Barak Hs User Guide

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The Barak HS

Users Guide

Users Guide Version Number: Revision V2.0 12-08


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Copyright: Matan Digital Printers (2001) Ltd.

All rights reserved.

No part of this publication may be reproduced, transmitted, transcribed, stored in aretrieval system, or translated into any language or any computer language, in any formor by any third party, without the prior written permission Matan Digital Printers (2001) Ltd.

Disclaimer

Matan Digital Printers (2001) Ltd., does not accept any responsibility for any damagecaused to its products by unauthorized personnel.

Environmental Policy

Customers are advised when changing consumables or any parts of theprinter, care should be taken to dispose of these consumables or parts inthe correct manner and according to the laws and regulations of the localauthorities.

For further details regarding the disposal of parts and consumables, contactyour local distributor.

Head OfficeMatan Digital Printers (2001) Ltd.14 Amal StreetRosh Ha'Ayin 48092

IsraelTel: (972) 3 9002720Fax: (972) 3 9002721Email for Customer Support: [email protected]

U.S. OfficeMatan USA Inc.90, Earhart Drive, Suite 4Williamsville NY 14221Tel: (1) 716 631 3770Fax: (1) 716 631 3576Email for customer support: [email protected]

Europe OfficeMatan EU, C/ Rosalia de Castro, 21, 08025, Barcelona, Spain.Tel: (+34) 902 932825Fax: (+34) 902 932826Email for customer support: [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


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Declaration of Conformity

This device complies with part 15 of the FCC Rules.Operation is subject to the following two conditions:(1) This device may not cause harmful interference, and(2) This device must accept any interference received, including interference that may causeundesired operation.

This Class A Industrial, Scientific and Medical Radio Frequency Generators also meets allrequirements of the Canadian Interference-Causing Equipment Regulations.

Cet appareil industriel, gnrateur de radio frquences pour applications scientifiques et mdicales,classe A, respecte toutes les exigences du Rglement sur le matriel brouilleur du Canada.

Limited Warranty

For a period specified in the contract, from the date of original purchase (Limited WarrantyPeriod), Matan Digital Printers (2001) Ltd., (Company), will, at Companys option, either replace orrepair any defective product (Product) manufactured by Company and sold by its authorizeddistributor, within its jurisdiction (Territory) to the person making a claim under this Limited Warranty,provided the original purchaser complies with the terms and conditions set forth herein below.This Limited Warranty applies only to a person or company that demonstrates to Companysreasonable satisfaction he or it was the original purchaser of a Product purchased in new conditionin the original package from an authorized distributor of Company in Territory. This Limited Warranty is

not transferable or assignable.If a claim is made within the Limited Warranty Period by the original purchaser, the Company willrepair or replace a Product that, in Companys reasonable judgment after inspection, is defective ineither workmanship or materials.Companys liability is limited to repair or replacement of a defective Product. Company will not beresponsible for any consequential or incidental damages or expenses of any kind or nature,regardless of the cause, even if Company has any knowledge regarding the probability of theiroccurrence. Without limiting the generality of this statement, Company will not be liable for injury topersons or property, loss of use of the Product, lost goodwill, lost profits, work stoppage, andimpairment of or damage to other goods. If any of the following have occurred, it will void thisLimited Warranty, and Company will have no liability of any kind to original purchaser if:

1. Product shows evidence it has been tampered with, or it has been subject to misuse, abuseor negligent use, or,

2. Any repair or alteration of Product was made by someone other than Company, includingthe distributor, except with Companys written authorization, or,

3. Product was either improperly installed, operated or used for a purpose for which it was notintended, or,

4. The original purchaser failed to provide normal maintenance, if any is required, inaccordance with Companys instruction manual, or,

5. The serial numbers or other factory-installed labeling has been altered or removed.

The original purchaser should return the defective Product to Company at the address set forthbelow, together with proof of purchase, packed with either the original packaging or other similarpackaging designed to avoid damage to Product during the course of shipment.THIS LIMITED WARRANTY IS GIVEN IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED.THERE ARE NO WARRANTIES AS TO THE FITNESS OF PRODUCT FOR ANY PARTICULAR PURPOSE.

COMPANY DISCLAIMS ANY OTHER WARRANTY, EXPRESS OR IMPLIED, THAT PRODUCT ISMERCHANTABLE.


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HOWEVER, IF COMPANY IS HELD LIABLE, WHETHER DIRECTLY OR INDIRECTLY, FOR ANY LOSS ORDAMAGE ARISING FROM UNDER THIS LIMITED WARRANTY OR OTHERWISE, REGARDLESS OF CAUSE ORORIGIN, COMPANYS MAXIMUM LIABILITY SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT,WHICH SHALL BE COMPLETE AND EXCLUSIVE REMEDY AGAINST COMPANY.ALTERATIONS AND ADDITIONS TO OR IN CONNECTION WITH ANY PART, HARDWARE OR SOFTWARE, OFTHE SYSTEM MAY ONLY BE CARRIED OUT BY MATAN OR PURSUANT TO ITS EXPLICIT AUTHORISATION,AND NO LIABILITY WHATSOEVER SHALL BE ACCEPTED BY MATAN FOR ANY ALTERATIONS ORADDITIOINS CARRIED OUT OTHERWISE, NOR FOR ANY EFFECT SUCH ALTERATIONS OR PROVISIONS MAYHAVE ON THE SYSTEM OR THE SUPPORT THEREOF.No employee or representative of Company is authorized to change this warranty in any way orgrant any other warranty.


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Table of Contents

1 INTRODUCTION................................................................................................1

2 SAFETY..............................................................................................................3

General Safety Hazards...........................................................................................3Safety Precautions and Measures ................................................................................................3Fire Prevention..................................................................................................................................3Eyewash Solutions............................................................................................................................4Accident Prevention.......................................................................................................................4Installation Provisions .......................................................................................................................4

Safety Signs ................................................................................................................5Printer Mounted Signs......................................................................................................................5Signed mounted close to the printer............................................................................................7

Ventilation..................................................................................................................8

Restricted Area .........................................................................................................8Wide-angle Mirror ............................................................................................................................9

Personal Safety....................................................................................................... 10Ink Handling....................................................................................................................................10

Working with Loctite......................................................................................................................10Working with the Barak5/3 HS Printer..........................................................................................11

Additional Safety Information.............................................................................. 12Mechanical Hazards .....................................................................................................................12First Aid Procedures .......................................................................................................................15Potential fire hazard ......................................................................................................................16

3 SPECIFICATIONS............................................................................................19

4 PREPARING THE PRINTER................................................................................21

Mains Power ........................................................................................................... 21

Pneumatic System................................................................................................. 21Air Supply.........................................................................................................................................22Filter System.....................................................................................................................................24

The Emergency Stop Buttons ............................................................................... 25

The Printer Hood..................................................................................................... 25

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5 POWERING UP THE PRINTER AND THE RIP STATION......................................27

Powering up the Printer ........................................................................................ 27

Powering up the RIP Station................................................................................. 28

Start-up Procedure ................................................................................................ 28

Activating and Using the Program...................................................................... 28

6 THE RIP PROCEDURE......................................................................................32

Baraks Workflow.................................................................................................... 32File Preparation..............................................................................................................................32Caldera RIP.....................................................................................................................................32The Barak Front End.......................................................................................................................33

Printing Modes and Maximum File Size .............................................................. 34Printing Modes & Speeds Barak HS..........................................................................................34

An Introduction to Caldera (V. 7.55) .................................................................. 35Quick Start for Caldera.................................................................................................................35Some Advanced Options ............................................................................................................41

Shut-down Procedure ........................................................................................... 43

7 CHECKING THE CONSUMABLES...................................................................44

The Ink System ........................................................................................................ 44

The Ink...................................................................................................................... 44

Pumps and Filters ................................................................................................... 45Ink Filters ..........................................................................................................................................45Ink Waste Tank ...............................................................................................................................46

Ink Vacuum Level .................................................................................................. 47

UV Lamps ................................................................................................................ 48

The Media ............................................................................................................... 49

The Ionizer ............................................................................................................... 50

The Expanding Core Holder................................................................................. 50Attaching the Expanding Core Holder......................................................................................51

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The Operators Control Buttons ........................................................................... 55

The Rear Control Panel......................................................................................... 55

The Vacuum/ Mesh Table .................................................................................... 56Adjusting the Carriage Height.....................................................................................................58

8 LOADING AND UNLOADING THE MEDIA......................................................59

Roll-to-Roll ............................................................................................................... 59Configuring the Software .............................................................................................................59Loading the Media for Roll-to-Roll Printing ................................................................................61Unloading the Media after Roll-to-Roll Printing.........................................................................63

FreeFall .................................................................................................................... 63Configuring the Software .............................................................................................................63Loading the Media........................................................................................................................64Unloading the Media after FreeFall Printing..............................................................................66

Flatbed .................................................................................................................... 67Configuring the Software .............................................................................................................67Flatbed Media Flow.......................................................................................................................68Loading the Media........................................................................................................................68Unloading the Media....................................................................................................................72

Printing on Mesh..................................................................................................... 73

9 MAINTENANCE...............................................................................................75

Printer Operation ................................................................................................... 75

Daily Maintenance................................................................................................ 76

Weekly Maintenance ........................................................................................... 79

Monthly Maintenance .......................................................................................... 81

Quarterly Maintenance........................................................................................ 81

Long-term Maintenance ...................................................................................... 82

10 TROUBLESHOOTING .......................................................................................83

Pneumatics ............................................................................................................. 83

Print Heads.............................................................................................................. 83

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UV System................................................................................................................ 83

Printing ..................................................................................................................... 84

The Ink System ........................................................................................................ 86

The Front End Software (Matan) ......................................................................... 87

Mechanics .............................................................................................................. 87

11 GLOSSARY.....................................................................................................88

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Table of Figures

FIGURE 1: RESTRICTED AREA ................................................................................8

FIGURE 2. THE PNEUMATIC SYSTEM...................................................................21

FIGURE 3: AIR PRESSURE GAUGES.....................................................................22

FIGURE 4: DIGITAL VACUUM GAUGE................................................................22

FIGURE 5. THE INK VACUUM LEVEL ADJUSTER...................................................23

FIGURE 6: WATER AND OIL FILTERS....................................................................24

FIGURE 7: EMERGENCY STOP BUTTONS.............................................................25

FIGURE 8: EMERGENCY STOP CORD.................................................................25

FIGURE 9: THE BARAK HS WORKFLOW...............................................................32

FIGURE 10: THE DISPLAY WINDOW.....................................................................37

FIGURE 11: THE PRINT WINDOW.........................................................................38

FIGURE 12: PAGE SETUP WINDOW.....................................................................39

FIGURE 13: THE COLORS DIALOG BOX.............................................................40

FIGURE 14: THE COMPOSE DIALOG BOX..........................................................41

FIGURE 15: TILING DIALOG BOX........................................................................42

FIGURE 16: INK CABINET....................................................................................44

FIGURE 17: MAIN INK TANKS & PUMPS..............................................................45

FIGURE 18: INK FILTERS & SLEEVES.....................................................................46

FIGURE 19: INK WASTE TANK..............................................................................46

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FIGURE 20: INK VACUUM LEVEL ADJUSTER........................................................47

FIGURE 21: THE CARRIAGE COVER....................................................................47

FIGURE 22: UV LAMP ASSEMBLY.........................................................................48

FIGURE 23: FLATBED MEDIA COLLECTOR TABLE................................................49

FIGURE 24. THE IONIZER......................................................................................50

FIGURE 25. ATTACHING THE MOUNTING STRIPS................................................51

FIGURE 25. THE OPERATORS CONTROL BUTTONS.............................................55

FIGURE 26: REAR CONTROL PANEL....................................................................55

FIGURE 27: THE VACUUM / MESH TABLE (WITH OPEN WINGS).........................56

FIGURE 28: MESH TABLE (WITH CLOSED WINGS)...............................................57

FIGURE 29: CARRIAGE HEIGHT GAUGE.............................................................58

FIGURE 30. LOADING MEDIA FOR ROLL-TO-ROLL PRINTING............................61

FIGURE 31. MEDIA PATH FOR ROLL-TO-ROLL PRINTING....................................62

FIGURE 32. PATH OF THE MEDIA FOR FREEFALL PRINTING ................................65

FIGURE 33. MEDIA PRINTED IN FREEFALL MODE................................................66

FIGURE 34. PATH OF THE MEDIA FOR FLATBED..................................................68

FIGURE 35. REAR FLATBED TABLE WITH EMPTY MEDIA LOADED........................69

FIGURE 36. FRONT FLATBED TABLE......................................................................69

FIGURE 37. MEDIA ON THE VACUUM TABLE......................................................70

FIGURE 38. MEDIA PRESSURE ROLLERS DOWN.................................................71

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FIGURE 39. MEDIA BEING PRINTED....................................................................72

FIGURE 40. PRINTED MEDIA ON THE FRONT FLATBED TABLE.............................72

FIGURE 41. VACUUM TABLE WITH ABSORBENT CLOTH AND CLOSED WINGS.73

FIGURE 42. VACUUM TABLE WINGS OPEN.....................................................74

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Notations in this Manual

This information is important and should be noted.

Information given in this message warns of a hazard.

Information given in this message refers to the only safe method ofinstallation or operation and must be adhered to.

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1 Introduction

This Users Guide describes the procedures for using the Barak5 HSand Barak3.0. HS printers.

The guide comprises the following sections:

Chapter 1 Is the Introduction (this chapter,) and sets out ourrecommended printing workflow.

Chapter 2 Is the Safety chapter.

Chapter 3 Details the specifications of the Barak5 and 3 HSprinter.

Chapter 4 Sets out the procedures for preparing the printer foruse.

Chapter 5 Sets out the procedures for powering up the printer andthe RIP Station.

Chapter 6 Describes the RIP procedures.

Chapter 7... Shows you how to check the printers consumables.

Chapter 8 Describes the Media loading and unloading procedures.

Chapter 9... Describes the Maintenance procedures.

Chapter 10... Is the Troubleshooting section.

Chapter 11... Is the Glossary.

The location of a label or a machine part is given assuming you arefacing the relative side of the printer.

For example, the Pneumatic System is located behind the PneumaticSystem Panel at the Front Lower Right Side of the printer, assuming youare facing the front of the printer. The Electronics System is locatedbehind the Electronics Panel at the Rear Upper Left Side of the printer,

assuming you are facing the rear of the printer.

The Matan HS printer is under constant development and we reservethe right to make changes to its specification, without prior notification.

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The following flowchart gives you our recommended workflow for usingyour Barak HS printer.

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2 Safety

This chapter provides important safety information. Make sure to readthis information carefully before operating the printer!

General Safety Hazards

Safety Precautions and Measures

Please refer to the Material Safety Data Sheet (MSDS) included with theink kit, to obtain relevant safety information and data, regarding theproper use, storage and handling, and disposal of Matan inks.

Make sure to post precautionary and warning signs in several strategiclocations. The following sections show examples that should be added

to the signs required by your local Occupational Safety and Local FireOrdinances.

Fire Prevention

The ink and flushing fluid should be kept in storage cabinets designedto hold flammable liquids and must be clearly labeled to comply withoccupational safety regulations. The storage cabinets must meet the

local fire and safety standards

You should not store more than the locally permitted amount of inksand flushing fluid in any single storage cabinet. Local fire regulationsregarding the use and storage of flammable materials must be strictlyobserved. Make sure that the inks are stored separately from any othermaterial.

CO2 Fire extinguishers must be easily accessible and visible from allapproaches to the Restricted Area. They must be reachable within 7.6 m

(25 ft) of the Barak5/3 HS printer and the flammable liquids storagecabinets, or according to local fire regulations.



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Eyewash Solutions

Provide Eyewash Stations complying with the local heath and safetystandards. They should be located within 7.6 m (25 ft) of the printerand the flammable liquid storage cabinets.

The location of these stations should be clearly marked and easilyaccessible so that they can be reached quickly if needed. You can obtainthese stations from companies that supply industrial safety equipment.

Accident Prevention

Both the electric power cable and air supply cable connected to theprinter should be channeled inside suitable conduits. Tripping over

loose wires may cause injury and/or damage to the printer.Installation Provisions

Only a qualified electrician should install the Barak5/3 printers. TheUser is responsible for providing electricity supply and compressed air,according to the Product Specification Sheet.



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Safety Signs

Printer Mounted Signs

The following safety signs are attached to the printer:

Label Description

Indicates the Mains Power Switch.

Emergency Stop buttons.

When pressed, will immediately turn off theprinter.

Emergency Stop Cord

Do not touch any electrical component orwiring while the printer is On.

Keep your hands clear of any movingparts while the printer in On.

Keep your hands clear of the X-Axis Motor

Assembly while the printer is On.

Keep your hands clear of all the Rollersand Shafts while the printer is operating.



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Keep your hands clear of all the Rollersand Shafts while the printer is operating.

Danger of UV radiation!Keep the Hood closed while the printer isworking.

Before servicing the UV lamps, allow themto cool down.

When servicing the lamps, wear UVgoggles that conform to internationalstandards.

Keep your hands clear of the Hood whenit is closing.

Keep clear of the moving Carriage.

Avoid contact between the Ink and yourskin.

Treat affected areas immediately.

Avoid contact between the Ink and youreyes.

Wear suitable protective goggles whenhandling the Inks.

Do not operate the printer without proper

site ventilation.

The following information should be read carefully.

Waste Disposal

A covered fireproof container clearly labeled as hazardous waste shouldbe placed in the production area, for disposing waste solvent and ink.The container must be electrically grounded during the transfer of

liquids into or from the container. If solvent-soaked rags or absorbents



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are used to clean the area, they must also be disposed of into a closedfireproof container and labeled as hazardous waste.

These waste containers must be located at least 7.6 m (25 ft) from theRestricted Area (see Figure 1 on page 8) Contact your local fire, healthand safety agencies for information regarding the storage and disposalof waste from the printer.

Signed mounted close to the printer

The following signs should be mounted around the work area:

Keep Work Area Clean

When you plan and design your site, provide convenient access towashing facilities, with suitable eye-washing equipment.

Always keep the working area clean and dust free.

Try to clean any spills as soon as they occur. Make sure to wear gloves,goggles, and long sleeves when cleaning up spilled ink. Absorb the inkin dry sand or soil and place it into a covered waste container. Move thecontainers at least 7.6 m (25 ft) from the Restricted Area.Flush the affected area with water.

Fire Protection

Provide dry carbon dioxide (CO2) fire extinguishers and install them in

easily accessible locations.

First Aid

An adequate first aid kit should be provided.



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Ventilation

The area in which the inks are handled should be well ventilated to prevent

accumulation of hazardous vapors. Use extreme care to avoid spillage, andprevent splashing of eyes or skin.

To prevent the accumulation of hazardous vapors, sufficient ventilationmust be provided to exchange the air in the Production Area,approximately 4 6 times per hour.

Restric ted Area

Figure 1: Restricted Area

The Restricted Area is defined as the area within 1 m (3.5 ft) from any

part of the Barak5/3 HS printer, e.g. any of the rollers, print headcarriage, printing table, etc.

When working with the optional Flatbed tables, the Restricted Area is tobe extended by 1 m (3 ft) both at the front and rear of the printer.

The Restricted Area is extremely hazardous when the printer is inoperation and proper safety guidelines must be followed to ensure a

safe work environment.



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Only the machine operator and authorized personnel may access the

Restricted Area.

It is mandatory that the machine operator presses one of the EMERGENCYSTOP buttons as soon as he sees an unauthorised person within the restrictedarea.

Moving parts can cause serious injury.

Wide-angle Mirror

You must install a wide-angle mirror that will provide the operator witha peripheral view of the restricted area around the printer insuring thatit is clear of authorized personnel prior to machine operation.



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Personal Safety

Ink Handling

Please take the following into consideration when handling inks orsolvents:

Do not store or handle near open flames, sparking tools orelectrical discharge.

Do not drink or otherwise ingest ink, cleaning fluid or wastefluids.

Do not smoke in the vicinity.

Dispose of empty containers, ink soaked rags and wasteaccording to relevant local and national authority procedures.

Be familiar with the relevant MSDS.

Store ink as instructed in the MSDS.

Clear spills immediately and dispose of ink soaked rags.

Do not operate the printer when there is spillage in the vicinity.

Do not allow untrained personnel to handle ink, cleaning fluidsor waste fluids or to enter the Restricted Area.

Keep children and animals away from the printer.

Wear multi-layer protective gloves (for example, 4H, Saranex, orNitrile gloves) when handling cleaning fluid, inks or any wastefluids to prevent contact with skin.

Always wear protective goggles while handling ink system,cleaning fluid or waste liquid.

Wear clothing that covers all body parts to prevent ink contactwith skin.

Ink can be irritating to eyes, throat and skin, and breathing itsvapors can cause dizziness or other symptoms. These symptomsmay not appear immediately.

Never wear contact lenses while handling inks or flushing fluid.

When using flushing fluid, make sure that the printer iscompletely shut down and cooled down.

Wash your hands thoroughly at the end of each work shift,before eating, smoking, or using the toilet. If ink spills on yourskin, wash immediately. Remove any clothing that iscontaminated with ink.

Working with Loctite

Avoid contact between Loctite and your eyes or skin.

Follow the manufacturers safety instructions very carefully.



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Working with the Barak5/3 HS Printer

Please take the following precautions when working with the

Barak5/3HS printer in order to ensure your personal safety:

All personnel are to read and understand the Users Guide andbe alerted to the potential hazards indicated by the safety labelsbefore operating this machine.

Only a trained and authorized person is to be permitted toservice and operate this machine.

Training should include instruction in operation under normalconditions and emergency situations.

Never climb onto any part of the printer. Always use a ladder orsteps if necessary.

Never use any part of the printer to help you maneuver on ornear the printer.

Never reach into the machine for any reason unless the machineis at a complete stop.

Never leave the machine stopped in such a manner that anotherworker can start it while you are in the restricted area.

Never change or deactivate the function of electrical interlocks orother machine "shutdown" switches.

Before starting the printer, check that all persons are clear ofthe printer, and that the machine is free of paper scraps, wraps

and other loose material that shouldnt be there.

There is a potential hazard of entanglement in this machinecaused by long hair, loose clothing, jewelry, or similar items.

Within 3 seconds of hearing the buzzer, keep at least 1 m awayfrom the machine.

Do not approach the printing area when the print head carriageis activated.

The areas around loading and unloading points are to be keptclear of obstructions that could endanger personnel.

Under no circumstances are the safety characteristics of this

equipment to be altered.

Routine inspections and corrective/preventative maintenance

measures are to be carried out, to ensure proper operation andsafety.

As a general rule, this equipment is not to be cleaned or servicedwhile in operation.

Never look directly at the UV light source.You must always wear suitable anti-UV goggles that conform tointernational standards.

If you are servicing the UV Lamps, allow the lamps ample time to

cool down first, as contact with the hot lamps can burn the skin.



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Avoid smoking, eating, or drinking within the printers RestrictedArea.

Follow the fire prevention precautionary methods described inthis chapter.

Shut OFF the main power switch when servicing electricalcomponents (AC power boxes or cables).

While the printer is operating, stand at the workstation. Do notapproach the printing area, and keep hands clear of movableparts.

While the printer is operating, certified operators and Matanfield service engineers only are permitted in the restricted area.

While loading and unloading heavy materials, make sure to wear

steel-toed safety boots. Do not attempt to load or unloadmaterials while the printer is operating.

Do not operate the printer while under the influence of drugs oralcohol.

Additional Safety Information

Mechanical Hazards

Cable Chain

The Flexible Cable Carrier carries all cables and pipes going from the PC

and ink system to the Carriage. The carriage moves continuously duringthe printing process along the chassis at a speed of up to 2.2 m/sec.

Contact between the moving Carriage and a foreign object can cause aninjury.

The Hood

The Hood, which is located at the front of the printer, protects the userfrom such dangers as UV rays and contact with the moving carriage.The printer will not operate unless the Hood is closed. Pressing one ofthe Emergency Stop buttons or pulling the Emergency Cord will stopthe Carriage immediatelyand the UV lamps are switched off.

To minimize this hazard a number of warning labels listing the dangersare attached to the printers back frame.

The Hood may injure a hand when closing. This hazard is minimized by:

Soft rubber protectors on its edge.

By a flashing light and a buzzer which are activated before theHood starts moving.

By a number of safety labels on the printers front frame,warning against this hazard.

The Hood is activated manually by an operator by turning aswitch on the front switch panel, which is located on the front

left side of the printer. There is a safety label near the knob



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instructing the operator to make sure the Hood is clear orforeign objects.

The Hood contains an air pressure lock mechanism, which liftsthe Hood in case the machine air pressure supply stops.

Press Roller and Shaft

There is a danger that the Press Roller and the Shaft could crush ahand while moving one roller next to another which is their printposition. This action is activated manually by the operator who turnstwo knobs on the rear of the left cabinet. There is a safety label nearthose knobs instructing the operator to make sure the rollers notobstructed.

Another potential hazard is for those rollers to pull and crush a finger

when the media is manually rolled backwards and somebody places ahand on the media. To minimize this hazard, there are a number ofsafety labels on the machine back frame which warn against thishazard. In addition there are five Emergency Stop buttons along themachine rear. Pressing one of those buttons stops the mediamovements immediately.

In addition, these two hazards can be minimized by instructing the

customer to draw on the floor and administer a safety zone of 1 maround the machine, as shown in Figure 1on page 8.

UV Radiation

The machine contains two UV lamps which operate while the machine

prints. While the machine is idle at the Home position, the UV shuttersare closed, and the UV bulbs are automatically turned off after 20minutes of idle time.

Looking at the UV light with the naked eye is dangerous. This hazard isminimized by the Hood being equipped with transparent UV-blockingpanels. In addition, the machine will print only while the Hood is closed.

The UV radiation is contained by the Hood and by opaque PVC sheetsalong the front and back of the printing table. There are safety labels onthe UV bulb assemblies and on the printers frame.

When working near the UV Lamps when they are switched on, you mustwear suitable anti-UV goggles that conform to international standards.



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Electrical Hazards

The printers electricity input is a 3-phase 380V 30 amp VAC,connected to the main electricity panel at the printers right side, whenlooking from the front of the printer.

The main electricity panel is protected by the cabinet metal doorand a rigid transparent plastic panel.

Single phase voltage at the PC.

Five motor drivers (located above the main electricity panel).

The UV bulbs assembly on the Carriage.

Human contact with these AC voltages may cause electrical shock andburns. This hazard is minimized by:

Over-current and over-voltage of a circuit breaker for the maininput and for each AC voltage within the machine.

By proper grounding of all electrical circuits.

By safety labels on each electrical cabinet door and close to allAC contact points.

In case of an overload, the circuit breaker triggers and switchesoff the printer. The machine operator is authorized to open thecabinet door in order to switch on a circuit breaker, in case ittriggers. The cabinet door is locked by a special key and not by aregular handle, to prevent occasional opening of the cabinet.Only a certified Barak5/3 HS technician is authorized to removethe plastic cover for access to the main Electricity Panel. Thiscan be done only after the main power is switched off.

Within the machine the AC voltages are converted to DC voltages of 5V,24V and 48V, and distributed to various points. Human contact withthese DC voltages may cause electrical shock and burns. This hazard isminimized by:

A circuit breaker for the main input and for each AC voltagewithin the printer.

By proper grounding of all electrical circuits.

By safety labels on each electrical cabinet door or panel.

Ink System

The ink system contains the main ink tanks, pumps, filters, manifold,secondary ink tanks, print heads and pipes.

As noted on the MSDS, the ink is a mixture of pigments, resins andadditives in organic solvents. Contact with the ink can cause irritationof the eyes and skin.

Each container of ink (and flushing fluid,) is supplied with an MSDS.This document provides important safety information and must be readcarefully.

There are safety labels by the Main Ink Tanks instructing the operatorto wear glasses and gloves while handling the ink. The ink is heated by



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the machine to its printing point. The heater will cut off if the requiredtemperature is exceeded.

To eliminate any inconveniences due to vapors and bad smell, themachine should be well ventilatedby changing the air at least 4 6times per hour.

First Aid Procedures

When in doubt, or when symptoms persist, seek medical attention.Never give anything by mouth to an unconscious person.

By inhalation

Remove the patient from the contaminated area into the fresh air.

If breathing is irregular or stops, administer artificial respiration.

If the person is unconscious, place them in the appropriate recovery

position.

Keep the patient warm and calm rest until medical attention arrives.

By contact with the skin

Remove contaminated clothing and wash it separately with an alkalinedetergent.

Throw away clothing should it be highly contaminated, in a suitablecontainer.

Avoid concurrent exposure to sunlight or other sources of UV radiation

which may increase skin sensitivity.

Wash thoroughly the affected area with plenty of cold or lukewarmwater and neutral soap, or use a suitable skin cleanser.

Do not use solvents or thinners. In the case of skin reddening or rashes,call a doctor immediately.

By contact with the eyes

Remove contact lenses.

Rinse the eyes copiously by irrigation with plenty of clean, fresh waterfor at least 15 minutes, holding the eyelids apart, until the irritation is

reduced.Avoid concurrent exposure to sunlight or other sources of UV radiationwhich may increase eye sensitivity.

Call a doctor immediately.

By ingestion

If swallowed, seek immediate medical attention. Do not induce vomiting,due to the risk of aspiration. Keep the patient still.



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Potential fire hazard

Use CO2 Fire Extinguishers.

In the case of more important fires you can also use alcohol resistantfoam and water spray/mist.

Do not attempt to extinguish the fire by using a direct water jet.

Specific r isks

As a consequence of combustion or thermal decomposition, hazardousby-products may be produced, such as carbon monoxide, carbondioxide, nitrogen oxides, or sulfur oxides. Exposure to combustion ordecomposition products may be a hazard to health. Pyrolized acrylatesact as a high irritant to the respiratory system.

Fire-proof protective equipment

Depending on the magnitude of the fire, heat-proof protective clothingmay be required, appropriate independent breathing apparatus, gloves,protective glasses or face masks and boots.

Other recommendations:

Cool with water the tanks, cisterns or containers close tosources of heat or fire.

Bear in mind the direction of the wind.

Do not allow fire-fighting residue to enter drains, sewers or

water courses.

Personal precaution

Eliminate possible sources of ignition and when appropriate,ventilate the area.

Do not smoke.

Avoid direct contact with the inks.

Avoid breathing vapors.

Environmental precautions

Avoid contamination of drains, surface or subterranean waterand soil.

In the case of large-scale spills or when the productcontaminates lakes, rivers or sewages, inform the appropriateauthorities in accordance with local regulations.

Cleaning-up methods

Contain and mop up spills with non-combustible absorbentmaterials (earth, sand, vermiculite, diatomaceous earth, etc.).

Clean preferably with a detergent.

Avoid use of solvents. Keep the remains in a closed container.



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Handling precautions

Comply with the local health and safety regulations.

Avoid any type of leakage or escape.

Keep the container tightly closed.

Recommendations for the prevention of fire and explosion r isks

Vapors are heavier than air; they may spread along floors to aconsiderable distance. They can form explosive mixtures with air andare able to reach distant ignition sources and ignite up or explode. Dueto its flammability, this material should only be used in areas fromwhich all naked lights and other sources of ignition have been excludedand away from other heat or electrical sources. Do not smoke.

Storage of Ink

Prevent unauthorized access to the storage areas.

Inks should be kept isolated from heat, sparks, flame and otherignition and electrical sources.

In order to avoid leakages, the containers, should be kept tightlyclosed and placed in a vertical position.

Maximum storage period: 12 months.

Temperature range: 5 25C (41 77F). Do not expose the inksto higher temperatures as this can cause premature curing.

The relative humidity should be approximately 20% - 50%, non-condensing.

Violent polymerization may occur at elevated temperatures. It isbest to avoid sources such as heat, light, gamma or X-raysduring transportation and storage. Overexposure to these typesof energy may cause premature gellation.

Keep away from reducing agents, oxidizing agents, acids, alkalis,metals, peroxides, polymerization initiators.

Store in the original container, protected from direct sunlight in adry, cool and well-ventilated area, away from incompatiblematerials, food and drink.

Use appropriate containment to avoid environmentalcontamination.

Storage of Flushing Materials

Flushing solutions should be stored between 10 - 35C(50 37.5F).

Store away from any type of UV light source or stray light sourceand in UV-light -resistant containers.

Keep away from heat, sparks, flame and other ignition source.After opening, keep the container tightly closed.



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3 Specifications

Printing Technology

Piezo Drop-on-Demand inkjet technology

Resolution: True 600 dpi., up to 1200 dpi apparent

Barak5/3 UV400 inks, pigmented UV curable, up to 2 years outdoor.

Printing Technology

Throughput

Coverage

The Barak5 HS: 316 sq m / hr (3,400 sq ft / hr)

The Barak3 HS: 246 sq m / hr (2,648 sq ft / hr)

Up to 180 m2/liter (1940 ft2/hr)Based on Matans tesing & average consumptionat a customers site.

Media

Handling

Hybrid

Media supported

Max print width

Max media width

Standard: Roll-to-rollOptional: Multi-roll, Freefall, Flatbed, Ionizer andExpanding Media Collector.

Up to three pairs of Flatbed Tables can be suppliedfor the Barak5 and up to two for the Barak3.

Flexible: Backlit paper, Blue-back paper, Carpets,Coated & Uncoated media, Flexface, Mesh, Self-adhesive Vinyl and Tyvek.

Rigid: (up to 25 mm 1 in) thick: Foam PVC, Acrylic,Aluminum, Foam Board and Corrgated Board.

5 m (197 in.) or 3 m (118 in.)

5.3 m (209 in.) or 3.8 m (150 in.)

RIP

RIP Software

Supported formats

Dedicated Barak5/3 RIP

EPS, PS3, TIF, PDF, PSD, JPEG, etc



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Ink Storage Temperature

Please refer to our MSDS document that is providedwith the Ink, or contact your local Support Center.

Barak5 HS

Unpacked: (H x W x D)1.9 m x 7.6 m x 1.1 m (75 in x 299 in x 43 in.)

Printer Dimensions

(Incl. feet and Warning Buzzer)

Barak3 HS

Unpacked: (H x W x D)1.9 m x 5.5 m x 1.1 m (75 in x 217 x 43 in.

Weight Barak5 HS

Unpacked approx.: 4500 kg (12,056 lb)

Crated: approx. 5500 kg (14,750 lb)

Barak3 HS

Unpacked approx.: 4350 kg (11654 lb)

Crated: 5000 kg (14736 lb)

Operating conditions*

Operating Temarature

Humidity

Air pressure

Electricty

20C 29C (68F 84.2F).

50% 80%, non-condensing.

6 bar (87 psi), airflow of 7 liters/sec, dry clean air.

30A/380V Three Phase 50 Hz.

Operating the printer under condition different from those describedabove, can adversly affect the print quality.



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4 Preparing the Printer

Mains Power

You must carefully adhere to the following instructions.Improper use of the power and electrical connection could endanger yourlife!

Check that the MAINS POWER CIRCUITBREAKERS are ON.

Pneumatic System

Figure 2. The Pneumatic System

Air PressureGauges

Water Fil ter

Air Supply Tap

SystemPressurestat

Oil Filter

Air PresssureGauges

Pressure RollerGauge

Ink VacuumLevel Adjuster


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Air Supply

The Air Compressor

Check that the AIR COMPRESSOR is connected to the printer and isturned ON.

The Air Pressure Gauges

4 Bar 4 Bar 6 Bar 0.2 0.4 Bar

Figure 3: Air Pressure Gauges

Check that the gauges are set to the pressure shown on theircorresponding stickers, as in Figure 2. The Pneumatic System isaccessible through the Front Right Access Door.

The Vacuum System

The amount of vacuum in the system is displayed on the digital VACUUMGAUGE, which is visible through the top right side of the CARRIAGECOVER.

Figure 4: Digital Vacuum Gauge

DigitalVacuumGau

ge


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1. Bring the CARRIAGE to the right side of the printer so that you canboth see the DIGITALVACUUM GAUGE on the CARRIAGE COVER (asshown in Figure 4) and make the necessary adjustments if required,with theINK VACUUM LEVELADJUSTER (as shown in Figure 5).

2. Adjust the vacuum (displayed on the digital VACUUM GAUGE,) tobetween -0.8 and -1.2, by turning the knob on the VACUUMADJUSTER.

3. To increase the vacuum, turn the VACUUM ADJUSTER clockwise, andto decrease the vacuum, turn it counter clockwise.


Figure 5. The Ink Vacuum Level Adjus ter



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Filter System

Figure 6: Water and Oil Filters

The PNEUMATIC SYSTEM includes two filters: a water filter and oil filter(Figure 6). You should drain both these filters weekly, by turning theFILTER RELEASES in a clockwise direction and then closing them when allthe water and oil have been drained.

Water Filter ReleaseOil Filter Release


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The Emergenc y Stop Buttons

The Barak5 HS printer is equipped with seven Emergency Stop Buttonsand the Barak3 HS with six (Figure 7), as well as an Emergency StopCord which is located along the front of both printers (Figure 8).

Make sure all the EMERGENCY STOP BUTTONS are pulled out, by turningthem clockwise.

Rear Emergency Stop Buttons Front Emergency Stop Buttons

Figure 7: Emergency Stop Buttons

Emergency StopCord

Figure 8: Emergency Stop Cord

The Printer Hood

If you accidentally open thePRINTER HOOD while the printer is working,the current file will be put into the PAUSE status and the printer will

stop. You have to click OK and click Play again, to continue the job.



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5 Powering up the Printer and the RIP Station

You must turn on the printer before you turn on the RIPSTATION.

Powering up the Printer

1. Turn the MAIN SWITCH (located on the left side, at the rear of theprinter,) to the ON position.

The POWER SUPPLY INDICATOR lights up.

2. Push the greenSTARTBUTTON.

The printers Workstation boots up.

If the POWER SUPPLY INDICATOR does not light up, press the button on

the printers computer.

After the printer is powered up, the programs MAIN SCREEN appears.



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Powering up the RIP Station

Turn on the RIPSTATION.

Start-up Proc edure

Action Frequency

Check Clean Switch on

Emergency stopswitches off

3Main power switch 3Start button 3Start SW Barak FE 3Perform INIT

(clear objects fromtable)

3

Print heads - Purge,clean & nozzle test

3 3

Every daybefore startingto print

Ac tivating and Using the Program

1. From the Workstations Desktop, click the Matan Icon .

The BARAK MAIN SCREEN appears.

When the MAIN SCREEN appears, the INK andPRINTHEADS begin to

heat up to the required temperature.

Printing StatusInk Tank Status Printer Status

UV Status

Print Preview

Media Status

LEFT TOOL BAR

One File Workflow

Queue Workflow

Control Panel

TOP TOOL BAR


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When the system is ready for printing, the PRINTER READY status barturns green, indicating that the required temperatures have beenreached. You can now purge the PRINTHEADS.

The INKTANK STATUS indicates the amount of ink present in the MAININKTANKS.

The UV lamps are also heated to their required temperatures. Whenthis is reached, the UVSTATUS will indicate UVSYSTEM READY, andthe lamp icon will turn green.

2. In the LEFTTOOLBAR, click ONE FILE WORKFLOW.

3. To open a PRINTJOB, click OPEN AJOB.

The SELECTBARAKJOB window appears.

4. Double-click the job you want to open.

The JOB SETTINGS dialog box appears with the selected job displayed,together with its properties.

Single Job Queue

Multi Job Queue


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5. Check the displayed Print Settingsand if necessary, make the followingchanges:

Number of passes

Noise factor

Print direction

Print speed

Number of UV lamps to be used.

The UV lamps power setting

6. Check the displayed settings for POSITIONING the file on the Mediaand if necessary, make the following changes:

Alignment

Print Offset

Step & repeat

Gap



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7. Check the displayed settings for the JOBS LABELand if necessary,make the following changes for what will be displayed:

File Name

Number of the printed copy

Printing Time

Mode

8. If necessary, change the MEDIAS QUANTITY

9. To accept the displayed settings but not print, click .

To print the current file, click PRINT .



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6 The RIP Procedure

This chapter gives an overview of the Barak HS workflow as well as theRIP process using the Caldera application.

Calderas full documentation is provided in PDF form on our CalderaInstallation CD.

Baraks Workflow

Figure 9: The Barak HS Workf low

Baraks workflow starts on a Mac / PC graphic application and usingCalderas GrandRIP+, converts the file.

The RIP procedure converts the input file into a 1-bit tiff file, which the

Barak workstation manipulates and prints.

File Preparation

Caldera accepts most of the standard graphic formats such as: PS, EPS,PDF, TIFF.

Caldera RIP

The Caldera application converts the graphic files to a Barak FormatFile which comprises a folder with six files (.mjob):

Four 1-bit tiff files (xxx_c.tif, xxx_m.tif etc.)

A preview file

A Job Ticket file (XML format)



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The Barak Front End

Baraks Front End manages the printing options and:

Loads files onto the system.

Sets the margins and location on the Media.

Sets step and repeat.

Sets the UV Lamps strength and other printing parameters.

File Manipulation Options

The following table shows the File Manipulation options.

Manipulation Caldera Barak

Scale, Distort, Rotate 90 3 Rotate 180, Mirror 3 3Step, Copies

3Tiling, Nesting 3 Color Management 3



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Printing Modes and Maximum File Size

The following table shows the various Printing Modes with theircorresponding File Size.

The maximum file size per color is 4 GB, therefore the maximum file

size for printing, is 16 GB.

Mode Max. length (m)@ 1.6 m length

Max. length(m) @ 3 mlength

Max. length (m)@ 5 m length

Print Area(m2)

Supreme 30 15 9 60

Quality 30 15 9 60

Swift 130 80 50 250

Express 300 130 80 50 250

Express 150 DD 500 300 180 900

Printing Modes & Speeds Barak HS

Mode Width of Pass(mm)

Number ofPasses

Resolution DPI Speed(m2/hr)Barak 5

Supreme 8.1 8 600 x 600 25

Quality 16.25 4 600 x 600 44

Quality Fast 16.25 4 300 x 600 86

Swift 16.25 4 300 x 300 86

Express 300 / 150 32.5 2 300 x 300 164

Express 300 65 1 300 x 300 316

Express 150 DD 65 1 150 x 150 316



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An Introduction to C aldera (V. 7.55)

Caldera is one of the top three leading wide format RIP softwareproducers.

Caldera is based on a user-friendly graphic interface withunique drag-and-drop options.

Caldera works on both Linux and Macintosh operating systems.

The Caldera computer should be used only for the RIP software.

Quick Start for Caldera

After activating the Caldera computer, the Caldera GrandRIP+application automatically appears.

The Application Bar gives you access to the applications tools and theImage Bar normally contains the icon of each loaded image.

In both bars, the icons comprise two sections (as shown below).

There are three ways to access the target (file or dialog box,) via theicon:

Upper Section double-click

Lower Section click or,

Drag and Drop the icon.

Appl ication Bar

Image Bar

Upper Section

Lower Section


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The File Manager

1. To load the required file, in the APPLICATION BAR, double-clickFILEMAN, use the browser to locate the required file and double-clickit.

An icon appears in the IMAGES BAR (from where you send it to print,)

and the FILEMAN dialog box appears, as shown below.

Select the File

Click Load

2. Select the require file and click LOAD.



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The Preview Window

1. In the IMAGES BAR, double-click the required image.The image is displayed, as shown below.

Figure 10: The Display window

Standard Tools(Ruler, measure)

Vector Tools(Crop.)


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The Main RIP Window

PageSetup

Figure 11: The Print Window

1. To print a file, access the PRINTMODULE by double-clicking BARAK inthe APPLICATION BAR by dragging and dropping the icon.

2. Drag and drop the required image from the IMAGES bar to the PRINTWINDOW.

3. Select the required resolution, the Medias width, and the type ofMedia.

4. Adjust the values in the PAGE SETUP dialog box before printing.

5. From the MAIN WINDOW, click PAGE SETUP to enable you to adjust thepage.

The PAGE SETUP window appears.



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The Page Setup Window

Figure 12: Page Setup window

1. Select the required options from the icons on the left side of the

window, as well as the three tabs, as shown in Figure 12, and clickCLOSE.

The Application automatically sets the Medias Color Management.

If you want, you can print the file at this stage by clicking PRINTin themain RIP dialog box.

You can adjust the color settings before printing.

2. From the main RIP dialog box, click COLORS.

Full Size

Keep Ratio

Center

Orientation

100%

Print beyondprinting area

Mirror


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Colors

The COLORS dialog box appears.

Figure 13: The Colors Dialog Box



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3. Make the required changes to the Colors settings in the differenttabs and click CLOSE.

4. From the MAIN RIP dialog box, click PRINT.

Some Advanced Options

The Compose Window

The Compose option enables you to compose a selection of different files

for printing (nesting). For this, you should use the Edition, Creation anddata Entry tools.

Figure 14: The Compose Dialog Box

Properties

Rotate

Nesting

Paste

Copy


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The Tiling Window

The Tiling option enables you to create multi-tiled prints. This is idealfor applications where the posters have to be attached to 4 m x 3 madvertisement panels, as well as exhibition stands etc.

Figure 15: Tiling dialog box

1. Define the poster size, # of tiles and tile size (left side of window).

2. Define overlaps, white and crop marks (right side of window).

3. Drag the file from the IMAGE BAR.

Usually, the client will send a file saved with a ratio of 1:10. If this is

the case, you should select Full Page or 1000%.4. Create TILES.



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Shut-down Proc edure

Unless there is an emergency, do not use the Emergancy Stop Buttons orCord to turn off the printer.

When turning off the printer, follow the shut-down procedure.

Action Frequency

Check Clean Switch off

UV Power off

Purge & Cleanheads

Close SW &Switch offcomputer

Wait until UVlamps cool offand havestopped

Every daybeforeshut-down

Main powerswitch



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7 Checking the Consumables

The Ink System

The following figure shows the Main Ink System.

Figure 16: Ink Cabinet

The Ink

Check that there is sufficient ink in all the four Main Ink Tanks.The order of the inks location (from left to right) is: Cyan, Magenta,

Black and Yellow, as shown in Figure 17.



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Pumps and Filters

Figure 17: Main Ink Tanks & Pumps

The Ink Pumps (two for each color,) deliver the ink from the Main InkTanks to the Secondary Ink Tanks which are located on the Carriage.

For full details of the printing procedures, see Chapter 9 in thisdocument.

Ink Filters

Each of the four ink systems has its own four filters, two non-returnvalves and two protective sleeves.

You must make sure the all four protective sleeves are always coveringtheir non-return valves. Otherwise, the ink will absorb light and prematurlycommence the curing process.

Main Ink Tanks

Cyan Magenta Black Yellow

Pair ofInk Pumps


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Figure 18: Ink Filters & Sleeves

Ink Waste Tank

The INK WASTETANK, shown in Figure 19, collects the waste ink from thetray located on the base of the CARRIAGE. It must be emptied every day

before the printing session and before each shift.

Figure 19: Ink Waste Tank

Two Pumps

Two 1-way Valve(covered bysleeve)

Pair of Sleevesto protect theNon-return Valve

from light

Four Ink Filters

Ink Waste Tank


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Ink Vac uum Level

The Ink Vacuum Level controls the ink so that it doesnt drip throughthe Print Head.

If the Ink drips from a Print Head, use the Ink Vacuum Level Adjuster,as shown in Figure 20, to adjust the vacuum level.


Figure 20: Ink Vacuum Level Adjuster

Monitor the vacuum level using the Ink Vacuum Level Gauge, inset into

the carriage Cover and shown in Figure 21.

Ink VacuumLevel Gauge

Figure 21: The Carriage Cover



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UV Lamps

Figure 22: UV Lamp Assembly

The printer has two ULTRA VIOLETLAMP ASSEMBLIES. Each assembly ismounted on a side of the Carriage, as shown above.

The filters must be changed every day.



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The Media

The Barak printer will print on the following types of Media:

Banner

Carpets

Self adhesive

Mesh

Paper

Rigid Media (optional)

For rigid media you have to prepare the Flat-bed Feeder and CollectorTables.

Figure 23: Flatbed Media Collector Table

Barak will print a maximum of three Media Rolls simultaneously.

For any of the media described above, you have to make sure that theCarriage is adjusted to the correct height, according to the Mediasthickness.



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The Ionizer

Figure 24. The Ionizer

The IONIZER an optional accessory (shown in Figure 24,) neutralizesthe electrostatic charge that accumulates on the MEDIA.

You should use the IONIZER when the atmosphere is damp or when youare using media that produces an electrostatic charge. It is manuallyactivated by operating its switch, as shown in Figure 24.

The Ionizer can used either for flexible media such as banner, fabric,mesh, paper, vinyl, etc., or on rigid media such as foamboard, forex andcorrugated carton.

The Expanding C ore Holder

The expanding Core Holder, which is an optional accessory, is used tostabilize the movement of the Feeder and/or Collector Core when theMedia has been printed in FreeFall mode.

It can be used when printing Multi-Roll jobs.

Ionizer

Ionizer Switch


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It has an extremely accurate side control, with a tolerance of 2 mm(0.08 in.)

It can handle cores with a minimum internal diameter of75 mm (2.95 in.).

The Core Holder handles cores with the following properties:

Up to 100 m (328 ft) long, or up to 100 Kg (220 lb).

Up to 3.00m (9.9 ft) width, with a minimum of 1.2 m. (3.95 ft).

Attaching the Expanding Core Holder

The Core Holder attached to the front of the printer, at the place wherethe printed Media will fall.

If you are using the holder as a Feeder, then it should be attached tothe rear of the printer, at the place where the new Media will be located.

To attach the Expanding Core Holders to the Media Core:

1. Using three T-nuts and screws for each strip, attach the two sets ofMounting Strips to the printers chassis as shown below.

Mounting Strips

Figure 25. Attaching the Mounting Strips

2. Fit the right or left Docking Bracket onto the Mounting Strips asshown below and lightly secure it with the black knob.



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Docking Bracket

Mounting Strips

3. Insert a Core Plate into an end of the core and using an air pressuregun, insert enough air through the Air Pressure Nipples until thecore does not move, as shown below.

Core Plate

Air In let Nipple

Air pressure gun

The Air Inlet Nipple is shown below.



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Air Inlet Nipple

4. Repeat the last step for the other end of the core.

5. Place the core on the Front Roller and Collector Shaft Z.

6. Tighten the two black knobs on each of the Docking Brackets.

The core will revolve when the Collector Shaft Z starts to revolve.

7. When the printed media reaches the Expanding Core Holder, wrap itround the core.

8. When you have finished the job, cut the Media and lift the

Expanding Core Holder away from the printer and place it on a flatsurface.

9. To release the core from the two Core Plates by pressing the Air InletNipples and then pull the Plates away from the core.

The following two figures show Media of different widths being fed ontothe Expanding Core Holder.



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1 m wide media

2 m wide media



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The Operators Control Buttons

There are five Operators Control Buttons located on the left side of thefront of the printer, as shown in Figure 26.

Figure 26. The Operators Control Buttons

The following table describes the function of each of the buttons.

Button Function

FlatBed To put the printer into FlatBed mode.

FreeFall To put the printer into FreeFall mode.

Hood To open or close the Hood.

Mesh Table To activate the Mesh Tabl option.

Vacuum Regulator To adjust the vacuum suction level.

The Rear C ontrol Panel

Figure 27: Rear Control Panel

FlatBed FreeFal l Hood Wing Switch Vacuum Regulator


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The Rear Control Panel is located at the rear of the printer, above theInk Cabinet. It comprises the following two switches:

Shaft: To activate the Shaft for loading media or the optionalFlatbed printing.

Press: To press on the media to apply tension.

The Vac uum/ Mesh Table

Figure 28: The Vacuum / Mesh Table (with open wings)

When the Media passes over the activated Vacuum Table, the vacuumprevents wrinkles in the Media.

The Vacuum Table should not be activated when printing on MeshMedia. The tables wings should be closed by activating the appropriateswitch. When using Mesh, the Absorbent Print Material should beplaced on the table.

The printer must not be activated when the Vacuum Tables Wings areclosed.

Incorrect adjustment of the Print Table height, can cause damage to thePrint Heads.

Vacuum Table =closed wings

Mesh table =Open Wings


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Figure 29: Mesh Table (with closed wings)

The level of vacuum applied to the Media is regulated by the VacuumRegulator, according to the media you use.

Single or Multi Media printing

Width of Media (the wider the media, the lower the vacuum).

Weight of Media (the heavier the media, the lower the vacuum).

Rigid Media (use low level of vacuum).

We recommend that you experiment until you find the optimal level.

The Vacuum Table height can only be adjusted by an authorised MatanTechnician.

When the Wings areclosed, placeAbsorbent PrintMaterial on the VacuumTable

Vacuum Table

Mesh TableWings


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Adjusting the Carriage Height

Figure 30: Carriage Height Gauge

The height of the CARRIAGE has to be adjusted according to thethickness of the MEDIA on which you are printing.

When the CARRIAGE HEIGHTGAUGE is set at 0 (zero), the carriage is2 mm above the MEDIA.

When you print on a 5 m banner on mesh that is 1 1.5 mm thick, youhave to set the CARRIAGE HEIGHTGAUGE accordingly.

On rigid materials, you should set the exact thickness of the MEDIA, on

the gauge. For example, with a thick Media (Kappa,) that is 5 mm thick,you should set the gauge at 5 mm.

You adjust the CARRIAGE height by using the CARRIAGE UP/DOWNBUTTON. Turn the switch counter clockwiseto raise the carriage andclockwise to lower it. When you let go of the button the CARRIAGE stops

moving.

The CARRIAGE HEIGHTGAUGE shows the height of the CARRIAGE above theVACUUMTABLE.

To manually adjust the CARRIAGE height, use the MANUALCARRIAGEHEIGHTADJUSTER.

CarriageUp/Down Button Carriage Height Gauge

Manual CarriageHeight Adjuster


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8 Loading and Unloading the Media

This chapter sets out the procedures for loading and unloading theMedia, according to the type of print option you require.

Roll-to-Roll

FreeFall

Flatbed

Multi-roll

Mesh

Roll-to-Roll

Configuring the Software

To Configure the software:

1. From the Main Screen, select Tools and from the drop-down menu,

choose Preferences, as shown below.

The preferences dialog box appears, as shown below.



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2. In the Machine Mode group box, check the Roll-to-Roll option andclick OK.

The following window appears.

3. Click OK and restart the program.



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Loading the Media for Roll-to-Roll Printing

The Media is loaded from the rear of the printer. Figure 36 shows the

general direction of the Media.

Figure 31. Loading Media for Roll-to-Roll printing

Media



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Figure 32 shows the path of the media for Roll-to-Roll printing.

Figure 32. Media path for Roll -to-Roll printing

To load the Media for Roll-to-Roll printing:

1. From the rear of the printer, place the Media on the Feeder Shaft Fand the Rear Roller.

2. Bring the media up and feed it between the Press Roller and FeederShaft Y, then pull it toward the Vacuum Table.



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3. From the front of the printer, pull the Media over the Vacuum Tableand down between the T Tension Shaft and the Free-Fall PistonRollers.

4. Feed the Media between the Front Roller and the Z Take-up ShaftCollector.

Unloading the Media after Roll-to-Roll Printing

To unload the Media printed Roll-to-Roll:

After the Media has been printed and collected onto the CollectorShaft Z, you have to unload it from the shaft.

FreeFall



1. From the Main Screen, select Tools and from the drop-down menu,choose Preferences, as shown below.




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2. In the Machine mode group box, check the FreeFall option and clickOK.



Loading the Media

The Media is loaded from the rear of the printer. Figure 36 shows thegeneral direction of the Media.



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Figure 33 shows the path of the media for Roll-to-Roll printing.

Figure 33. Path of the Media for FreeFall Printing



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To load the Media for Roll-to-Roll printing:

1. From the rear of the printer, place the Media on the Feeder Shaft F

and the Rear Roller.

2. Bring the media up and feed it between the Press Roller and FeederShaft Y, then pull it toward the Vacuum Table.

3. From the front of the printer, pull the Media over the Vacuum Tableand down between the T Tension Shaft and the Free-Fall PistonRollers.

4. You can now either let the Media fall freely to the floor, or feed itonto the FreeFall Collector Roll, as shown in Figure 33.

Unloading the Media after FreeFall Printing

Figure 34. Media printed in FreeFall mode.

To unload the Media printed in FreeFall mode:

If you have collected the printed Media onto the FreeFall CollectorRoll, cut the Media. Above the roll and remove it together with theroll.

If you have let the Media fall onto the floor, cut each job separatelyfrom the printed media.



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Flatbed



1. From the Main Screen, select Tools and from the drop-down menu,choose Preferences, as shown below.




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2. In the Machine mode group box, check the Flatbed option and clickOK.



Flatbed Media Flow

Figure 35 shows the path of the media for FlatBed.

Figure 35. Path of the media for FlatBed

Loading the Media

Before loading the Flatbed Media, you have to place a Flatbed table atboth the front and rear of the printer.

To load the Media:

1. Place a Flatbed Table adjacent to the rear of the printer where youwant to print on the Media, and another table at the front of theprinter, opposite the rear table, as shown in the two following

figures.



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Figure 36. Rear Flatbed Table with empty media loaded

Figure 37. Front Flatbed Table

2. Check that the Media Pressure Rollers are in the UP position asshown below. If they are not, turn the Flatbed switch located on theUsers Control Panel in a counter clockwise direction. The rollers will

rise to the UP position.



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3. Place the empty Media on the rear Flatbed table and feed it through

the printer, over the Vacuum Table, until its front edge is locatedover the Vacuum Tables front edge, as shown below.

Figure 38. Media on the Vacuum Table

4. Turn the Flatbed switch located on the Users Control Panel in aclockwise direction.

The Media Pressure Rollers lower onto the Media, as shown below.

MediaPressure Rollers

Medias frontedge

Tables frontedge



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Figure 39. Media pressure Rollers DOWN



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Figure 40. Media being printed

The printed Media is fed onto the front Flatbed Table and is ready tobe unloaded.

Figure 41. Printed Media on the Front Flatbed Table

Unloading the Media

To unload the printed Media:

Remove the printed media from the Front Flatbed Table.



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Printing on Mesh

The procedure for printing on Mesh media is exactly the same asdescribed above for Roll-to-Roll and FreeFall, except for the following

steps.

To print on Mesh Media:

1. Close the Wings on the Vacuum Table by pushing the buttonmarked Guardrail/Mesh, on the Users Control Panel, as shown inFigure 42.

Figure 42. Vacuum Table with Absorbent Cloth and closed Wings

2. Place the Absorbent Cloth along the Vacuum Table.

Make sure that the Carriage height is set so that it cannot crash into theclosed Wings!

The printer is now ready to print on Mesh Media.

Closed WingAbsorbent Cloth


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3. To return to the other printing modes, open the Wings by pushingthe button again on the Users Control Panel, and remove theAbsorbent Cloth (see Figure 43).

Figure 43. Vacuum Table Wings open



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9 Maintenance

To obtain optimum performance from your Barak HS printer, you mustcarry out the following maintenance procedures on a regular basis:

Proper operation & maintenance is crucial to the efficiency of themachine and its life.



Unless there is an emergency, do not use the Emergancy Stop Buttons orCord to turn off the printer.

When turning off the printer, follow the shut-down procedure.

Printer Operation

Before each job Adjust block carriage high according to substrate andmode.

Perform nozzle test.

Before Mesh print Put absorbant cloth on the table.

After Mesh print Remove the absorbant cloth and clean table ifnecessary.

Vacuum level ( 0.8 1.0 ) Check and adjust if necessary.

Main Ink tanks Check the ink level, fill if needed.



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Daily Maintenanc e



Media Sensor Clean the sensor using clean paper with alcohol on adaily basis or whenever you sense that there is an errorin the Media measuring process.

Purge Sink Clean the cured ink on the sink, using a scraper.

Manually move the Carriage and pull the Sink towardyou.

Around the Printer Keep area free of foreign objects and dirt.

Make sure that only the operater attends to the printersmaintenance and is allowed inside the saftey area as

described in the Safety section.

Purge Sink



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Waste Tank Set up a regular schedule of emptying the Waste Tank.

UV Filters When you have a daily heavy print load, replace theUV Filters on a daily basis. If your print load is not heavy,

then you need to replace the filters when they becomediscolored.

Waste Tank



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Vacuum Table Clean surface with a cloth and alcohol (and whenrequired, clear blocked holes with a needle).

VacuumTable



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Weekly Maintenance

Lubricate Carriage Bearings

Water Filter Empty the filter by opening the tap, and draining outthe water into a suitable container.

Oil Filter Empty the filter by opening the tap, and draining outthe waste oil into a suitable container.

Grease Nipp les

Water Filter

Oil Filter



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Clean Free Fall Rollers Use alcohol and an absorbant cloth to clean bothrollers.

Make sure that the customer has cleaned the rollersand has removed all the deposits.



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Monthly Maintenance

Clean rubber roll Y & T Rollers Use alcohol and an absorbant cloth to clean both rollers.

Make sure that the customer has cleaned the rollers andhas removed all the deposits.

Clean Metal Roll ers Use alcohol and an absorbant cloth to clean the rollers.Make sure that the customer has cleaned the rollers andhas removed all the deposits.

Quarterly Maintenance

Ink Filters and Pumps Replace Ink Filters and Pumps.Make sure that the customer changes the Ink Filters andpumps every three months if necessary, instruct him how tocarry out

Documents

Barak Hs User Guide