are used to select the op ons that appear in the so ware frames in the display
screen
Arrow keys
The arrow keys are used to
- Move the cursor within a message in the display screen

- Change the value or parameters in certain so ware frame op ons
- Change the prin ng massage
Alphanumeric keypad
Use the alpha keypad to enter alphabe c characters,special characters and numbers into the message
appearing in the display screen. Special characters are those characters which appear on the keyboard
in green and red
Black : Alphabe c characters or numbers

Red : Special charcters
Green: Special characters or op onal languages: Chinese, Cyrillic, Arabic,
Polish, Greek, Korean,Romanian,Cze
To enter an alphabe c characters or numbers into the message, press the desired key. The printer will
place the uppercase version of that character/number into the message at the current loca on of the
cursor.
To create a lowercase character, press the CAPS LOCK key and the light on turns OFF. No ce that the
character will appear in the display screen as a lowercase character.
Light ON: Uppercase characters
Light OFF: Lowercase characters
7.167
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CHAPTER PROGRAMMING
Special characters are those characters which appear on the keyboard in green and red. To enter a spe-
cial character into the message, follow these guidelines:
For special characters shown in red, press the RED Fn key while pressing
the desired key.
For special characters shown in green, press the GREEN Fn key while
pressing the desired key.
Push the main power to switch the sys-

tem ON.
To check the so ware release press + in the main page and the display shows the fol-
lowing page:
Z 3000
Release: 3000 Rel. 1.02 Arb. ST-NB
In this specific case the so ware release is 1.02 with the Arabic language.
7.168
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PROGRAMMING CHAPTER
Main Page
B
F
A G D C
A) MGS : the number of the current selected message. In this case

the message number 1 is currently in print.
B) THE GRAPHIC DISPLAY: shows which message is currently in print.
C) CLOCK: the clock is set in HH:MM:SS mode and with a 24 hour clock ( 00 - 24 )
D) DATE: the calendar is set in DAY/MONTH/YEAR.
E) SYSTEM STATUS : shows the current status of the system
TURNING THE SYSTEM ON...............

TURNING THE INK STREAM ON ......
TURNING THE HIGH VOLTAGE ON...
TURNING THE SYSTEM OFF..............
PURGING THE SYSTEM......................
>> ADD INK IMMEDIATELY !! <<
>> SYSTEM READY <<
>> INK STREAM ON <<
>> SYSTEM IN STANDBY <<
>> SYSTEM OFF <<
F) VISUALIZED ALARM AREA: In this area is visualized the message when an alarm occurs.
Enter in the Alarms Page to check which kind of alarm it is.
G) PASSWORD SYMBOL: This symbol shows when the system is protected by password.
7.169
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CHAPTER PROGRAMMING
Turning The System On
Push the main power to switch the sys-

tem ON.
Press : the green LED is on and the system is flushing the tubus. In the mean me the display
shows the following page:
A er 40 seconds the system automa cally switches the ink stream on, the display shows the following
page:
7.170
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PROGRAMMING CHAPTER
A er 50 seconds the system automa cally switches the High Voltage on, the display shows the following
page:
A er 60 seconds the green LEDS (on the keys and ) turns ON the system is ready to
print. The display shows the following page:
7.171
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CHAPTER PROGRAMMING
CAUTION: If the Start Up procedure has not been successfully concluded,

the LED on bu on will turn to red and the system displays
the alarm message on the main page:
Press bu on to display the specific alarm
Press the display shows the following page:
Self Cleaning. (following the instruc ons described in the chapter 8 page 235)
7.172
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PROGRAMMING CHAPTER
Turning The System O
CAUTION: do not switch the system o by turning the main power switch o directly.
Press START/STOP bu on which allows the system to complete the automa c shut down
procedure.
Press the display shows the following page
Press to enable for 100 seconds the standard automa c shut down procedure.
Press + to enable for 120 seconds the extended automa c shut down procedure.
The display shows the following page:
7.173
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CHAPTER PROGRAMMING
A er the automa c shut down procedure the LED on bu on will switch OFF and the display
shows the following page:
When the display shows >> SYSTEM OFF << , push the
main power to switch the system OFF.
Several regular maintenance func ons to ensure op mum printer opera on
do not clean the nozzle during the shut down procedure.The dry ink makes a protec on cap
over the nozzle hole to keep out air and dust from entering into the nozzle, because they can
cause unstable ink stream. During the automa c shut down procedure, only clean the gu er
conduit by flushing the gu er on the printhead with proper solvent (8 seconds). Clean the
printhead, specially the nozzle, at the start of every shi or work period.
in case you do not use the system for an extended period of me (more than 3-4 days) it is
strongly recommended to switch the system o by pressing
+ doing the extended shut down.
7.174
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PROGRAMMING CHAPTER
Alarms Page (chapter 3)

The alarm are visualized by LEDS and on the MAIN DISPLAY.
In the system are present 2 dierent alarm levels:

Press bu on to go into the ALARM PAGE to see the specific alarm:
7.175
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CHAPTER PROGRAMMING
Press and/or to visualize the General Status of Alarms
* Low Priority Alarm *

MAKE-UP MISSING: The Make-up cartridge is empty, put a new one. If it is ignored for more
than 2 hours, the printer switches o automa cally.
INK LEVEL LOW: Ink level in the mixing tank is low and it is neccessary to add a new Ink
cartridge. If it is ignored for more than 4 hours, the printer switches o
automa cally.
TANK TOO FULL: Ink level in the mixing tank is too high, remove some ink through the
draining pipe.
VISCOMETER FAULT: The viscometer is not working properly. Check the metal sensor and
the visco valve on the manifold.Verify the viscometer circuit cleaning.
** High Priority Alarm **

HIGH VOLTAGE ALARM: Spark between the H.V. plates.
GUTTER ALARM: Ink stream missing into the Gu er.
PRINT-HEAD COVER MISSING: The print head cover has been removed or it has not
been correctly fixed.
PRESSURE ALARM: Ink pressure is not correct.
7.176
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PROGRAMMING CHAPTER
Menu Set
Press to go into the MENU SET and the display shows the following page
To move amoung the pages, use the and/or keys
To move the cursor amoung the dierent fields use the keys or
Once the cursor is in the desired loca on, modify the field and then press to save the new
value in the memory. If you don t want to save the value, use one of the arrow keys to move into an-
other field.
Place the cursor in the desired posi on and press or to change the value of the parameters
with the symbol <- ->
CAUTION: depending on the CODING TYPE and MATRIX SELECTED it is necessary to do not
set the PRINT SPEED VALUE lower then the minimum value usable like described
into the print speed table.
7.177
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CHAPTER PROGRAMMING
PRINTING PARAMETERS
Photocell: This parameter is used to enable/disable the Photocell for the prin ng mode.
Encoder: This parameter is used to enable/disable the Encoder for the prin ng mode.
Print Speed: This parameter is used to change the prin ng speed of the printer. If you increase this
value you reduce the prin ng speed of the system, instead of decreasing this value you in
crease the prin ng speed of the system.
Print Delay: This value defines the me between of the moment when the product sensor is exci -
ted (when the product to be printed is detected) and the moment when the system starts
to print.
Print Repeat: This parameter is used to enable/disable the Print Repeat for the prin ng mode.
This func on is used to print with a constant frequency on a con nuous product.
Repeater Time: when the automa c repeater is enabled, the prin ng is con nuous and occurs at
intervals determined by this value (repeater me). The values of this range start from 0 to
32767. The way the repeater operates depends on the product sensor set up:
PHOTOCELL = Y, the print repeater is ac vated only when the photocell is excited;
PHOTOCELL = N, the print repeater is always ac ve.
Reverse Text: This func on is used to enable/disable the reversed print mode for each character.
Inverted Text: This func on is used to enable/disable the inverted print mode (upside down) for
each character.
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SETTINGS PAGE
Load Rod Amplitude: this parameter is used to modify the amplitude of the oscillator sinusoidal
signal. This value can modify the posi on of the break point.
H.V. Value: refers to the high voltage value on the deflector plates read by the system according
to the SET parameter (0-15).
Pressure: refers to the ink pressure value inside the hydraulic circuit checked by pressure tran-
sducer (TPT04).
Flight Time and Phase Peak: These parameters are used for the service procedure in order to
iden fy the posi on of the break point. (for trained people only)
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SYSTEM PARAMETERS
Ink Type: refer to the ink type currently used in the system (111,221,153...)
Viscosity: shows the actual value of the ink viscosity (READ) and the reference se ng (REF).
Ink Temperature: shows the actual value of the ink temperature inside the hydraulic circuit.
Board Temperature: shows the actual value of the electronic compartment (logic board).
The fields INK LEVEL, MAKE-UP LEVEL, INK TANK FULL and GUTTER INK are visualized parame-
ters only and they are not modifiable.
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CONFIGURATION
Serial address: it is the serial address of the system. The value cannot be changed bykeyboard and
follows the se ng of the SW2 switch on the logic board (4 minidip - 16 combos). The defalt
value is 0 (zero).
Baudrate: it is the speed of data transmission. The available values are: 4800,9600 or 19200 bps
(default value).
Serial Type: it is the protocol handshaking used for the data transmission. The available values are
RS 232.
Coding Type: this parameter is used to set the default coding type (ini al) for each message.
Language: this parameter sets the language for the men pages. To modify it, use
LEFT ARROW and RIGHT ARROW.
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ENABLE PAGE
H.V. alarm: no ces the electrosta c charge between the deflec on plates. The ink stream auto
ma cally stops and the system shows an alarm message on the display.
Gu er alarm: no ces the absence of ink into the gu er. The ink stream automa cally stops and
the system shows an alarm message on the display.
Pressure alarm: no ces a not conforming pressure in the hydraulic circuit. The ink stream and
the motors automa cally stop and the system shows an alarm message display.
Start up flushing: enable the print head flushing during the system start up procedure.
Print direc on: enable the possibility to receive informa on about the prin ng line direc on
from an external device.
MESSAGE REPORT
The REPORT value shows how many mes the selected message in the field MESSAGE NUMBER
has been printed.
To reset just a report, press CTRL and F1.

To reset the reports of all the messages, press CTRL and F2.
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Press to go into the COMMANDS PAGE and the display shows the following page
Press F1 to enable the Purge Valve for 30 seconds.
CAUTION: it is possible to enable and

disable the Purge valve only when the is OFF
Press F2 to enable the Viscometer Valve for 30 seconds and to

start the Viscometer Cycle
Press F3 to enable the Make-up Valve for 5 seconds.
Press F4 to enable and disable the Ink Valve. The purge is auto-
ma cally enabled for the first 10 second during the ac va on and
for 30 seconds during the deac va on.
CAUTION: it is possible to enable or
disable the Ink valve only when the is OFF
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Edit Page
Press to go into the EDIT PAGE and the display shows the following page:
To Select the Text type: Default value : TEXT

Press 1 me : DATE
Press 2 mes: TIME
Press 3 mes: INC. COUNTER
Press 4 mes: DEC. COUNTER
Press 5 mes: BATCH
Press 6 mes: SHIFT
Press 7 mes: BARCODE
Press 8 mes: LOGO
Press 9 mes: TEXT again
To Select the Font to use: Default : Font=7X5

Press 1 me : Font=9X7
Press 2 mes : Font=10x8
Press 3 mes : Font=16X10
Press 4 mes : Font=5X5
Press 5 mes : Font=7X5 again
NOTE: the default coding type depends on the CODING TYPE VALUE presents into the MENU
SET at CONFIGURATION page.
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Press or to select the op ons of the field
To move the cursor amongst the dierent fields use the keys or
Press to exit. The display shows the follwing page:
Select the func on by pressing (save the message) or (exit without saving the
message)
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Brief Coding Type Guide (16 dots so ware)

In the Z 3000 (16 Dots So ware) are present 4 dierent coding types: 1L7x5, 2L7x5, 16 HS, 16 S, where
the following fonts are available: 5x5, 7x5, 9x7, 10x8, 16x10.
1L7x5: this coding type allows to print 1 line with 5x5 or 7x5 fonts and it is suitable for the applica on
where the produc on line speed is very high.(refer to speed table chapter 0 page 0.28)
This coding type, moreover, designs compact characters.
2L7x5: this coding type allows to print 2 lines with 5x5 or 7x5 fonts and it is suitable for the applica on
where the produc on line speed is low. (refer to speed table chapter 0 page 0.28)
This coding type, moreover, designs compact characters with higher quality.
16 S: this coding type is the standard one and it allows to print up to 2 lines with the smallest font 5x5.
Moreover, it is possible to print 2 lines 7x5, 1 line 9x7, 1 line 10x8 and 1 line 16x10 (the biggest font)
with the standard character design. It is used also to print logos 16 dots high with standard produc on
line speed. This coding type, moreover, can exploit a good throw distance (refer to speed table chapter
0 page 0.28)
16 HS: this coding type allows to print 1 line with 5x5, 7x5, 9x7, 10x8, 16x10 fonts and 2 lines with 5x5 or
7x5 fonts. It is suitable for the applica on where the produc on line speed is very high with the standard
character design.
It is used also to print logos 16 dots high with high produc on line speed. (refer to speed table chapter
0 page 0.28)
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System Password
The user has the opportunity to insert own messages, prin ng parameters and to protect these se ngs
with a programmable operator PASSWORD. The system is supplied without any password store.
First procedure for password inser on
Press and a er to go into the PASSWORD PAGE, the system shows the following page
(the cursor is already in the correct posi on)
Enter the desired password and press twice
Enter again the desired password and press
Now, if everything is done correctly, the following page will appear:
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If the password is not correct or any error is done during this procedure, when the PASSWORD CONFIR-
MATION is requested the following page will be displayed for few seconds:
The system returns to the main page but it is not protected yet. To insert the the protec on password it is
necessary to repeat the procedure from the beginning.
How to enable the password
The user, a er the password inser on procedure, can decide if the system has to be protected or not
protected by password
Press +
Now the system allows three op ons:
RETURN PROTECTED VERSION: The system enable the protec on with the
password choosen during the password inser on procedure.
CHANGE PASSWORD: the so ware allows the user to change the previ-
ous password with a new one.
EXIT: the system does not enable any protec on
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Pressing the protec on password is enabled so (without password) it is not allowed to

enter to modify the prin ng and/or messages parameters pages. The following page will be dis-
played:
A er a few seconds the system shows automa cally the Main display with the symbol
To disable the protec on press again + and the following page will be displayed
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If the correct password is inserted, the system is no more protected and the following page is displayed:
A er a few seconds the system automa cally shows the Main display without the symbol
When the system is not protected, but already started with the protec on procedure it is possible to re-
store the protec on previously removed, simply wri ng again the key combina on
+ and choosing op on in the displayed page:
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Logo Editor
Press and to go into the LOGO EDITOR, the system shows the following page:
a er few seconds the system shows automa cally the following page:
D
B
A: Drawing Cursor used to draw the logo

B: Shows the posi on (in dots) of the Drawing Cursor
C: Number of the Logo
D: Logo saved for default into the LOGO NUMBER 0
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It is possible to store and print 30 logos with dimensions (un l) 16 by 90 dots.
Logos are iden fied from a two digits number (00-29) and they can be inserted in any point of the text
message.
Move the cursor amongst the dierent fields NUMBER , HEIGHT AND WIDTH using the
key to change the following values:
NUMBER: Reference number of the current selected logo. In this field is possible to select one of
30 logos digi ng a number from 0 to 29.
HEIGHT: Define the height of the logo digi ng a number from 1 to 16.
WIDTH : Define the width of the logo digi ng a number from 1 to 90.
Once the cursor is in the desired loca on, modify the field and then press to save the new value
in the memory.
Fuc on keys:
Default func on: For default the EDIT command is enabled. In the logo area the cursor
pixel is flashing. Use the four arrows on the right hand side of the dis-
play to move the cursor pixel.
Press 1 me: The DRAWS command is enabled.In the logo area a displayed pixel be-
comes fixed. Moving with the four arrows on the right hand side of the
display, black pixels are created.
Press 2 mes: The CANCEL command is enabled. In the logo area a pixel is dispalyed
and moving it with the four arrows on the right hand side of the dis-
play it will possible to cancel black pixels (if present).
Press to: The CANCEL LOGO command allows to cancel the complete logo (if
present).
Press to: The SAVE command allows to save logo selected.
Press to: The EXIT command allows to exit from the LOGO EDITOR.
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Distributor Page +
Press and to go into DISTRIBUTOR PAGE, the system shows the following page:
Press to move in the second DISTRIBUTOR PAGE
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Press to move in the third DISTRIBUTOR PAGE
16 S
16 S
S
S
From the new DISTRIBUTOR PAGE 3 it is possible to enable/disable the Coding Types into the Menu
EDIT, during the CODING selec on. Depending on the customer requirements this func on allow
to disable the coding types not used, for an easier messages crea ng.
The values presents in the Distributor Page are:

INK TYPE USED: to select the ink type currently used in the system
CAUTION: depending on the INK TYPE USED selected the system automa cally set up all
REFERENT VALUES present into MENU SET at SISTEM PARAMETERS page. Here below the
parameters modified automa cally
READ REF.
INK LEVEL...................................... = 2033 2500

MAKE-UP LEVEL........................... = 2032 2500
TANK FULL LEVEL......................... = 2350 2500
GUTTER SENSIBILITY................... = 2571 3000
VISCO SET (25C): to insert the calibra on value of the viscometer

(visible on its lable)
NOZZLE SIZE: to select the diameter of the nozzle (50m or 70m)
TEMPERATURE MEASURE UNIT: to change the measurement unit of the ink and logic
board. It is possible to select C or F.
TPT04 : to enable the TPT04 used in the system (always enabled)
F1 ---> FLUSHING STSTEM START : to start the complete hydraulic flushing circuit (service maintenance
refer to chapter 2 page 65)
F2 ---> EMERGENCY STOP FLUSHING : to immediately stop the automa c hydraulic flushing circuit (ser-
vice maintenance refer to chapter 2 page 65)
F3 ---> EXIT : to go out from the distributor page
COUNTER HOURS: to set/erase a life- me for a period of me
SERVICE HOURS: to set the working hours before next maintenance (refer to chapter 7 page 194)
SERVICE DATE (ddmmyy): to set a date for the next maintenance (refer to chapter 7 page 194)
MULTIPLIER REPEATER: when in the system is enabled the PRINT REPEAT func on, and
the maximum REPEATER TIME value (32767) is not enough, it is possible to mul ply the
REPEATER TIME value by MULTIPLIER REPEATER (refer chapter 7 page 193)
PRESSURE REV. ALARM: to enable or disable the alarm on the force motor revolu ons
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Mul plier Repeater
Into Distributor Page 2 it is possible to set the MULTIPLIER REPEATER VALUE.

This parameter, adjustable from 1 to 255, mul plies the REPEATER TIME value present into MENU SET
at page PRINTING PARAMETERS. Here below how to set:
REPEATER TIME..........................(1/32767) = 1 where 1 corresponds 0,000222 Sec
The formula to calculate the me between each print is:
TIME BETWEEN EACH PRINT= (REPEATER TIME x 0,000222) x MULTIP. REPEATER VALUE
Example 1:
REPEATER TIME.....................(1/32767) = 20000
MULTIP. REPEATER = 1
then
(20000x0,000222) x 1 = 4,44 seconds THE SYSTEM PRINTS EVERY 4,44 SECONDS
Example 2:
REPEATER TIME..........................(1/32767) = 20000
MULTIP. REPEATER = 2
then
(20000x0,000222) x 2 = 8,88 seconds THE SYSTEM PRINTS EVERY 8,88 SECONDS
MAXIMUM TIME BETWEEN EACH PRINT = 30 MINUTES
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Maintenance Warning
The Maintenance Warning provides the preven ve maintenace schedules. When this warning triggers
(STATUS=ON), it means that the system advises the user (does not aect the normal working system) to
call the service department for a regular hydraulic maintenance.
This alarm is adjustable by working HOURS and se ng DATE. Here below how to set up the maintenance
warning alarm.
How to set up the maintenance warning alarm

Press + digit the password ____________(uppercase) to go into
DISTRIBUTOR PAGE and select the second page:
In order to enable this MAINTENANCE WARNING ALARM it is necessary to set up the 2 following values:
SERVICE HOURS: refers to the motors/pumps working hours; this parameter decreases from the entered
value to 0. When the SERVICE HOURS= 0 HOURS the alarm turns on. The hours value must be entered
during the system installa on and updated a er each system flushing. Depending on the ink type used,
set SERVICE HOURS like the suggested maintenance scedule show you.
The hours counter will con nue to decrease (nega ve value) and it will show you the actual service
hours from the alarm turning on.
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SERVICE DATE: refers to the next service maintenance date. When the SERVICE DATE will be reached the
alarm turns on. The date must be entered during the system installa on and updated a er each system
flushing. Depending on the ink type used, set SERVICE DATE like the suggested maintenance scedule
show you.
CAUTION: both the SERVICE HOURS and SERVICE DATE must be set
PREVENTIVE MAINTENANCE SCHEDULE FOR

Standard inks
Working Hours Maintenance Schedule Procedure
8 Hours per Day up the system and verify all parameters
da ng *
system parameters and print head adjust-
expira on date
16 Hours per Day
da ng *


24 Hours per Day system parameters and print head adjust-
expira on date

da ng *
* verify on www.zanasi-coding.com (reserved area) for new available so ware
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When the MAINTENANCE WARNING ALARM triggers (STATUS=ON) the system shows the following
page:
* * * * * WARNING * * * * *
MAINTENANCE REQUIRED! PLEASE
CONTACT THE ASSISTANCE
The maintenance warning page appears for 5 seconds every me the main power switch is turned on.
During the system opera ng the SERVICE logo appears in the main page to always remind the required
maintenance like here below:
THE MAINTENANCE WARNING ONLY ADVISE THE USER WITHOUT COMPROMISING THE REG-
ULAR SYSTEM WORKING.
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The So ware changes automa cally the Viscosity Reference Value depending on the room temperature
in order to maintain constant the ink viscosity. The constant viscosity gives the following advantages:
- CONSTANT VISCOSITY EVEN WITH THE TEMPERATURE VARIATIONS

- PRINTING STABILITY
- LOWER MAKE-UP CONSUMPTION
- LONGER INK LIFE INTO THE SYSTEM
The so ware is able to maintain constant the viscosity using the following parameters:
Ink Type Used:
This parameter is related to the ink used into the system.

NOTE: Modify this parameter ONLY if the ink type changes from the one set in Zanasi.
In the case that the Main Board has to be changed, be sure to set up the
new one with the same parameter.
Visco Set (25C):
This parameter is related to the value present on the viscometers label.

NOTE: Modify this parameter ONLY if the Viscometer has been replaced (see on label).
In case that the Main Board has to be changed, be sure to set up the new
one with the same parameter.
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Depending on the values presents into the DISTRIBUTOR PAGE the system automa cally modifies the
three following values showed into the SET MENU at SYSTEM PARAMETERS page:
Viscosity Read:
This parameter is related to the current ink viscosity value.
NOTE: This value can not be changed
Viscosity Ref:
This parameter is related to the current viscosity SET POINT.
NOTE: This value can not be changed.
The so ware automa cally changes it depending on the room temperature
Ink Type Used:

This parameter depends on the value present into the Distributor Page: INK TYPE USED.
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Press in the MAIN PAGE to disable the func on CAPS LOCK (the led has to be OFF)
Press to go into MENU SET at PRINTING PARAMETERS page
Press and to RESET the system
CAUTION: The RESET procedure will erase all the Messages and Passwords.
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Communica on protocol
1.1 General descrip on
This chapter gives a descrip on of the Z3000 serial communica on protocol available on the sy-
stem to allow the connec on of one or more prin ng systems to a PC. This protocol also allows to
collec ng datas, which can be even used for produc on controls and warehouse managing in real
me.
SERIAL LINE RS 232
1.2 Generic data sequence
0 1 2 3 4 5 6 7 ... ... ...

Master Slave
$ X X Data Data Data Checksum Checksum CR
Address Address
The generic data sequence is:
Index:
0 $ String start character (ASCII 36)

1 Master Address Serial address of the console. Hexadecimal: it can be 0-15
(a character of value 0-F)
2 Slave Address Always set at 0 (zero). JET4000 do not foresee this address
3-4 XX Iden fica on of the data string format (2 characters)
5-... Data Data string (245 characters maximum)
Data format depends on the above men oned iden fica on
... Checksum 2 characters for checksum.
They can be subs tuted by 2 SPACE characters (ASCII 32)
... CR String end character (Carriage Return: ASCII 13)
Important: data string does not have to contain the $ character.
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1.3 Serial line specifica ons of Z 3000 prin ng system
Serial line is available on a 15 pins male socket connector, situated on the side part of the
cabinet.
Characteris cs:
SERIAL LINE (HOST COMPUTER) RS232C/RS485 - Programmable

START BIT 1
STOP BIT 1
DATA LENGTH 8 bits
BAUD RATE 4800, 9600, 19200 bit/s
PARITY BIT not present
FLOW CONTROL any
The connector plug has the following signals (front view):
1 COM1 (square pin) 6 +24Vdc

2 TX 232 7-15 not used
3 RX 232
4 not used
5 GND
Basing on the connector type (9 or 25 pins socket), at computer side, connec ons are:
1.4 Wri ng text messages
To send a text message to the system, send the sequence:

0 1 2 3 4 5 6 7 8 9 - - - - - - - - - -
$ MA SA W T n n n m x x x x x x x x CR
Index:
0 $ String start character
1 MA Always set to 0 (zero). JET4000 do not foresee this address
2 SA Serial address of the system
3-4 WT Iden fica on of the data string format: Write Text (2 characters)
5-7 n Code reference number for text message (000 - 099)
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8 m Print mode:
A: Normal
B: Reversed (upside-down)
C: Inverted (from the end to the beginning)
D: Reversed and Inverted
9-.. xxx... Text message (245 characters maximum)
... Blank Space 2 characters ASCII 32 or 2 characters for checksum
... CR String end character (ASCII 13)
The system will send back the following string:
0 1 2 3 4 5
$ MA SA O K CR
Index:
1 MA Master serial address
2 SA Slave serial address
3-4 OK Communica on OK (2 characters)
5 CR String end character
A en on: if $ characters have to be inserted into the text message (xxx..), they have to be sent
as (extended) ASCII 235 and not as ASCII 36 (which is the string start character).
1.5 Reading text messages
To read a text from the system, send this character sequence:
0 1 2 3 4 5 6 7 8 9 10
$ MA SA R T n n n CR
Index:
2 SA Serial address of the system
3-4 RT Iden fica on of the data string format: Read Text (2 characters)
5-7 n Code reference number for text message (000-999)
8-9 Blank Space 2 Characters ASCII 32 or 2 characters for checksum
10 CR String end character (ASCII 13)
The system will send back the following string:
0 1 2 3 4 5 6 7 8 9 - - - - - - - - - -
$ MA SA R T n n n m x x x x x x x x CR
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Index:
5-7 n Code reference number for text message (000-999)
8 m Print mode: A: Normal
B: Reversed (upside-down)
C: Inverted (from the end to the beginning)
D: Reversed and Inverted
9-.. xxx... Text message
A er the first 9 characters you will receive the text of the selected reference number.
1.6 Reading the parameters
The following parameters can be read from the system:
0 1 2 3 4 5 6 7
$ MA SA R P CR
Speed 00000-32767
Code reference number of text message selected for prin ng 000-999
Print delay 00000-65535
Encoder: enabled/disabled 1=YES, 0=NO
BCD: enabled/disabled 1=YES, 0=NO
BCD strobe: enabled/disabled 1=YES, 0=NO
Automa c Print Repeater: enabled/disabled 1=YES, 0=NO
Product Sensor: enabled/disabled 1=YES, 0=NO
Repeater Time 00000-32767
Printer Model 1-2
Coding type 0-6
Bit direc on 0-1
To read these parameters from the system, the following character sequence must be sent:
0 1 2 3 4 5 6 7 16 17 26 27 36 37 40 41 42 43
$ MA SA R C n n l - u - a - p - cks cks CR
Index:
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3-4 RP Iden fica on of the data string format: Read Parameters (2 characters)
The system will reply:
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
$ MA SA R P v v v v v n n n r r r r r -
Index:
3-4 RP Iden fica on of the data string format: Read Parameters (2 characters)
5-9 vvvvv Speed Value (5 digits)
10-12 nnn Code reference number of text message selected for prin ng (3 digits)
13-17 rrrrr Print delay (5 cifre)
18 ... Encoder enabled/disabled (1 digit)
19 ... BCD enabled/disabled (1 digit)
20 ... BCD strobe enabled/disabled (1 digit)
21 ... Automa c print repeater enabled/disabled (1 digit)
22 ... Product sensor enabled/disabled (1 digit)
23-27 ... Repeater me (5 digits)
28 m Printer model (1 digit) 1=JET4000Smart; 2=JET4000 Custom
29 t Coding type (1 digit) 0=17-S ; 1=16; 2=3r9x7; 3=24; 4=32 1V; 5=32 2V;
6=32 3V
30 q Bit direc on (1 cifra) 0=Disabled; 1=Enabled
31-32 ... 2 Characters for checksum
1.7 Se ng the parameters
Send the following characters sequence:

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
$ MA SA W P v v v v v n n n r r r r r -
Index:
2 SA Slave serial adderss
3-4 WP Iden fica on of the data string format: Write Parameters (2 characters)
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5-29 ... Data format as for Read Parameters command (see previous paragraph)
The system will reply with the sequence shown at paragraph 9.4:
0 1 2 3 4 5
$ MA SA O K CR
1.8 Reading the values of the counters
All 16 available Counters can be read via serial line.

The character sequence needed is:
0 1 2 3 4 5 6 7 8 9
$ MA SA R C n n CR
Index:
3-4 RC Iden fica on of the data string format: Read Counters (2 characters)
5-6 nn Code reference number for the counter (00-15)
0 1 2 3 4 5 6 7 16 17 26 27 36 37 40 41 42 43
$ MA SA R C n n l - u - a - p - cks cks CR
Index:
3-4 RC Iden fica on of the data string format: Read Counters (2 cara eri)
5-6 nn Code reference number for the counter (00-15)
7-16 ii.... Counter start value *
17-26 ii.... Counter stop value *
27-36 dd.... Current Value *
37-40 pp... Counter step (001-999) **
41-42 cks 2 Characters for checksum
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* 10 characters ASCII: the first character is a SPACE, then 9 characters which represent the
counter value, maximum 999999999.
** 4 characters ASCII: the first character is a SPACE, then 3 characters which represent
the counter step.
1.9 Se ng the Counters
Send this character sequence:
0 1 2 3 4 5 6 7 16 17 26 27 36 37 40 41 42 43
$ MA SA W C n n l - u - a - p - cks cks CR
Index:
3-4 RC Iden fica on of the data string format: Read Counters (2 characters)
5-6 nn Counter number (00-15)
7-16 ii.... Counter start value *
17-26 ii.... Counter stop value *
27-36 dd.... Counter current value *
37-40 pp.... Counter step (001-099)**
0 1 2 3 4 5
$ MA SA O K CR
1.10 Se ng the Counters to zero (0)
To set a counter to zero, send this character sequence:
0 1 2 3 4 5 6 7 8 9
$ MA SA C C n n CR
Index:
2 SA Serial address
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3-4 CC Iden fica on of the data string format: Clear Counters (2 characters)
5-6 nn Code reference number of the counter (00 - 15) *
... Blank Space 2 Characters ASCII 32 or 2 characters for checksum
* by sending the character A (All) instead of nn, all the counters will be cleared.
0 1 2 3 4 5
$ MA SA O K CR
1.11 Reading the reports
To read the report of a specific text message, send the following character sequence:
0 1 2 3 4 5 6 7 8 9 10
$ MA SA R R n n n CR
Index:
3-4 RR Iden fica on of the data string format: Read Reports (2 characters)
5-7 nnn Code reference number of the text message (000-999)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
$ MA SA R R n n n r r r r r r r r r cks cks CR
Index:
3-4 RR Iden fica on of the data string format: Read Reports (2 characters)
5-7 nnn Code reference number of the text message (000 - 999)
8-16 rrr... The actual value of the number of mes the message has been printed (9
cara eri)
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1.12 Se ng reports to zero (0)
To set the report value for a par cular text message to zero (0), send this character sequence:
0 1 2 3 4 5 6 7 8 9 10
$ MA SA C R n n n CR
Index:
3-4 CR Iden fica on of the data strig format: Clear Reports (2 characters)
5-7 nnn Code reference number of the text message (000-999) the report of which is
to be cleared
By sending the character A (All) into the 5th posi on of the string, all the re
ports will be cleared.
0 1 2 3 4 5
$ MA SA O K CR
1.13 So ware release reading
Sending the sequence:
0 1 2 3 4 5 6 7
$ MA SA R L CR
Index:
3-4 RL Iden fica on of the data string format: Read reLease (2 characters)
The system will reply with its name and the so ware release installed:
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0 1 2 3 4 5 6 ... ... ...
$ MA SA R L ... ... cks cks CR
Index:
3-4 RL Iden fica on of the data string format: Read reLease (2 characters)
5-... ... System name and so ware release
... cks 2 Characters for checksum
... CR String end character
1.14 Batch number Wri ng
Send the sequence:
0 1 2 3 4 5 9 10 14 15 23 24 25 26
$ MA SA W L a - b - c - CR
Index:
3-4 WL Iden fica on of the data string format: Write Lo o (i.e. Batch) (2 characters)
5-9 ... 5 Characters for the Quan ty value (present value) 00000-99999
10-14 ... 5 Characters for the Quan ty value (set value) 00000-99999
15-23 ... 9 Characters for the Lo o (Batch) value
0 1 2 3 4 5
$ MA SA O K CR
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1.15 Batch number Reading
Send this sequence:
0 1 2 3 4 5 6 7
$ MA SA L R CR
Index:
3-4 LR Iden fica on of the data string format: Lo o (i.e. batch) Read (2 characters)
0 1 2 3 4 5 9 10 14 15 23 24 25 26
$ MA SA L R a - b - c - CR
Index:
3-4 LR Iden fica on of the data string format: Lo o Read (2 characters)
5-9 ... 5 Characters for the Quan ty value (present value) 00000-99999
10-14 ... 5 Characters for the Quan ty value (set value) 00000-99999
15-23 ... 9 Characters for the Lo o (batch) value
1.16 Se ng the prin ng message code
The following sequence sets the code reference number for the message to be printed:
0 1 2 3 4 5 6 7 8 9 10
$ MA SA W M x x x CR
Index:
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3-4 WM Iden fica on of the data string format: Write set Message (2 characters)
5-7 ... 3 Characters to set the prin ng message code (000-255)
The system will send back:
0 1 2 3 4 5 6 7 8 9 - - - - - - - - - -
Index:
5-7 n Message number (000 - 099)
8 m Print mode: A: Normal B: Reversed (upside-down) C: Inverted (from the
end to the beginning) D: Reversed and Inverted
9-.. xxx... Text of the message just set
1.17 Reading the prin ng message code
The following sequence reads the code reference number of the text message selected for prin ng:
0 1 2 3 4 5 6 7
$ MA SA R M CR
Index:

1 MA Master mserial address
3-4 RM Iden fica on of the data string format: Read set Message (2 characters)
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0 1 2 3 4 5 6 7 8 9 - - - - - - - - - -
Index:
5-7 n Message number (000 - 099)
8 m Print mode: A: Normal B: Reversed (upside-down)
C: Inverted (from the end to the beginning) D: Reversed and Inverted
9-.. xxx... Text message
1.18 Reading the system alarms and status
Send this character sequence:
0 1 2 3 4 5 6 7
$ MA SA R A CR
Index:

3-4 RA Iden fica on of the data string format: Read Alarm (2 characters)
5-6 Blank Space 2 Characters ASCII 32 or 2 characters for eventual checksum
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
$ MA SA R A a0 a0 a1 a1 a2 a2 a3 a3 m s CR
Index:

3-4 RA Iden fica on of the data string format: Read Alarm (2 characters)
5-6 a0 Alarms/inputs 0-7 status *
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13 m Selected system model **
14 s Selectes system status ***
* Each pair digits (a0, a1 ...) holds the value of one byte hexadecimal format. The 8 bits of the byte
represent the status of 8 alarms/inputs. For example, a0 = 01 means: alarm/input #0 on (1 value)
it is an high value; alarms/inputs #1-7 o (0 value) are low.
7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 1
The organiza on structure of the alarms/inputs into the data frame is always the same: it does not
depend on the selected system. On the other way, the dierent prin ng systems use only some of
these data according to the following table:
Digit pair Bit Alarm/input L
a0 0
1
2 Ink level low X
3
4
5
6
7
a1 0
1 High voltage alarm X
2 Gutter alarm X
3 Tank too full alarm X
4 Make-up alarm X
5
6
7 Viscometer alarm X
a2 0
1
2
3
4
5
6
7 Casing missing alarm X
a3 0
1
2
3
4
5
6
7
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** the iden fica on data for Z3000 is 1!
*** the character establishing the state of the system can be:
0 OFFLINE
1 ONLINE
2 WAITING
3 HV ON
4 WARNING
5 INK ON
6 WASHING
1.19 Time and date wri ng
Time and date of the system can be read sending the following sequence:
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
$ MA SA W K o o m m s s g g m m a a CR
Index:
3-4 RK Read clocK (2 characters)
5-6 oo Hours (00-23)
7-8 mm Minutes (00-59)
9-10 ss Seconds (00-59)
11-12 gg Day (01-31)
13-14 mm Month (01-12)
15-16 aa Year (last two digits 00-99)
0 1 2 3 4 5
$ MA SA O K CR
1.20 Time and date reading
The current me and date used by the system can be read sending the following sequence:
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0 1 2 3 4 5 6 7
$ MA SA R K CR
Index:
3-4 RK Iden fica on of the data string format: Read clocK (2 characters)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
$ MA SA R K o o m m s s g g m m a a cks cks CR
Index:
3-4 RK Read clocK (2 characters)
5-6 oo Hours (00-23)
7-8 mm Minutes (00-59)
9-10 ss Seconds (00-59)
11-12 gg Days (01-31)
13-14 mm Month (01-12)
15-16 aa Year (last two digits 00-99)
17-18 cks 2 Characters for cheksum
1.21 Unknown command
When the system does not recognize the command received from the PC (if the system adress and
the checksum are correct), the following sequence will be sent back:
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
$ MA SA ? U N K N [ ... ... ... ... ... ] CR
Index:
3-7 ?UNKN UNKNown message (5 characters)
8 [
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9-13 .... The first 5 caracters of the received message, including the system ad
dress but not the character $.
14 ]
1.22 Checksum control
To increase PC data transmission reliability, instead of two SPACE characters (ASCII 32), the system
can process two hexadecimal checksum characters.
The checksum has to be calculated as the sum of all the caracters transmi ed by the PC, including
and star ng from the character $. The checksum must be a number smaller than 256; if bigger or
equal, you must subtract 256. Once calculated, the checksum must be transmi ed in hexadecimal
format.
Example:
Message Checksum Checksum characters to be transmi ed
$00WT000ABCD 36+48+48+87+84+48+48+48+65+66+67+68 = 713
713-256=457 -> 457-256=201 -> C9
If the checksum sent to the system was not calculated in this way or if the system receives a wrong
checksum because of signal noise, the following sequence will be sent back from the system:
0 1 2 3 4 5 6 7 8 9 10 11 12
$ MA SA ? C K S U M = X X CR
Index:

3-8 ?CKSUM Wrong checksum, ChecKSUM (6 characters)
9 = Equal symbol
10-11 XX Sum of all the characters received by the system (including the checksum sent
by the PC and with the excep on of the CR character) codified in an exadeci
mal format.
1.23 Logo or graphic wri ng
As described in chapter 6 it is possible to send un l 50 graphic images to the system. Alle 50 images
are numbered using a two digits number (00-49) and the dimensions are (un l) 32 lines by (un l) 90
columns.
The dots columns composing the graphic image, numbered fro 01 to 90, are sent using the following
sequence:
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0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 - - -
$ MA SA L W n n n h h w w vc vc vc vc vc vc vc vc ... ... CR
Index:
3-4 LW Iden fica on of the data string format: Logo Write (2 characters)
5-7 nnn Logo number (000-049)
8-9 hh Height (01-32)
10-11 ww Width (01-90)
12-19 vc First column value (4 byte) in exadecimal
20-... Eventual other columns values (4 byte per column) in exadecimal
...-... Space 2 Characters ASCII 32 or 2 characters for checksum
... CR String end character
The system will send back the same sequence of the paragraph 9.4:
0 1 2 3 4 5
$ MA SA O K CR
1.24 Logo or graphic reading
To read a graphic stored in the system, send the following sequence:
0 1 2 3 4 5 6 7 8 9 10
$ MA SA L E n n n CR
Index:
3-4 LE Iden fica on of the data string format: Logo rEad (2 characters)
8-9 Blank space 2 Characters ASCII 32 or 2 characters for checksum
The system send back:
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0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 - - -
$ MA SA L E n n n h h w w vc vc vc vc vc vc vc vc ... ... CR
Index:
3-4 LE Iden fica on of the data string format: Logo rEad (2 characters)
8-9 hh Height (01-32)
10-11 ww Width (01-90)
12-19 vc First column value (4 bytes) in exadecimal
20-... Values of the other columns (4 bytes per column) in exadecimal
...-... Blank Space 2 Characters ASCII 32 or 2 characters for checksum
... CR String end character3
1.25 Reading the workshi
To read the workshi send the following sequence:
0 1 2 3 4 5 6 7
$ MA SA R S CR
Index:
3-4 RS Iden fica on of the data string format: Read Shi (2 characters)
0 1 2 3 4 5 6 7 8 9 10 7
$ MA SA R S .. .. .. .. .. .. -
Index:
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3-4 RS Iden fica on of the data string format: Read Shi (2 characters)
5-8 ... Workshi #1 star ng hour (4 digits) 0000-2359
21-29 a.. Alfanumeric string to set workshi #1 (9 digits)
30-38 b.. Alfanumeric string to set workshi #2 (9 digits)
39-47 c.. Alfanumeric string to set workshi #3 (9 digits)
48-56 d.. Alfanumeric string to set workshi #4 (9 digits)
1.26 Se ng the workshi
Send this sequence:
0 1 2 3 4 5 6 7 8 9 10 7
$ MA SA W S .. .. .. .. .. .. -
Index:
3-4 WS Iden fica on of the data string format: Write Shi (2 characters)
21-29 a.. Alfanumeric string to set workshi #1 (9 digits)
30-38 b.. Alfanumeric string to set workshi #2 (9 digits)
39-47 c.. Alfanumeric string to set workshi #3 (9 digits)
48-56 d.. Alfanumeric string to set workshi #4 (9 digits)
0 1 2 3 4 5
$ MA SA O K CR
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Character Control
A combina on of characters (control characters) is used to insert within a message special func-
ons (date, expira on, etc.), to set a new font matrix, to insert a barcode or a logo and many more.
In case you are sending the messages from a Personal Computer, these characters must be sent via
serial line.
ATTENTION: herea er the character ^ is the ASCII 94 character and the character | is the ASCII
124 character.
The following is a list of the combina ons of characters to obtain the special func ons:
^Ax^ Codings type:
x=0 code type 16-S

x=1 code type 16-HS (default for all models)
x=2 code type 3L-9x7
x=3 code type 24-S
x=4 code type 32-HQ
x=5 code type 32-S
x=6 code type 4L-7x5
x=7 code type 1L-7x5 (default for all models)
x=8 code type 2L-7x5 (default for all models)
|B acsss...| To print barcode

Barcode type:
t=0 ITF - A (Z4500,Z5000 only)
t=1 ITF - B (Z4500,Z5000 only)
t=2 ITF - C (Z4500,Z5000 only)
t=3 2/5 Industrial
t=4 UPC- A
t=5 Code 39
t=6 Ean 13
t=7 Ean - Code 128 A (Z4500,Z5000 only)
t=8 Ean - Code 128 B (Z4500,Z5000 only)
t=9 Ean - Code 128 C (Z4500,Z5000 only)
Digit under barcode:

f = 0 without digit
f = 1 with digit
barcode hight:
a = 0 16 dots
a = 1 24 dots
a = 2 32 dots
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side digits:
c=0 normal barcode
c=1 digits are printed beside barcode
barcode value:
sss... alfanumeric string with barcode values
^c^ To print upside down
|Cnnkprc| To print the date (see the descrip on below)

Prin ng format:
nn = 00 DMY
nn = 01 MDY
nn = 02 MY
nn = 03 DM
nn = 04 MD
nn = 05 D
nn = 06 M
nn = 07 Y
nn = 08 Julian day
nn = 09 Julian Day / Year
nn = 10 Fiscal week
nn = 11 Week day
Month format
k=0 English
k=1 Italian
k=2 French
k=3 German
k=4 Spanish
k=5 Turkish
k=6 Number
Year digits number

p=0 One digit
p=1 Two digits
p=2 Four digits
Separator character
r = any character
Expira on
c = +qqwwweer Expira on date(qq hours, www days, ee
months, r years)
c=0 It is not an expira on
|Gnnx| Print the logo number nn (00-49)
x = 0 normal logo
x = 1 reverse logo
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|Lcn| Print the batch

c = + display zeros true; format with le ers false
c = - display zeros false; format with le ers false
c = display zeros false; format with le ers true
n = 0..9 Counter digits number
^N0^ To select the 5x5 font matrix.
^N5^ To select the 24x16 font matrix
^N6^ To select the 32x18 font matrix
|Onfcm| To print the me

n=0 Hour Minutes Seconds
n=1 Hour Minutes
n=2 Hour
n=3 Minutes
n=4 Seconds
n=5 Quarters of an hour
f=0 Format with le ers false

f=1 Format with le ers true
c = Separator character
m=0 It is not an expira on
m = +nncc Expira on of nn hours and cc minutes
^K0n^ Bold. n is a number from 0 to 9 that gives the level of bolderiza on. De
fault: 0.
^Pnnnnnkkkkk^ To change the print parameters. nnnnn=speed (00000-32767),
kkkkk=print delay (00000-65535).
^Qn^ Interline. n (0 to 9) indicates the distance between two lines.
Default: 2.
^r^ to enable nega ve prin ng
^R^ to enable inverted prin ng
|Tn| to print the shi
n = 0 Numeric format
n = 1 Le er format
n = 2 Custom format
|Wnncd| Decremental (or incremental U) counter

nn = Counter number (00-15)
c = + display zeros true; le er format false
c = - display zeros false; le er format false
c = display zeros false; le er format true
d= Counter digits number (1-9)
^Z^ To move to the following line of text (to change to a new line)
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Characters map
The printable caracters have been mapped usign the ASCII code un l 127.
There are a lot of excep on between 127 and 255. The list of the value of the byte to send to obtain
a certain character is given herea er:
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NOTES
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7.226
Print Head Prac ce 8
Troubleshoo ng Flowchart
Basic Configura on
Self Cleaning
How to Check if the Nozzle is Cleaned
Global View of the Print Head
How to Adjust the Ink Stream in the Middle of the Charge Electrode
How to Disassemble the Nozzle
How to Clean the Nozzle
How to Assemble the Nozzle
How to Adjust the Ink Stream into the Gu er
How to Replace the Oscillator
How to Replace the Tubus
How to Find the Prin ng Range
Prin ng Quality Depending on the Lod Road Amplitude Range
General Errors
Phase Errors
H.V. Errors
Electrosta c Charge Errors

Z3000
8
PRINT HEAD PRACTICE CHAPTER
SET THE SYSTEM WITH

Troubleshoo ng
BASIC CONFIGURATION
1 AND CHECK THE VALUES
Flowchart
OK
SELF CLEANING WITH

2 GUTTER CLOSE OK
OK
CHECK THE CORRECT
PRINTING SPEED USED
CODING TYPE USED
OK
USING THE PROBE CHECK OK
REPLACE THE NO THE CORRECT VALUE
RESISTORS DIRECTLY ON THE H.V.
PLATES
OK
3 IS THE
NOZZLE OK
NO CLEANED?
GLOBAL VIEW OF THE
4 HYDRAULIC CIRCUIT AND
YES PRINTHEAD
CHECK & ADJUST:

- Ink stream in the middle of
5 the charge electrode CHECK THE EXIRATION
DAY OF:
INK AND MAKE-UP
ALIGNMENT of the INK

STREAM with H.V. ON
Check if it is present:
- GROUND of SYSTEM &
LINE
- CORRECT POWER
FIND THE PRINTING SUPPLY
RANGE USING FONT - ELECTROSTATICS
11 16x10 CHARGE
DID YOU YES

FIND THE STOP
PRINTING
RANGE?
NO
8.229
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CHAPTER PRINT HEAD PRACTICE
NO
DISASSEMBLE THE
6 NOZZLE
OK
CLEAN THE NOZZLE

7 NO
OK
ASSEMBLE the NOZZLE
AND CHECK IF THE
8 NOZZLE IS CLEANED
IS IT THE
SECOND
CLEANING?
OK
IS THE
INK NO YES
STREAM
STABLE?
GLOBAL VIEW OF THE
4 HYDRAULIC CIRCUIT AND
PRINTHEAD
YES
ADJUST the INK STREAM

ALIGNMENT
9 with H.V. ON CHECK THE EXPIRATION
DATE OF:
INK AND MAKE-UP
USE
A MESSAGE
WITH FONT 16X10
FIND THE PRINTING

11 RANGE REPLACE THE NOZZLE
DID YOU
FIND THE YES STOP
PRINTING
RANGE?
NO
10 REPLACE TUBUS
8.230
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8
CHECK IF THE NOZZLE

3 IS CLEANED
OK NO
IS THE IS IT THE
INK NO
SECOND
STREAM CLEANING? YES
STABLE?
YES
ADJUST the INK STREAM POSSIBLE INK

ALIGNMENT
9 with H.V. ON CONTAMINATED
USE SYSTEM FLUSH

A MESSAGE OK and REPLACE
WITH FONT 16X10 ALL FILTERS
FIND THE PRINTING

11 RANGE
END
8.231
Z 3000
8
1 Basic Configura on
Disconnect every device connected to the system (Encoder, BCD, Serial Line..), take note about the cus-
tomer se ng values and set up the system in basic configura on (see the follow table).
MENU SET
PRINTING PARAMETER PAGE
Photocell = Y
Encoder = N
Print Speed = 400
Print Delay = 0
Inveted text = N
Reverse text = N
Print Repeater = N
Repeater Time = 2000
SETTING PAGE
H.V. Se ng = 15 (or 5)
Load Rod Amp. = 100
Pressure = 300 (or 330)
ENABLE PAGE
H.V. Alarm = Y
Gu er Alarm = Y
Pressure Alarm = Y
8.232
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8
2 Self-Cleaning
Press screwdriver key (the motors/pumps must be on)
Press F1 bu on: this func on enables the automa c purge procedure. Dur-
ing this me flush the nozzle with the squeeze bo le (solvent).
CAUTION: open and close the gu er with finger while you flush the nozzle in order
to create a greater suc on for the purge cycle. Do not repeat this opera on more
than 3 mes in a few minutes.
NOZZLE
GUTTER
CAUTION: Dry the print head before restar ng the ink stream with a lint free cloth
8.233
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8
3 How to verify if the Nozzle is cleaned
Press to restart the system
CAUTION: The system should not stay in prin ng status, but only with the ink
stream, so the led on must be OFF
Press to go into the COMMAND PAGE and the diplay shows the following page:
Using bu on, switch OFF and ON (for 5 mes) the

ink stream in order to check the ink stream stability.
CASE 1 CASE 2
= ink stream posi on
into the gu er
CASE 1: The ink stream is stable, for each restart it has the same posi on so NOZZLE IS CLEANED.
CASE 2: The ink stream is not stable, for each restart it has dierent posi ons so NOZZLE IS NOT
CLEANED.
8.234
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8
4 Global View of the Print Head
Charge Electrode
CAUTION: The ink stream must pass in the middle

of the Charge Electrode.
8.235
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8
5 How to adjust the Ink Stream in the

middle of the Charge Electrode
CAUTION: Turn Power o before doing these opera on!!!
If the ink stream does not pass in the middle of the Charge Electrode:
1 - Turn the power OFF
2 - Uncrew the two screws (3x8 slo ed) that fixes the Tubus to the support
3 - Li the Tubus and loose only the screw 1 (3x6 slo ed) to move the tubus support right or le to
adjust the ink stream in the middle of the electrode charge
4 - Fix again the Tubus to the support with the two screws (3x8 slo ed)
5 - Switch the system on to check the ink stream alignment
8.236
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8
6a
How to disassemble the Nozzle (70m)
Gently loosen the nozzle from the tubus using the specific tool (nozzle key) by mee ng the two ps
with the two li le holes present into the nozzle and unscrew it.
8.237
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8
6b How to disassemble the Nozzle (50m)
Unscrew the two screws (3x8 slo ed) that fixes the tubus to the support
Li the Tubus from the support and do not damage the pipes. Do not unsolder the red wire and do not
disconnect the pipes. Gently loosen the nozzle from the tubus using the specific tool (nozzle key) by
mee ng the two ps with the two li le holes present into the nozzle and unscrew it.
8.238
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8
7
How to clean the Nozzle
- Using the correct cleaning solution (depending on the ink), put the Nozzle in the Ultrasonic
Cleaning bath for 5 minutes.
Repeat this procedure 3 times and then dry the Nozzle with cleaned compressed air.
8
How to assemble the Nozzle
- Clean the nozzle seat with correct

cleaning solu on
- Tighten the nozzle back to the tubus.
- Dry the head before star ng the ink stream,

using a lint free cloth
- Turn the system ON
- Disable the GUTTER ALARM
- Line up the ink stream into the Gu er

4
- Check ink stream stability
3 - Put a metal washer on the Cover sensor
- Turn the H.V. ON
- Adjust the ink stream with H.V. ON
1 2
- Remove the metal washer.

- Put back the cover on the head
- Enable the GUTTER ALARM
- Check the print quality
8.239
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8
9 How to adjust the Ink Stream

into the Gu er
CAUTION: Turn the bu on ON before adjus ng the Ink Stream :
6 5
7
4
1
2
1. Put a metal washer (5) on the Cover sensor (7) and hold it by the black knob (6).
2. Enable Ink stream and H.V.
3. Tighten screw 1 (3x6 slo ed)
4. Loosen screw 2 (3x8 slo ed) and adjust the ver cal alignment (gu er axis) with
screw 4 (3x8 slo ed).
5. Tighten screw 2
6. Loosen screw 1 and adjust the horizontal alignment with a piece of paper on the
gu er side (deflec on axis) with screw 3 (3x6 slo ed).
7. Turn screw 3 clockwise un l you see ink drops on the paper
8. Turn screw 3 counterclockwise un l the drops on the paper disappear
9. Tighten screw 1.
8.240
Z3000
8
Wrong Ink Stream Adjustment:
Correct Ink Stream Adjustment:
8.241
Z 3000
8
How to replace the Oscillator

Required parts:
- New Oscillator
No ces:
- Turn power o before doing these opera on
- Never open the Tubus cap!!!
Procedure:
- Unscrew the two screws (3x6 slo ed) that fixes

the tubus to the support
8.242
Z3000
8
- Li the Tubus from the support and loosen

the nozzle using the nozzle-key
- Clean the nozzle in the ultrasonic cleaning
bath following the procedure at page
- Unsolder the black wire

- Disconnect the two pipes and remove the
oscillator from the support
new Oscillator
old Oscillator
- Replace the old Oscillator with the new

one
If there are already the two pipes connected to the tubus, and they are in good condi ons, follow from
otherwise con nue here below.
*
37 mm (1.46 inches)
- Cut two pieces of pipe 4x2 with length

37mm (1.46 inches) and 54mm (2.13 inches).
54 mm (2.13 inches)
37 mm (1.46 inches)
- Wet the two pipes with solvent and connect

them to the tubus.
54 mm (2.13 inches)
8.243
Z 3000
8
- Insert the two pipes in the stainless steel
*
fi ngs
- Solder the black wire
- Clean the nozzle seat with correct

cleaning solu on
- Li the Oscillator and ghten the Nozzle
using the special nozzle-key.
- Tighten the screws (3x8 slo ed) on the side

- Dry the head before star ng the ink
stream using a lint free cloth
- Turn the power ON

4 - Check ink stream stability
- Put a metal washer on the Cover sensor
3 - Turn the H.V. ON
- Adjust ink stream with H.V. ON
1 2

8.244
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8
10 How to replace the Tubus
Required parts:
- New Tubus
No ces:
- Turn power o before doing these opera on!!!
- Never open the Tubus cap!!!
Procedure:
- Disconnect the two pipes (do not use the cu er)

- Remove two screws (3x6) that fixes the Tu
bus to the support
8.245
Z 3000
8

tubus from the support
new Tubus
old Tubus
- Replace the old Tubus with the

new one
If there are already the two pipes connected to the oscillator, and they are in good condi ons, follow
from * , otherwise con nue here below.
37 mm (1.46 inches)
- Cut two pieces of pipe 4x2 with length

37mm (1.46 inches) and 54mm (2.13 inches).
54 mm (2.13 inches)
37 mm (1.46 inches)
- Wet the two pipes with solvent and connect

them to the tubus.
54 mm (2.13 inches)
8.246
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8
* - Insert the two pipes in the stainless steel

fi ngs
- Tighten the screws (3x8 slo ed) on the side

- Dry the head before the star ng the ink,
use a lint free cloth to dry the head
- Turn the power ON
4 - Put a metal washer on the cover sensor

3 - Line up the ink stream into the Gu er
1 2


8.247
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8
11 How to find the Prin ng Range
CAUTION: Set up the system with the basic configura on before finding the
prin ng range
CAUTION: Turn the bu on ON before finding the Prin ng Range
Press to go into the MENU SET
Press to move into the SET PAGES un l the display shows the follwing page:
8.248
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8
How to change the LOAD ROD AMPLITUDE when the print quality is poor:
- To move the cursor amongst the dierent fields use the keys or
- The Load Rod Amplitude value range is from 30 to 220. Set the value at 30.
- Press to save the new Load Rod Amplitude value
- Wait for 10 seconds for the charge se le.
- Do some prints to check the prin ng quality.
- Repeat the process increasing the Load Rod Amplitude value of 10 points un l the max
value available: 220
- During the process, take note about the Load Rod Amplitude value when the prin ng quality is
correct.
- When the prin ng quality becomes poor take again note about the Load Rod Amplitude value.
- Take the lowest and highest value where the prin ng quality is correct and calculate the
Medium value.
- Set Lod Rod Amplitude = Medium Value
Press to EXIT and to go back to the MAIN PAGE
8.249
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8
Prin ng Quality depending on the Load Rod

Amplitude Range
Load Rod Amplitude = 30 Load Rod Amplitude = 100
Load Rod Amplitude = 70


NOTE: In this example the PRINTING RANGE starts from 65 up to 220 and we set the final LOD ROAD
AMPLITUDE VALUE: 145.
8.250
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8
How to change from 70m to 50m
Required parts:
- Complete Tubus 50m
- 50m Tubus Support
Procedure:
- Disconnect the two pipes

- Remove the two screws (3x8) that fix the Tubus
to the support
8.251
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8

tubus from the support
- Unscrew the two screws (3x6 slo ed) that

fixes the support to the green board
- Replace the 70m support with the

50m support
- Fit the tubus 50m on the support

- Reconnect the two pipes
8.252
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8
- Fit the 50m tubus on the support,

solder the black wire and screw the
two fixing screws (3x8 slo ed).
- Dry the head before star ng the ink
stream, use a lint free cloth to dry the
print head
- Press to go into the MENU SET and using
or select the SETTINGS PAGE
to modify the H.V. VALUE. With a tubus 50m set the

H.V. VALUE between 1 and 6 (default=5)
- Press to move on the PRESSURE field to
modify the PRESSURE SET value. Using a tubus 50m

the working pressure must be 330

- Check if the ink stream passes in the
middle of the Charge Electrode
Charge Electrode
8.253
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8
If the ink stream does not pass in the mid-

dle of the Charge Electrode:
- Switch the system o
- Uncrew the two screws (3x8 slo ed)
that fixes the Tubus to the support
-Li the tubus and loose only the
screw 1 (3x6 slo ed) to move
the tubus support right or le to adjust the
1 ink stream in the middle of the electrode
charge
- Switch the system ON to check the
adjustement
4
- Put a metal washer on the cover
3 sensor
- Turn the H.V. ON
1 2
- Remove the washer and put the cover back on the

head
- Enable the H.V.

8.254
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8
General Errors
The prin ng head is too far away from the product
Wind or Vibra on
Wind or Vibra on
Wind or Vibra on
Not regular product movement
Not regular product movement
8.255
Z 3000
8
Phase Errors
8.256
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H.V. Errors
8.257
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8
Electosta c Charge Errors
8.258
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8
NOTES
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8.259
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NOTES
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8.260
System Installa on 9
Unit Posi oning
System Checking
Temperature
Distributor Page
Customer Training
Shipping
Troubleshoo ng Form
Installa on Form
Z 3000
9
SYSTEM INSTALLATION CHAPTER
Unit Posi oning
Unit area: the user must have an easy access to

the keyboard and to the hydraulic compartment
in order to reduce the possibility of errors or
accidents.
Security area: avoid water, very dusty enviroment
and all the other dangerous agents
Keyboard always visible (for the alarms)
Avoid interferences with nearby instruments/machines
Do not bend or close the vapor collec on pipe
Support characteris cs:
do not close ven la on grid

stability, no vibra ons
horizontal
electrically insulate
9.263
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9
CHAPTER SYSTEM INSTALLATION
Security distance from the product

Slight vibra ons
Easy access for the daily maintenance purposes
Avoid interference with nearby instruments/machines
Well grounded
Allowed posi ons:

A) PRINTING ON THE TOP
E
2 2 .1 X P IR
2 .0 Y
9
E
2 2 .1
E
22 .12X P IR
Y
.09
E
22 .12X P IR
Y
.09
E
22 .12X P IR
Y
.09
E
22 .12X P IR
Y
.09
9.264
Z 3000
9
B) PRINTING ON THE SIDE
H
1
BA
TC
5 4 .J H
41
BA
T CH
54.
J41
BA
T CH
54.
J41
BA
T CH
54.
J41
Print-Head slightly inclined
9.265
Z 3000
9
C) PRINTING ON THE BOTTOM
It is required:
- Pressurized print head
9.266
Z 3000
9
ENCODER
The figure shows an installed encoder on a produc on line and its corresponding components.
9.267
Z 3000
9
System Checking

The power supply must be free from cuts or varia ons in power.
If so, provide inser ng an UPS con nuity unit (sinusoidal wave)
System properly grounded (between Neutral-Ground: 0.6/2V)
Produc on Line properly grounded

Electrosta c charges -> Remove by metal brush
Interferences with nearby instruments/machines -> Protec ons
Dusty -> Pressurize the Print-Head
Condensing humidity -> Presurize the Print-Head
Chemical substance -> Presurize the Print-Head
Fan Filter
Temperature
Very high -> Verify the opera ng temperature range 5-45 C (41-104 F)
Very low -> Switch the system ON 30 minutes before to start the prin ng
Distributor Page
Ink type used -> Verify the correct se ng
VISCO SET (25C) -> Verify the correct se ng
SERVICE HOURS and SERVICE DATE (Maintenance Warning)
Customer Training
Very specific training
Switch the system ON
Switch the system OFF
Sample maintenance
9.268
Z 3000
9
Shipping
Use every me the pallet to ship the system.
System complete empty (NO INK/MAKE-UP).
Troubleshoo ng Form
When the system presents any kind of problem it is strongly recommended to fill the TROUBLESHOOTING
FORM in order to improve the assistance service procedure. These technical informa on are very useful
during the service phone.
(This form is downloadable from Zanasi web site www.zanasi-coding.com)
TROUBLESHOOTING
DISTRIBUTOR NAME:
COMPANY NAME
SYSTEM GENERAL INFORMATIONS

SYSTEM MODEL
SERIAL NUMBER
SOFTWARE RELEASE (press CTRL + 0)
INSTALLATION DATE
Batch and EXPIRY Date of the INK
Batch and EXPIRY Date of the MAKE-UP
EDIT INFORMATION (parameters of the message)
NUMBERS OF LINE
FONTS used into the message
CODING TYPE
BOLD
INTERLINE
SPEED
DELAY
9.269
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9
MENU SET (all the follow informations are stored into the MENU SET)
PHOTOCELL (Y/N)
ENCODER (Y/N)
PRINT SPEED (1/32767)
PRINT DELAY (0/65535)
PRINT REPEATER (Y/N)
REPEATER TIME
INVERTED TEXT (Y/N)
REVERSED TEXT (Y/N)
Load Rod Amplitude (SET) =
H.V. VALUE (SET) =
H.V. VALUE (READ) =
FLIGHT TIME =
PHASE PEAK =
PRESSURE (SET) =
PRESSURE (READ) =
SUCTION (SET) =
VISCOSITY (REF) =
VISCOSITY (READ) =
INK USED =
INK TEMP. =
BOARD TEMP. =
H.V. ALARM (Y/N) =
GUTTER ALARM (Y/N) =
PRESSURE ALARM (Y/N) =
FLUSHING ON START UP (Y/N) =
9.270
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9
THE FOLLOWING VALUES ARE

+
STORED INTO THE DISTRIBUTOR PAGE
INK TYPE =
VISCO SET (25C) =
TYPE OF SIZE =
TPT (TYPE) =
VISCOMETER LABEL VALUE
Visco SET POINT (the value present on the label)
REGULAR MAINTENANCE
Latest Hydraulic Flushing (Date)

Latest Filter changing (Date)
Latest Ink Changing (Date)
INSTALLATION DETAILS
ROOM TEMPERATURE
ROOM ENVIRONMENT
POWER SUPPLY
Z-4000 GROUND CONNECTIONS (Y/N)
CONVEYOR SPEED
PRINT PER MINUTE
PRODUCTION LINE ground connections (Y/N)
TYPE OF PRODUCT
PARTS ALREADY REPLACED
DEFECTS
9.271
Z 3000
9
Installa on Form
It is strongly recommended to fill the INSTALLATION FORM for each installed system in order to have a
complete report for each customer.
(This form is downloadable from Zanasi web site www.zanasi-coding.com)
INSTALLATION FORM
GENERAL INFORMATION
COMPANY NAME:
COMPANY LOCATION:
COMPANY ADDRESS:
PRODUCTION MANAGER (Name):
USER REFERENCE PERSON (Name):
INSTALLATION DATE:
SYSTEM GENERAL INFORMATION
PRINTER TYPE/NAME:
INTERNAL SERIAL NUMBER:
CE NUMBER:
INK TYPE:
MAKE-UP TYPE:
BATCH AND EXP. DATE OF INK:
BATCH AND EXP. DATE OF MAKE-UP:
SOFTWARE RELEASE (ctrl+0 in the main page):
INSTALLATION SETUP
PRODUCT TYPE:
PRODUCT MATERIAL:
PRINTHEAD POSITION:
THROW DISTANCE(cm):
POWER SUPPLY VOLTAGE:
PRINTER GROUND CONNECTION (Y/N):
PRODUCTION LINE GROUND CONNECTION (Y/N):
CONVEYOR SPEED (MT/MIN OR MT/SEC):
OPERATING ROOM TEMPERATURE:
ROOM TEMPERATURE RANGE:
LAMP ALARM (Y/N):
PRINTHEAD PRESSURISATION (Y/N):
ENVIROMENT TYPE (DUSTY,WET,CLEAN):
9.272
Z 3000
9
MESSAGE INFORMATION
NUMBER OF LINES PRINTED:

CODING TYPE (17S ,16HS,3L 9X7):
FONT TYPE (5X5,7X5,9X7.):
INTERLINE VALUE:
BOLD VALUE:
INVERTED MODE (Y/N):
REVERSED MODE (Y/N):
SYSTEM SETUP
PHOTOCELL (Y/N):
ENCODER (Y/N):
PRINT SPEED VALUE:
PRINT DELAY (PHOTOCELL ONLY):
PRINT REPEATER (Y/N):
REPEATER TIME (PRINT REPEATER ONLY):
LOAD ROD AMPLITUDE (SET):
H.V. VALUE (SET):
H.V.VALUE (RED):
PRESSURE (SET):
PRESSURE (READ):
SUCTION POWER SET (1000/2500):
INK TYPE:
VISCOSITY (REF):
VISCOSITY (READ):
INK TEMPERATURE:
LOGIC BOARD TEMPERATURE:
H.V. ALARM (Y/N):
GUTTER ALARM (Y/N):
PRESSURE ALARM (Y/N):
FLUSHING START-UP (Y/N):
DISTRIBUTOR PAGE SETTINGS + PASSWORD
INK TYPE SELECTED (111,153,221..):

VISCO SET VALUE (ON VISCOMETER LABEL):
TPT02 (Z-4000) (Y/N):
TPT04 (Z-5000) (Y/N):
NOZZLE SIZE (50u OR 70u):
SYSTEM SERVICE STATE (HOURS AND/OR DATE):
PRESSURE REVOLUTION ALARM (Y/N):
9.273
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9
NOTES
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9.274

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Training Manual

Head Oce: Branch Oces:

Zanasi ITALIA Zanasi, Milano

1.00 November 2010

Graphic Operator Interface

Hydraulic system overview

Electrical and Power Supply System Overview

Print Head Overview

Technical Specifica ons

Chapter 1 - Hydraulic Compartment

Turning the System ON

Turning the System OFF

Hydraulic Circuit Flowchart

Force Circuit Flowchart

Suc on Circuit Flowchart

Viscometer Circuit Flowchart

Make Up Circuit Flowchart

Purge Circuit Flowchart

Flush Circuit Flowchart

Chapter 2 - Hydraulic Maintenance

Tubolar Filters Replacement Procedure

Main FIlter Replacement Procedure

Damper Replacement Procedure

Solenoid Valve Cleaning Procedure

Viscometer Cleaning Procedure

Viscometer Replacement Procedure

Force Pump replacement procedure

Connec ons Tank-Pipe

Note of the Flushing System Procedure

Start-up procedure a er flushing

Suggested Maintenance Schedule

Chapter 3 - Alarms of the System

How to see the Specific Alarm

*Low Priority Alarms*

*High Priority Alarms*

Ink Level Low

Tank Too Full

Print Head Alarms

Print Head Cover Missing

High Voltage Alarm

Chapter 4 - Electronic Compartment

Switching Power Supply

Main Logic Board

Test Point Checking Procedure

External Connec ons

Print Direc on Input

Serial Line (connec on to the pc or to the scanner)

Connec ons Main Board - Print Head

Connec ons on the Print Head

Print Head Cover Sensor

Print Head Micro Valve Card

Chapter 5 - Print Head

Print Head Working Principle

Print Head Layout

Chapter 6 - First Start Up Of The System

Removing the Printer from the Carton

Preparing the Printer for Use

Print Head Set-Up

Turning the System ON

Failed Star ng Procedure

Turning the System OFF

Chapter 7 - Programming So ware Release 1.02

Low Priority Alarms

High Priority Alarms

Low Priority Alarms

High Priority Alarms