Installation Manual

Anapurna Mw
Essential Information

a. Product Code of Anapurna Mw: E9N8M

b. Gross Weight of the boxed engine : 1200 kgs
c. Dimension of the box (with the engine): W 1500 x H 1940 x L 3780
d. Gross Weight of the accessory box: 230 kgs
e. Dimensions of the accessory box: W 730 x H 1940 x L 1820

Tools / Equipment Required

a. Forklift – able to lift 2 tons & forks of size 1.8 meters long
b. Metal Stripers (to cut the metal straps)
c. Knives (to cut the plastic covering and straps)
d. Cutting Pliers (to cut tie wraps etc)
e. Philips Screw driver (long and short handle)
f. Spirit Level (to check and adjust the level of the engine)
g. L – key set
a. Specifically 4mm, 3mm and 2.5 mm
h. 32 mm wrench (comes with the engine)
i. Multi meter (volt meter)
j. Head Height Tool
k. 20 times magnifying glass with blue filter to check Yellow Ink

Documents required

a. Install Guide (this document)

b. UV Lamp Power Settings (M Series).pdf
c. TN Roll to Roll calibration on version 2 engines V1.2.pdf

Consumables Required

a. Set of inks (6 colors + white) + cleaning solution (no ink comes with the engine)
b. Request customer to arrange some rigid and flexible media (no media comes with the engine)
c. Black board or any coloured media to check White Print heads & to print sample jobs with White ink

Software / PC Requirement

a. Customer to arrange for a new PC (see pre-site)

b. Wasatch Rip

Man Power

a. One engineer
b. Assistance from customer while unpacking ( 2 – 3 people required to push the engine)

Procedure

1. Anapurna Mw comes in two boxes (both card board boxes). The bigger box contains the engine and the
smaller box (accessory box) has the extension tables
2. Remove the metal straps and the plastic cover

3. Take away the top cover first; then lift the box
4. The engine comes wrapped in a silver cover; cut it from bottom so that it can be used as a dust cover for the
engine (in the initial days – if the room is not ready)

5. The engine is strapped to the wooden palette. The extension tables are sitting on the small box (strapped to
the palette

6. Remove all the straps and covers

7. While taking the tables off the palette, wind the brakes up - so that tables can be moved away easily on the
floor

8. Lift the engine off the palette with the help of a 3 ton forklift (with forks of 1.8 meters long)

9. When the engine is lifted up, make sure that the engine feet are screwed in. Also cut the plastic straps off the
wheels. This is to make sure that engine can be moved on its wheels when placed on the floor

10. Put the engine down on the floor and roll it to its position; making sure the floor is level, otherwise use the
forklift to position the engine

11. Using the 32 mm spanner (comes with the engine; in the accessory box), put the feet down and make sure
weight is off the wheels
12. Level the engine with the help of a spirit – level (you can also use spirit levels installed on the engine. When
the engine is levelled, please lock the counter nuts on the legs. (Make sure the weight of the engine is off the
wheels)

13. Remove the black cover from the carriage & manually wind the carriage up. Remove the foam blocks under
the carriage. Also remove the plastic protection plate from under the print heads and make sure the base
plate is clean (do not wipe, a gentle tap with lint free cloth is good)

14. Remove all other tapes / straps etc from the engine

15. The carriage is locked at the factory. To unlock the carriage remove the panel behind the carriage and take
the locking brackets off (using 3 mm L-key). Store them with the customer for future use (if required)

16. Make sure there is no other obstruction for the carriage to move; (Gently move the carriage left and right to
check if the carriage is free of any obstruction)
17. Open the ink door and pour the inks in the respective tanks

18. You will find the Ink Refill PCB behind the ink door; all ink pump connectors are removed from the PCB during
shipment. Put all the ink pump connectors back on the PCB (making sure they go to their respective
positions)

Note:
W1 is the pump for White Ink – pumping ink from the Main Tank to the Sub Ink Tank
W2 is the pump for White Ink – pumping ink from the Sub Ink Tank to the Main Tank
19. A couple of other things to check:
a. Check if the Main Ink Tank Float Sensors are connected to their correct position. The wires are
marked with letters and you can observe K, C, M, Y, Lc, Lm (etc) on the PCB

b. Check if the ink manifold (behind the ink door) has all the ink connections done properly (making sure
no ink lines have been swapped)

Left to Right:
1. White Ink going back to Main Ink Tank (W2)
2. White Ink going to Sub Ink Tank (W1)
3. Black Ink going to Sub Ink Tank
4. Cyan Ink going to Sub Ink Tank
5. Magenta Ink going to Sub Ink Tank
6. Yellow Ink going to Sub Ink Tank
7. Light Cyan Ink going to Sub Ink Tank
8. Light Magenta Ink going to Sub Ink Tank
9. Solution going to Sub Ink Tank
20. Remove the top two covers on the carriage (to access the Main Board). Leave the sub ink tank (float valve
sensor) connectors disconnected for the time being (not connected to the Main PCB)

21. Remove the front two panels of the engine (under the table / belt)

22. Connect 3 Phase power to the engine (Left to Right: Phase 1, Phase 2, Phase 3, Neutral & Ground). This is
behind the front right panel of the engine

23. Install the 6 mm compressed air connection (air should be dry, free of any moisture). The input regulator is on
the rear of the engine behind the rear right panel. Make sure the engine gets 100 psi or 6 bar (dry
compressed) air input pressure
24. Open the UV box (behind the front left panel) and check / adjust the connections for 50 / 60 Hz. Also put the
voltage tabs to 4 on all four transformers (Check Tech Note on Lamp Settings)

25. Check the input voltages and turn the Main Circuit Breaker + the Internal circuit breakers ON

26. Turn the Power On, let the engine boot up

27. Bleed all the Ink Filters (Leave some rags under the ink filters)

28. After bleeding all the ink filters, turn the engine OFF and connect the sub ink tank float sensors on the Main
PCB making sure they are connected to the correct position

Black J5 Yellow J8 White J 11

Cyan J6 Lt. Cyan J9 Cleaning Solution J 12
Magenta J7 Lt. Magenta J 10 Sub Air Tank (White) J 15

(Images attached on the next page)

29. Before we start filling the inks, open the valve of the sub air tank (rear side of the carriage) and place a rag +
a bottle (or container) under the tap. This is done to make sure that air in the ink lines escape through the sub
air tank
a. Make sure the Negative Pressure for both (color & white) is set to zero before you open the sub air
tank valves (the orange handle valves)
b. Open both valves (for color & white)
c. Make sure the ink valves (in the front) are on ‘S’ and solution valves are on ‘I’
d. Close the sub air tank valves (the orange handle valves) after the sub ink tanks are full of ink

30. Turn the engine ON and this time you will observe that the ink pumps will start working (pumping the ink).
After few seconds, a message will appear on the Control Panel

‘PAUSE Refill – Over Time’

This message appears as a safety, Press PAUSE from the Control Panel and the ink pumps will start
pumping again. You may have to press PAUSE 7 to 8 times before all sub ink tanks are full

31. Make sure the valves on the sub air tank are now closed (the orange handle valves)

32. Disconnect all the Ink Pump connectors from the Ink Refill PCB (Behind the Ink door)

33. So far the ink has not been introduced to the print heads. The sub ink tanks are full of ink but this ink may
contain impurities (solution etc) as the engine is new and was packed some weeks back. To get rid of the old
ink (in the ink lines), empty the sub ink tanks 3 times

34. Turn Off the engine and with the ink valves closed (at ‘S’ position), disconnect the ink tubes. Put a tray (or
empty ink bottle) under the ink valves and open the ink valve (to ‘I’ position) one by one. The idea is to take
the ink out of the sub tank
35. Once all the sub tanks are empty, reconnect the ink tubes to their respective position and close the ink valves
(to ‘S’ position). Turn the engine ON & as the sub ink tanks are empty, the pumps will start working again.
Press ‘PAUSE’ to fill the sub ink tanks completely

36. Repeat the above steps 2 – 3 times making sure the old ink / solution in the ink lines is now removed and ink
has been introduced in the sub ink tanks

37. Once all ink tanks are full, set the negative pressure to (approx) -.036 for the Color print heads and -.041 for
the White print heads

38. There is one more thing before we introduce the inks to the print heads; we need to clean the solution bar and
flush the print heads with cleaning solution

39. Remove the front panel

40. Remove the Black Tube-End from the mini valve (1) and place a empty bottle under it (2)

41. Open the Mini Valve and Press the Solution Valve Button; cleaning solution will start pouring through it. Keep
pressing the button till you get ‘clear - clean’ solution out of the valve

42. Close the mini valve and re-install all the parts

43. Flush all the print heads (using Cleaning Solution); print heads need to be flushed before introducing the ink

44. After Flushing, Purge all the print heads and perform a PRIME test

a. Follow the daily start up procedures from the Operator Manual

b. Make sure to check all print heads (the color print heads and white print heads)
c. For checking White print heads, you will need a black board or a clear film

45. Check all the alignments (Feed, Horizontal and Bi-directional); use a 20 times magnifying glass to help you
with this exercise
46. Print the Sign Off Test; this should be done in two copies; leave a copy at the customer and the other copy
goes to the office (sales rep)

a. Do not print the Sign Off on the first day of install as the print heads might have cleaning solution in
nd rd
them; ideal to do it on the 2 or 3 day

47. Default Settings & Passwords

a. Set the IP address of the engine to 192.168.1.5

b. Check if the engine has the latest firmware
c. Password for Factory Settings
While at Offline Mode, Press: F1 F6 F4 F3 F2 F5
d. Password to reset Lamp Hours (after replacing the lamps)
While at UV Lamp Options, Press: F6 F1 F4 F2 F5 F1 F3

48. Note 1:
a. If you observe that the White Ink is still a bit blue-ish / cyanish, you will have to clean the white sub
ink tank (taking the ink out of the white sub tank)

b. In some engines, before they were shipped, the White Ink Line was checked using Light Cyan ink;
there is a high possibility of having some (left over) light cyan ink in the sub ink tank, white sub air
tank and the over flow tube (between the white sub ink tank and white sub air tank)

c. Open the White Sub Ink Tank and clean it properly

d. Clean the Sub Air Tank and the tube which runs between the white sub ink tank and sub air tank
(over flow tube)

49. Note # 2
a. Keep a copy of the Important Parameters at the customer
b. Before leaving the customer, check the roll to roll calibration – have a look at the tech note ‘TN Roll to
Roll calibration on version 2 engines V1.2.pdf’
c. Align the Front & Rear (Output & Input) extension tables making sure the roller surface should be
level with the belt on top of the vacuum table, and NOT with the belt on the conveyor belt drive roller
 Parameters of Anapurna Mw

Customer Name: ___________________________________

Date: ___________________________________
Anapurna Mw Sr. #: ___________________________________
Firmware: ___________________________________
IP Address: ___________________________________

Head Voltages (Physical Values on the Print Heads)

K C M Lm Lc Y W1 W2
Left
Right

Factory Settings:

1. Head Voltages (F2 from Factory Settings)

K C M Lm Lc Y W1 W2
Left
Right

2. System Reference
a. Print Origin: ___________________________________
b. Null Point: ___________________________________
c. Head Gap Ref: ___________________________________
d. H-Temp Limit: ___________________________________

3. White System

a. Pump Empty Time: ___________________________________

b. Weep No: ___________________________________
c. Pump Circulation Time: ___________________________________
d. Circulation: ___________________________________

Calibrations

1. Horizontal

K C M Y Lc Lm W1 W2
Left
Right

2. Bi Directional

K C M Y Lc Lm W1 W2
Left
Right

3. Feed Adjust: ___________________________________