Z1

User Guide

Rel: 2.01
 Release Date Changes

1.00 23/02/2016 First release

2.00 23/09/2016 Updated for 24V system

2.01 12/01/2017 Accessories updated

 Zanasi Z1

Index
GENERAL INFORMATION........................................................................................................................ 4
SAFETY REGULATIONS ........................................................................................................................ 11
TECHNICAL SPECIFICATIONS ............................................................................................................. 20
TRANSPORT, PACKAGING AND STORAGE ....................................................................................... 24
CONSTRUCTION AND FUNCTION ........................................................................................................ 30
INSTALLATION AND INITIAL OPERATION .......................................................................................... 41
OPERATION ............................................................................................................................................ 58
Z1 REMOTE MANAGER ......................................................................................................................... 80
FAULTS.................................................................................................................................................... 82
DISASSEMBLY ........................................................................................................................................ 88
LIST OF ACCESSORIES AND SPARE PARTS ..................................................................................... 91
APPENDIX ............................................................................................................................................... 96

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1. General Information
General Survey

Congratulations! You have purchased a high-quality print system. Our concern is to make sure that you
profit from this system to your entire satisfaction over many years. In order to ensure this, we strongly
recommend you to let our experienced specialists perform the installation.

Limitation of Liability

All pieces of information and notes of this manual have been arranged in consideration of applicable
standards and regulations, state-of-the-art technology as well as our cognition and experiences over
many years.

The manufacturer assumes no liability for damages caused by:

 Non-observance of this manual

 Non-observance of the intended use

 Use of unqualified personnel

 Manipulations at the system

 Technical changes

 Use of spare parts that are not approved by the manufacturer

The actual scope of delivery may differ from the explanations and illustrations provided herein in the
case of special designs, additional order options or after recent technical changes.

The obligations of the supply contract the General Trading Conditions as well as the Terms of Delivery
of the manufacturer and the valid legal regulations at the moment of conclusion of a contract
generally apply.

Technical changes within the scope of improvement and development are subject to change without
notice.

Warranty Clause

The warranty conditions are conform to the valid General Trading Conditions of the manufacturer at
the moment of purchase.

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Copyright Protection

This documentation or parts of this documentation may only be copied, photocopied, reproduced or
translated into other languages for personal use. Without previous expressed written permission of
Zanasi s.r.l. a reproduction for circulation to a third party is not permitted.

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Purpose and Scope of this service manual

This manual enables safe and effective use of the Zanasi Z1.

The Operating manual is a component of the device and must be stored close to the device to be
accessible to the staff at all times. The staff must have read this manual thoroughly and understand
the content before starting any work. Compliance with all safety notes and instructions given in this
manual is a basic prerequisite to safe operation.

Furthermore, the local accident prevention regulations and general safety provisions for the area of
application of the device are applicable.

Images in this manual serve to provide a basic understanding and may differ from the actual device
version.

Hints for Use of this Manual

Please find in the following a detailed explanation of the notations and representations used in this
manual.

Keys and buttons which you must push appear in squared brackets.

Example: Push [Enter] - button to save changes...

Procedures which should be followed in a specific order are listed in numbered

paragraphs.

Step Procedure
1 Disconnect power plug

Important messages are written in bold text and/or highlighted in grey.

This is an example for an important message!

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Special notes:

 … refers to a result, following an action by the operator.

 … refers to a chapter or document.

Figures and drawings are numbered serially in the particular chapter. For example „Fig.
2-1“ is the first figure in chapter 2.

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Explanation of Technical Terms

Technical Term Explanation

CartClip Cartridge holder for storage of already opened cartridges to

protect them against leaking or drying out of nozzle plate

Conveyor The conveyor transports the products, which should be printed

and pass them by the print head

DPI Dots Per Inch

1 Inch = 25,4mm

Encoder A shaft encoder is used for the automatic detection of the

conveyor speed and defines the print speed

Flexbracket Flexible mounting bracket of the control system.

Funai-Lexmark Manufacturer of the ink cartridges

Ink cartridge Original Funai-Lexmark cartridge

LED Light emitting diode

Left-hand Installation of the system with cartridge holder on the left side

Nozzle plate On the nozzle plate is the two-rowed arrangement of per 300
nozzles, which ejected the ink.

Print direction Direction of movement of the product on the conveyor belt

viewed from the control system in the print direction

Print intensity Contrast of the print image. If necessary this parameter must be
changed to optimize the print image. A higher intensity gives
greater blackening and longer ink drying time

Print speed Print speed = Speed of the conveyor. The speed of the conveyor
must be keep constant

Print start delay Offset print, i.e. by how much is printing delayed in millimeters
after the product is detected by the product sensor.

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Print width The number of pixel can be increased or decreased using this
parameter. The print image becomes narrower or wider.

Product sensor A sensor for the detection of the product. Mostly used are
optical sensors (photo sensor, reflex sensor)

Right-hand Installation of the system with cartridge holder on the right side
(standard configuration)

TIJ Thermal Ink Jet

CartClip Cartridge holder for storage of already opened cartridges to

protect them against leaking or drying out of nozzle plate

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Customer Service

Please contact your local distributor for technical information.

If failures at the print system occur, you should be prepared with the following information:

 Detailed error description.

 All information on the name plate of the print system

 Version number of the system software and of the Z1 Remote Manager software

 Configuration (Advanced, Pro)

 Special functions of the software or hardware

 When did the error occur for the first time?

Prior to call our hotline service, please have a look at the manual for potential references to eliminate
the error.

Furthermore, our staffs are always interested in new information and experiences with the use of the
product and which may be valuable for improvements to our products.

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2. Safety Regulations
Behavior in Case of an Emergency

The operating personnel have to be familiar with the operation and the location of safety,accident
notification-, first aid- and rescue devices.

What to do in Case of an Emergency?

 Initiate immediately all required emergency measures for injured persons. Observe valid
safety regulations in any case in order to avoid further damages to persons.

 Call medical attendance for injured persons.

 Eliminate all accident causes.

General Safety Regulations

Safety regulations provide information in written and symbol form in order to warn you against
dangers and to instruct you to avoid any damage to persons or to properties.

Safety regulations are started by signal words indicating the level of danger.

Safety regulations may be placed directly at the print system or in documents about this print system.

Explanation of Danger Degrees

This symbol indicates a hazardous situation which, if not

avoided, will result in death or serious injury. All safety
regulations have to be observed to avoid any damage to
persons.

This symbol indicates a hazardous situation which, if not

avoided, could result in death or serious injury. All safety
regulations have to be observed to avoid any damage to
persons.

This symbol indicates a hazardous situation which, if not

avoided, may result in minor or moderate injury. All safety

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regulations have to be observed to avoid any damage to

persons.

This symbol indicates a hazardous situation which, if not

avoided, may result in damage to properties. All safety
regulations have to be observed to avoid any damage to
properties.

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Intended Use

The working reliability of the print system is ensured only with intended use.

The Z1 has been designed, built and must be used exclusively for the intended purpose described.

The Z1 serves to create print images and to print these from the top or side onto smooth and
absorbent product surfaces. The product must pass the Z1, i.e. positioned on a conveyor belt

All working conditions and instructions, prescribed in this manual, will be observed.

Any use beyond the intended use or any alternative use of the equipment is regarded as misuse and
may lead to hazardous situations.

Misuse of the device may lead to hazardous situations. Refrain, in particular, from subjecting the
apparatus to the following:

Any claims arising from damages due to undesignated use are rejected.

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Reasonably Forseeable Misuse

Another use as fixed in the „Intended Use“ or even more applies as not intended!

For damages caused by not intended use

 the operator bears the complete responsibility,

 the manufacturer assumes no liability.

If you do not use the system according to the regulations, risks may occur!

Not intended uses are e.g.:

 operation in explosive atmosphere

 the print system comes in contact with food

Retrofitting and Changes at the Print System

Unauthorized retrofitting and changes at the system lead to an immediate expiration of liability and
warranty covered so far by the manufacturer! This is also valid for interventions and program changes
at programmable control systems as well as program changes at control units as far as they are not
described in this Manual.

The electromagnetic performance of the system can be affected by amendments or changes of any
kind.

Do not arrange any changes or amendments at the systems without consultation and written approval
of the manufacturer.

Warning Notices at Print System

Particular sources of danger at the print system are marked by yellow labels. The used pictograms
point out to following dangers:

Danger to Life

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Special hazards

The following section identifies the remaining risks, determined following a risk analysis.

Observe the safety notes listed here and the warnings in other chapters of the manual to minimize
health hazards and avert hazardous situations.

Risk of injury through incorrect handling of batteries!

RISK OF INJURY!

Rechargeable and primary batteries contain toxic heavy

metals. They must be treated as special refuse and deposited
at municipal collection points or be disposed of by a
specialized company. Batteries must be handled with
particular care.
Therefore:

– Never throw batteries into a fire or subject batteries to

high temperatures. Explosion hazard.
– Do not charge batteries. Explosion hazard.
– Fluid escaping through incorrect use may cause skin
irritations. Avoid contact with the fluid. In case of contact
with the fluid, rinse with ample water. If the fluid comes
into contact with the eyes, rinse immediately with water
for 10 minutes and consult a doctor without delay.

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Edges and corners pose risk of injury!

RISK OF INJURY!
Sharp edges and pointed corners may cause abrasions and
cuts to the skin.
Therefore:
– Be cautious when working near sharp edges and pointed
corners.
– If in doubt, wear protective gloves.

Risk of stumbling posed by dirt, objects lying about and

connecting lines!

RISK OF INJURY!
Dirt, objects lying about and connecting lines for power, data-
and signal lines may cause slipping and stumbling resulting in
severe injuries.
Therefore:
– Always keep working area clean.
– Remove objects no longer required.
– Mark stumbling areas with yellow-black marking tape.
– Non tension connecting lines to system and pass it that no
places of danger do arise

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Remaining Risks

The print system is constructed for a safe operation. Hazards that are not preventable due to
construction purposes are limited as far as possible by protection devices. A certain amount of risk is
always existent! The knowledge about the remaining risks assists you to arrange your work safer and
to avoid incidents. In order to avoid the dangers, please observe additionally the particular security
advice in the single chapters.

Disposal

This print system complies with the RoHS 2 EU-Regulation 2011/55/CE with observance of the fixed
using prohibitions and avoiding pollutants.

Unauthorized persons

Work at the print system should only be performed by reliable personnel.

Only trained personnel are allowed to operate the print system. Trainees, apprentices etc. must be
supervised by an experienced person while working at the print system.

Prior to start running the labeler the operator has to ensure that the manual of the labeler is available
to all users of the machine and that the users have read and understood the manual. Only then the
system may be put in operation.

The responsibility for the different tasks at the print system must be clearly specified and kept. There
must be no ambiguous authorities for this may put the safety of the users at risk. Arrange a detailed
work schedule if several persons work on the machine.

All work on the electrical equipment must be carried out by skilled electricians only.

Failures may be eliminated by authorized personnel only.

All work associated with the assembly, adjustment and maintenance at the machine may be carried
out only by trained or instructed personnel.

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Personal Protective Equipment

Wear following protective equipment when performing work at the system:

SAFETY SHOES

Wear for protection against falling off parts and slipping.

PROTECTIVE CLOTHING

Are tight-fitting clothes with low tensile strength, with tight sleeve
and without distant parts
Wear a hairnet if applicable
Do not wear jewelry or wrist watches

PROTECTIVE GOGGLES

For protection against splashes of detergents and flying parts

SAFETY GLOVES

For protection against sharp-edged items

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Personal Protective Equipment for the Protective Safety Protective

Safety Shoes
following tasks Clothing Gloves Goggles

Transport x x x

Setting up and connecting of the system x x x x

Maintenance Work x x x

The documentation of the manufacturer of the single

system components has to be observed!

Working Places Operator Personnel

The print system is an automatic working system and does not require any operation for the printing
procedure.

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3. Technical Specifications
General

97 x 82 x 122 mm (3.82 x 3.23 x 4.8 inch) excluded

Dimensions (H x W x D)
bracket, ink cartridge and connections

Weight 570 g

Environmental Temperature: 5 - 40 ° C

Environmental Conditions: 10-90 % relative humidity (non-condensing)

Protection Rating IP 40

Maximum operating time The system is designed for continuous operating

Electrical

Voltage Power Supply: 100 - 240 VAC / 50-60Hz (1~)

Voltage System: max. 1,25 A @ 12V, 0,625 @ 24V

Current consumption: max. 1,25 A

Power consumption: max. 15 W

Power consumption Standby: 1,6 W

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Data interfaces

EIA 232 Sub-D 15 Pol

Ethernet RJ45

USB USB-A socket for stick

Connections

Input voltage Sub-D 15 Pol

Sensore Sub-D 15 Pol

Encoder Sub-D 15 Pol

In / Outputs Sub-D 15 Pol

Traffic light Sub-D 15 Pol

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Performance data

Cable length System unit / Power supply 1,8 m (5.9 ft)

Text layout Software Z1 Remote Manager

Parameter input Software Z1 Remote Manager

Fonts All available Windows fonts

(optional) customer-specific fonts

Print height 1 to 12,7 mm (0.04 to 5 inch.)

Max. print resolution1) in dpi 300/600

User language Software: Italian, German, English,

French, Spanish, Japanese

Barcodes1) EAN 8, EAN 13, EAN 128, Code

2/5, Code 2/5 check, Code 39,
Code 39 check, Code 128,
DUN14, GS1 Databar

2D-Codes1) Datamatrix, GS1 Datamatrix,

OR-Code, PPN-Code

Automatic functions1) Date, Time, Counter,

customer-specific links

Graphic Monochrome bitmap-

graphics can be created i.e.
with Paint or other software.

Print image storage 9 print images

Print image lenght 23.600 Pixel = 1m at 300dpi

Storage; optional expandable in GB 1

Storage in MB 32

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Max. print speed in

at 300dpi, depending on resolution)
60 m/min (196.5 ft/min)
Advanced
90 m/min (295.3 ft/min)
Pro

Print direction L/R or R/L, from top or side.

Print from bottom is not
possible.
1)
Not available in all versions

The preferred print direction is from left to right. When printing from right to left, the minimum
print start is 25 mm to the box front edge. If a lower distance is desired, an external photo sensor
must be installed or the system can be modified to left-hand.

Inks

Specification Type

Black INK ZL01 WD THERMAL BLACK

INK ZL02 ED THERMAL BLACK
INK ZL03 WP THERMAL BLACK
INK ZL04 WP THERMAL BLACK

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4. Transport, Packaging and Storage

Transport

Check the delivery for completeness and transport damages immediately upon receipt.

Proceed as follows in case of externally visible transport damage:

 Decline delivery or accept with reservation only.

 Record extent of damage in the transport documentation or on the delivery note of the
carrier.

 Initiate complaint.

Scope of Delivery

The scope of delivery depends on the ordered options and the customer’s application. Please control
the scope of delivery when receiving the systems on the basis of the delivery note.

Scope of Delivery - Basic:

 1 x System unit

Optional:

 Power supply 24V / 15W

 USB-Stick

 Operating Manual on the USB-Stick

 Z1 Remote Manager-Software on the USB-Stick

 Mounting bracket

 Ethernet cable 3 m (9.8 ft)

 External product sensor

 Encoder

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Symbols on Packaging

As part of the installation and further use it may happen that the operator put user or maintenance
personnel in charge of handling of packages. Therefore note the following important notes:

This way up

The arrowheads indicate the top of the package. They must always face
upward to avoid damage to the content.

Fragile

Identifies packages with fragile or sensitive contents.

Handle the package with care, do not drop or subject to impacts.

Keep dry

Keep packages away from moisture and keep dry.

Protect from heat

Protect packages from heat and direct sunlight.

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Transport and Unpackaging

Safety Instructions

Material damage due to incorrect transport!

Remove the packaging material and the transportation safety

devices on installation site and transport the print system in its
original packaging to the place of installation.

Danger due falling parts!

– Wear safety shoes!

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Packaging
On Packaging

The individual packages are packed in accordance with the expected transport conditions. Only
environmentally-friendly materials were used for packaging.

Packaging serves to protect the individual components against transport damage, corrosion and other
damage, up to the assembly stage. Do not, therefore, damage the packaging - remove shortly before
assembly only.

Original packaging is available from the manufacturer to ensure optimal dispatch of the system.

Please contact your local distributor.

Handling of packaging materials

Dispose of packaging material in accordance with the applicable statutory provisions and local
regulations.

Environmental damage!

Packaging materials are valuable raw materials and can, in

many cases, be re-used or profitably recycled and re-used.
Therefore:
– Dispose of packaging materials in an environmentally-
responsible manner.
– Observe the locally applicable disposal regulations. If
necessary, commission a specialized company for disposal.

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Storage
Controller

Store the controller under the following conditions:

 Do not store outdoors.

 Keep dry and free of dust.

 Do not expose to aggressive media.

 Keep away from direct sunlight.

 Avoid mechanical shock.

 Storage temperature: 5°C to 45°C.

 Relative humidity: maximum 60% not condensing.

Ink cartridge

New original sealed ink cartridges have a shelf life of up to 1 year. Observe the printed expiry date! The
shelf life of different cartridge types differs.

Storage under 2 days:

Leave the ink cartridges in the print head holder and wipe off or rinse, if necessary, before restart.

Storage over 3 days:

Insert the ink cartridge in a cartridge clip (CartClip).

Store Ink cartridge

If ink cartridges are not used for an extended period of time, they must be stored in a cartridge clip
(CartClip) to prevent the ink in the nozzles from drying out.

To do this, the ink cartridges must be removed from the controller.

Instruction

To insert the ink cartridge in the CartClip:

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Step Procedure
1 Insert the ink cartridge in the CartClip. The nose of the cartclip to the back slightly
until the cartridge click into place. (see Fig. 4-1)

Fig. 4-1: Inserting the ink cartridge in the CartClip

Instruction

To remove the ink cartridge from the CartClip:

Step Procedure
1 Pull the nose of the cartclip to the back slightly and remove the cartridge.

Fig. 4-2: Removing the ink cartridge in the CartClip

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5. Construction and function

Brief description

The Z1 is a thermal Inkjet Coder of Zanasi s.r.l., for printing images quickly and cleanly onto smooth
and absorbent product surfaces.

A print image, for instance, contains product descriptions, graphics, quantities, shelf life data, barcodes
and product serial numbers.

The print images can be created directly with PC installed Remote Manager Z1 software and can be
loaded in/or sent to the Zanasi Z1 by means of a USB stick or a network.

Up to 9 print images can call up for printing via keyboard.

The Z1 comprises the controller and an external 24V power supply

Controller

The Zanasi Z1 comprises essentially a controller with integrated control electronics, cartridge bay with
clamp and the connections for the power supply, shaft encoder, external photo sensor, in-/outputs at
the back side of the system. At the top are a keypad with 4 control LEDs and a USB-A socket for a data
transfer via USB-Stick.

The system unit is directly installed with a optional mounting bracket on the production line. The coder
consists of a system unit and a ink cartridge from Funai-Lexmark.

Standard the cartridge holder is mounted on the right side also referred to as right-hand.

The preferred print direction is from left to right. When printing from right to left, the minimum print
start is 25 mm (0.98 inch.) to the box front edge. If a lower distance is desired, an external photo
sensor must be installed. Or the system can be modified to left-hand.

The preferred print direction is than from right to left. When printing from right to left, the minimum
print start is 25 mm (0.98 inch.) to the box front edge.

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Ink cartridge

The ink is contained in the cartridge ink ducts and the viscosity and surface tension of the ink prevents
it from running out.

A heating element, which generates a steam bubble when current is briefly applied (0,8 µs), is fitted
behind each jet opening.

This steam bubble gives the ink between the heating element and the jet opening an impulse and
therefore “shoots” a defined quantity of ink out of the opening.

When the steam bubble reforms, a corresponding quantity is drawn from the storage container and
the process can begin again. This process of ejecting an ink drop can be repeated 18,000 times a
second.

Print images 1 mm to 12.7 mm (0.04 to 0.5 inch.) high can be produced with a wide variety of fonts.

Various special inks are available for coding on many different surfaces.

The system is optimized for Funai-Lexmark cartridges.

The ink settings (Fire pulse, spitting, warming) will set optimal by using Funai-Lexmark cartridges.

These values cannot determine and set by using other cartridges. Then the ink level is 1% (warning
level).

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System versions

The print system is available in 2 different versions:

Advanced e Pro.

The print system will be delivered as Advanced version standard. If the requirements exceed the scope
of services of the Advanced version, an upgrade with costs to the Pro versions is available.

Le specifiche delle due versioni separate si trovano nella tabella che segue.

SYSTEM VERSION
FUNCTION
Advanced Pro
60 90
max. Speed at 300 dpi

1m (3.28 ft) 2m (6.56 ft)

Layout length

50 - 900 50 - 900
DPI horizontal

300 / 600 300 / 600

DPI vertical

Printer + TTF Printer + TTF

Fonts

9 9
Number of layouts

Yes Yes
Text fields

Yes Yes
Counter fields

Yes Yes
Date fields

Yes Yes
Date offset

Yes Yes
Logos

Yes Yes
Barcodes

No Yes
2-D Codes

Yes Yes
Action fields

Yes Yes
USB-Stick Data transfer

Yes Yes
Ethernet interface

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SYSTEM VERSION
FUNCTION
Advanced Pro

Password No No

Spitting Yes Yes

Warming Yes Yes

RS232 Yes Yes

Internal sensor Yes Yes

External sensor Yes Yes

Encoder Yes Yes

In-/ Outputs 2I / 4O 2I / 4O

LED LED
Ink level display

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Complete overview Z1

3
1

4
5

Fig. 5-1: Z1 right-hand-model

No. Description
1 CONTROL PANEL WITH ENTRY KEYS AND LED-STATUS LIGHTS

2 FRONT PANEL

3 INK CARTRIDGE

4 OPENING FOR INTERNAL PRODUCT SENSOR (LIGHT BARRIER)

5 CARTRIDGE NOZZLE PLATE

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3 4

Fig. 5-2: Z1 Z1 right-hand-model

No. Description
1 USB-A SOCKET

2 NETWORK CONNECTION (RJ45)

3 SUB-D 15 POL

4 INK CARTRIDGE CLAMP

5 GROUND CONNECTION

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1
2

Fig. 5-3: Z1 right-hand-model

No. Description
1 MOUNTING RAIL; OPTIONAL EXTRAS

2 FASTENING POINTS (M4)

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Right-hand-/left-hand-model

The Zanasi Z1 is delivered as right-hand-model standard. I.e. the preferred print direction is from left
to right. When printing from right to left, the minimum print start is 25 mm to the box front edge. If a
lower distance is desired, an external photo sensor must be installed or the system can be modified to
left-hand. Both models are shown in the figure below.

right-hand-model left-hand-model

Fig. 5-4: Z1 in Righthand- and Lefthand-model

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Flexible bracket (Flexbracket)

The Flexbracket is an optional available mounting bracket, which adjust a variable distance up to 20
mm between print system and product. The print system is provided with a special formed deflector
and a linear movable bracket.

The print system is mounted on the production line that the product hit the deflector. The print
system is pressed in position, against the spring power of the Flexbracket. After the product passes the
print system moves the print system by spring power back in starting position.

The Flexbracket should use for print speeds up to 30 m/min. For higher speeds is a constant guide
not guaranteed and the print result can be manipulate negative.

Fig. 5-5: Z1 with Flexbracket and universal mounting bracket

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No. Description
1 CONTROL SYSTEM

2 FLEXBRACKET DEFLECTOR

3 FLEXBRACKET

4 MOUNTING RAIL

5 CLAMP BRACKET

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Name plate

The nameplate is attached to the bottom of the system and displays the following:

 System type

 Serial number

 MAC-address

 Article number

 Supply voltage

 Power consumption

 Address of manufacturer

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6. Installation and Initial Operation

Safety notes

Risk of stumbling posed by dirt, objects lying about and

connecting lines!

RISK OF INJURY!
Dirt, objects lying about and connecting lines for power, data-
and signal lines may cause slipping and stumbling resulting in
severe injuries.
Therefore:
– Always keep working area clean.
– Remove objects no longer required.
– Mark stumbling areas with yellow-black marking tape.
– Non tension connecting lines to system and pass it that no
places of danger do arise

Edges and corners pose risk of injury!

RISK OF INJURY!
Sharp edges and pointed corners may cause abrasions and
cuts to the skin.
Therefore:
– Be cautious when working near sharp edges and pointed
corners.
– If in doubt, wear protective gloves.

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Installation

Only an optimally aligned installation of the system can ensure a continuous operation

with a low rate of failures and a minimum wear. For an optimized installation of the system, fine
tunings adapted to environmental conditions are essential. For the fine tunings, a complex expert
knowledge is required basing on experience with print technique.

The complexity of a wear-optimized installation requires a high measure of specialized

knowledge and experience, which cannot be obtained completely by reading this manual. Therefore
the installation of the print system must be made by a technician from your local distributor or
examined by a final inspection. Damage or damages based on an incorrect installation, represent no
case of warranty.

Requirements to the Site of Installation

When choosing the installation location the following conditions apply:

 Consider the generally accepted ergonomic criteria in accordance with workplace

ordinances as well as country-specific legislation.

 The installation location must be a dry and dust-free room, ideally with an ambient
temperature of approx. 18…25 °C.

 The installation location may not be subject to fast temperature fluctuations

(condensation!).

 Do not set up the controller directly next to or above hot surfaces, since this will affect
cooling of the controller.

 If the controller is operated on a tripod (accessory), the stability of the tripod on an even
foundation must be ensured.

 The controller may not be exposed to flammable, explosive, corrosive gases or chemical
vapors.

 The controller may not be installed in the vicinity of high voltage equipment or power
supplies.

 The controller may not be subjected to direct vibrations or shocks.

 Keep controller away from oil or water.

 The controller may not be exposed to strong magnetic or electric fields.

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Placing the Print System

 The installation position has to provide sufficient access for user and service technician.

 Observe that all mounting parts are fixed sufficiently.

 Consider all points of the "Intended Use" in the chapter safety regulations.

To achieve a clean, sharp print result the distance from the product to be printed to the cartridge
nozzle plate is important. The optimum distance is 0 to 4 mm between the deflector and the product.
A greater distance will adversely affect the print result, particularly at high conveyor belt speeds.

The higher the print speed the shorter must be the distance. At speeds of less than 20 m/min a
distance of up to 8 mm between the nozzle plate and the product may still be acceptable.

Flexbracket installation

Material damage due to improper print system installation!

With the print system switched on, a defect may occur in the
system electronics.
Therefore:

– Only install the system when it is switched off.

Required Resources

 Screwdriver Torx®, SW TX10

 Allen key ® SW 2,5

 Allen key ®, SW 3

Instruction

Please install the Flexbracket as follows:

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Step Procedure
1 Disconnect both fixing bolts (this will used again) of the deflector and remove it
from the system unit (see Fig. 6-1).

Fig. 6-1: Disassembly deflector

2 Put the Flexbracket-deflector on the system unit and tighten it with both fixing bolts
(see Fig. 6-2).

Fig. 6-2: Flexbracket-deflector installation

3 If a mounting rail is already mounted under the system unit, disconnect the fixing
bolts and remove the mounting rail (see Fig. 6-3).

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Step Procedure

Fig. 6-3: Disassembly mounting rail

4 The slide of the Flexbracket must be pull in such a position that the borings for
the insertion and tightening of the fixing bolts are available. Furthermore the pull
spring at the Flexbracket must be push away laterally.

Set the fixing bolts in the counterbore of the Flexbracket. Positioning the
Flexbracket on the system unit and tighten (see Fig. 6-4).

Fig. 6-4: Flexbracket installation

5 Proceed with the installation

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Positioning the Print System

Material damage due to improper print system installation!

With the print system switched on, a defect may occur in the
system electronics.
Therefore:

– Only install the system when it is switched off.

Possible material damages!

Product mounting rails prepared by the customer protect the

system unit from vibrations and damage whilst the product is
passing the system unit. (Position B in Fig. 4)

Required Resources

 Setscrew wrench (Allen key®)

Instruction

Please install the print system as follows:

Step Procedure
1 Attach mounting brackets to the production line.

2 Insert the mounting rail fitted underneath the controller into the clamping piece of
the mounting holder and lock.

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Step Procedure

0 – 8mm(0-0.31 inch.)

Fig. 6-5: Installation of the Z1 at the production line

3 Set the distance from the print head to the product surface. A distance of 0 to 8
mm is optimal. (see Fig. 6-5)

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Connecting the Print System

Possible material damages!

To prevent faults due to potential differences, an electro-

conductive connection between control unit and conveyor
belt must be established.

Material damage due to induced currents!

If the connection cables of the controller run close to high

voltage or heavy current cables in the cable duct, induction
may cause malfunctioning or damage.
Therefore:
– Lay all connection cables of the controller spatially
separate from high voltage and heavy current cables.

The Print system needs electricity for its functions.

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Overview of the print system connectors

2
3

4 Fig. 6-6: Electrical connections

No. Description
1 ETHERNET

2 OPTIONS

3 USB-A

4 GROUND CONNECTION

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Ground print system

Instruction

Please connect the ground connection of the print system with ground connection of the conveyor as
follows:

Step Procedure
1 Connect the ground connection of the print system with ground of the conveyor.

Fig. 6-7: Ground connection at the print system

Connecting to Supply Voltage

Requirements

 Power supply according to "Technical Data" is installed close (max. 1,5 m away) to the
printing site.

Instruction

Please connect the print system with supply voltage as follows:

Step Procedure
1 Enclosed the power supply are several country-specific power plugs. Mount the
right power plug to the power supply (see Fig. 6-8).

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Step Procedure

Fig. 6-8: Installation power plug

2 Connect the power plug to the power socket on the Z1. (DC 12V-24V).

3 Connect the power pack with the power supply.

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Connecting the encoder

If more options will be used simultaneously, a splitter-cable can used.

Requirements

 The optional shaft encoder is mounted at the production line.

 Ideally runs the measuring wheel of the shaft encoder on the conveyor belt, near the
print system.

Instruction

Please connect the optional shaft encoder with the print system as follows:

Step Procedure
1 If necessary install the optional shaft encoder on the production line and connect it
to the option-connection socket.

Fig. 6-9: Option-Socket (Sub-D 15-pole) on the system-back and Sensor-LED on the top side of the system

2 Set the system-clock to Shaft encoder by the Z1 Remote Manager software.

(System settings – Print parameter)

3 Set the shaft encoder resolution by the Z1 Remote Manager software 600 dpi with
the delivered shaft encoder from Zanasi. (System settings – Print Parameter)

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Step Procedure
4 Set the intensity by the Z1 Remote Manager software so, that the desired effective
resolution can be reached. (System settings – Print parameter)

5 The Sensor / Encoder LED lights red, if the shaft encoder isn’t connected or doesn‘t
rotate.

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Connecting the optional Product Sensor

If more options will be used simultaneously, a splitter-cable can used.

Requirements

 The optional shaft encoder is mounted at the production line.

 The sensor is mounted in product running direction, near the Zanasi Z1

 Between the sensor and the nozzle plate is maximum a product, because another print
activation is otherwise ignored

Instruction

Please connect the optional product sensor with the print system as follows:

Step Procedure
1 If necessary install the optional shaft encoder on the production line and connect it
to the option-connection socket.

Fig. 6-10: Option-Socket (Sub-D 15-pole) on the system-back and Sensor-LED on the top side of the system

2 Set the sensor input of the system to External by the Z1 Remote Manager
software. (System settings – Advanced settings)

3 The Sensor LED lights green with print activation from product identification to the
end of the print.

4 If no print image is loaded, the Sensor LED lights yellow as long as the sensor is
covered.

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Connection to a network

A RJ-45-connection allows a connection of the print system to the customer LAN (Local Aera Network).

The LED on the top of the system lights green if a network is available. The LED flashes yellow with
data communication.

Instruction

Please connect the print system with the network as follows:

Step Procedure
1 If required connect the print system to the network by a RJ45 socket.

Fig. 6-11: Ethernet-socket (RJ 45) on the system-back and network LED on the top side of the system.

2 Set the desired IP address by the Z1 Remote Manager software. (System settings –
System Config – IP-Address)

3 Add the system in the Z1 Remote Manager software to operate it by the Z1 Remote
Manager software. (Connections – Add system – Enter name and IP address)

Each IP address can place in a network once only. Otherwise there is an address conflict and the
system can’t address. Please contact your system administrator.

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Inserting Ink Cartridge

If a new ink cartridge is inserted, the cartridge counters must be reset.

Use the ink cartridge as soon as possible after having removed the protective foil or the cartclip.

Instruction

Please insert the ink cartridge in the print system as follows:

Step Procedure
1 Remove the protective foil or CartClip from the nozzle plate an insert the ink
cartridge in the holder.

2 Before replacement of the cartridge, wipe the nozzle plate once with a lint-free
cloth.

3 Move the stop lever for the ink cartridge in the unlocked position.

4 Insert the ink cartridge in the cartridge holder vertically and push the cartridge
forward with the lever. (see Fig. 6-12).

Fig. 6-12: Insert the ink cartridge

5 Lock the stop lever for the ink cartridge.

The correct position of the ink cartridge is displayed in the main menu. The LED lights green after a
correct insertion.

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Removing Ink Cartridge

Damages by misuse!

An electronic fault can’t waive with a going print process and

simultaneous removing of the cartridge.
Therefore:
– Only change the cartridge when the print process is
stopped.

Instruction

Please remove the ink cartridge from the print system as follows:

Step Procedure
1 Unlock the stop lever for the ink cartridge.

2 Remove the ink cartridge from the cartridge holder. (see Fig. 6-13)

Fig. 6-13: Remove the ink cartridge

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7. Operation
User interface of the print system

LED STATUS ON-/OFF-BUTTON

GREEN: O.K. Print sPrint start / Print stop

Flashing: Standby Short: Text selection confirmation

YELLOW: Printstop Long: (>10 Sek.) Standby-mode

Flashing: Read/Write USB-data transfer Switch on the Off Standby-mode

RED: Failure print head not identified ON-/OFF BUTTON + INK BUTTON

Flashing: If the text selection is confirmed by pressing SELECTION-BUTTON

Activate the purge process
the ON-/OFF-BUTTON
1 x short: Selection print image 1
Flashing: Fast = USB failure
2 x short: Selection print image 2

3 x short: Selection print image 3

LED DEL SENSORE
…
GREEN: Print
9 x short: Selection print image 9
YELLOW: Photo sensor activation without data
Confirm the text selection within 5 sec.by a short pressing
RED: No shaft encoder signal the ON-/OFF-BUTTON

Flashing: Shaft encoder too fast Up to 9 print images can be saved. If more often pressed
than print images are in the memory, the last print image in
OFF: No print signal the memory will be selected.

SELECTION-BUTTON + ON/OFF-BUTTON
LED INK
increases the start delay +1mm
GREEN: O.K.
SELECTION-BUTTON + INK-BUTTON
YELLOW: : Ink below 5%
decreases the start delay -1mm

RED: Ink empty

INK-BUTTON
OFF: No cartridge
Short: Test print (The last loaded image will be print once)

LED NETWORK
(>5 sec.) Reset ink level

GREEN: Connected INK_BUTTON + ON-/OFF-BUTTON

YELLOW: Network activation activate the purge process

ROSSO: Network failure

Fig. 7-1: User interface on the top side of the system

When starting the system unit the progress of the starting process can be monitored on the LED’s. If
errors occur during booting, an error code is transmitted via the LED’s and can be analyzed in more
detail.

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Switching ON

Requirements
 The print system is connected with power.

 The system is in standby-mode

Instruction
Please switch the print system on as follows:

Step Procedure
1 Press short on the [ON-/OFF]-Button on the top side of the print system.

Fig. 7-2: ON-/OFF-BUTTON on the top side of the system

2 The system conducts a self-test and is ready to use after approx. 10 seconds.

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Switching OFF

Requirements
The print system is connected with power and switched on.

Instruction
Please switch the print system off as follows:

Step Procedure
1 Keep the [ON-/OFF]-Button on the top side of the print system pressed for approx.
10 seconds. The print system passes to standby mode.

Fig. 7-3: ON-/OFF-BUTTON on the top side of the system

2 The Status LED flashes every 10 seconds shortly in the standby-mode.

3 Disconnect the power supply from the print system for a completely switch off.

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Print Stop

Instruction
Please activate a Print Stop / a Print Pause as follows:

Step Procedure
1 Presses once short the [ON-/OFF]-Button on the top side of the print system.

Fig. 7-4: ON-/OFF-BUTTON on the top side of the system

2 The Power LED lights yellow on print stop.

Print Start

Instruction
Please activate a Print Start as follows:

Step Procedure
1 Presses once short the [ON-/OFF]-Button on the top side of the print system.

Fig. 7-5: ON-/OFF-BUTTON on the top side of the system

2 The Power LED lights green with successful print activation.

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Select Print Image

Up to nine print images can be saved in the memory of the Zanasi Z1 for a direct call up at the system
unit.

Instruction
Please select a print image as follows:

Step Procedure
1 To select the saved print image, ranks third (3.00I), press the [SELECT]-Button three
times short.

Fig. 7-6: SELECT-BUTTON on the top side of the system

2 To confirm the text selection pressing the [ON-/OFF]-Button within 5 seconds.

Fig. 7-7: ON-/OFF-BUTTON on the top side of the system

3 After pressing the [ON-/OFF]-Button, the selected text is confirmed with the
flashing STATUS LED. I.e. if text 3 is selected, the STATUS LED flashes three times.

Fig. 7-8: Status-LED on the top side of the system

4 The print images 1.00I to 9.00I can selected for printing in this way.

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Loading Print Image

Print Images can load to the Zanasi Z1 print system as follows:

 USB-Stick

 Software Z1 Remote Manager with existing network connection via RJ45 or

 By serial interface EIA 232

Load print images incl. fonts, logos and parameter with a USB-stick automatically.

The files can load to a USB-stick by Z1 Remote Manager.

After the connection of a USB stick an automatic run of commands will be made to query the system
status.

At the same time a directory „Zanasi“and a subdirectory with the name of the serial number of the
system, i.e. „P11905-z1“ will be created in the main directory of the USB stick. There will be saved all
system specific data.

The stick must be connected once on the system to post this information, so that the iDesign software
can work with the system after that.

The transfer of the data and commands happen by the directly after the connection of the stick. After
this the „Status.ast“ file is created.

Process:

After the connection and identification of the stick, the data will be read from the stick and the Status
LED flashes quickly meanwhile (4x/second)

Thereafter, data written on the stick and the Status LED flashes slowly meanwhile (2x/second)

If the LED lights constant, the stick can be removed after 2 seconds.

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Load print image with a USB-Stick

Needed tools
 USB-Stick

Requirements
 The used USB stick was connected for a „Initializing“ to the print system.

 The print image, created with the Z1 Remote Manager Software, is transferred to the
USB stick.

Instruction
Please load the print image from the USB-Stick to the memory of the print system:

Step Procedure
1 Connect the USB-Stick to the USB-socket on the top side of the print system.

Fig. 7-9: : USB-A socket on the top side of the system

2 Wait until the data exchange is completed. The STATUS LED flashes during the data
exchange and lights constant after finishing.

Fig. 7-10: STATUS-LED on the top side of the system

3 Remove the USB-Stick from the print system (2 seconds after the LED flashes
constantly).

If the USB-stick is removed to early or during data transfer, a data loss can happen.

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Set print start delay

Change the print start delay with a key combination.

Instruction
Please set the print start delay on the system as follows:

Step Procedure
1 Press the [SELECT]-button and [ON-/OFF]-button to increase the print start delay.

Fig. 7-11: SELECT-BUTTON and ON-/OFF-BUTTON

2 The delay increases about 1 mm with each keypress

3 Press the [SELECT]-button and the [INK]-button to decrease the print start delay.

Fig. 7-12: SELECT-BUTTON and INK-BUTTON

4 The delay decreases about 1 mm with each keypress.

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Loading Print Image with Z1 Remote Manager

Requirements
 The Zanasi Z1 print system is connected with the Z1 Remote Manager Software by a
network or serial interface

Instruction
Please load a print image from Z1 Remote Manager to the memory of the Zanasi Z1 print system as
follows:

Step Procedure
1 Select the menu Functions on the left side of Z1 Remote Manager

2 If several print systems are connected with the Z1 Remote Manager software,
click on the illustration of the corresponding print system which shall be
selected.

3 Click on the button [Printing].

4 Select the desired directory by pressing the directory button. The print
images, saved in Z1 Remote Manager can be found in the directory
C:\user\public\Z1 Remote Manager\label standard.

5 Click to select the desired print image. The selected print image is shown in
the preview.

6 Click on the button [Print start] to print the selected print image. A window
with “Print start ok” is shortly shown for the confirmation.

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Step Procedure

1
4
3
6
2
5

Fig. 7-13: Print image selection in Z1 Remote Manager

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Setting of the parameter by Z1 Remote Manager software, i.e. Print Start Delay

The print start delay can be set in this menu, i.e. by how much is printing delayed in millimeters after
the product is detected by the product sensor.

The delay can be selected between 0 and 999 millimeters (0-39.33 inch.).

The print start delay relates to the beginning of the print layout.

Requirements
The Zanasi Z1 print system is connected with the Z1 Remote Manager software via a network or serial
interface or the data can be transferred via USB-Stick.

Instruction
Please set the print start delay via the Z1 Remote Manager software as follows:

Step Procedure
1 Select the menu Functions on the left side of Z1 Remote Manager.

2 If several print systems are connected with the Z1 Remote Manager software, click
on the illustration of the corresponding print system which shall be selected.

3 Click on the button [Settings].

4 Click on the menu slide „Print parameter“ to call up the corresponding menu.

5 Set up the print start delay by click on the arrow keys or by input via keypad.

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Step Procedure

1
4

Fig. 7-14: Set up the print start delay in Z1 Remote Manager

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To rinse the nozzles manually

Material damage due to splashing ink!

During spitting, splashing ink soils the surroundings.

Therefore:
– Hold an absorbent cloth in front of the ink cartridge nozzle
plate.

After extended periods of no printing, it may be necessary to rinse the ink cartridges to open up
clogged nozzle channels again.

During rinsing (purging), all ink cartridge nozzle ducts are addressed to eject some ink. The rinse
process takes max. 2 seconds or rather so long as the button will be pressed and hold.

Needed tools
 Absorbent cloth

 Or paper / cardboard

Instruction
Please rinse the nozzle channels as follows:

Step Procedure
1 Hold a absorbent cloth on front of the nozzle plate of the ink cartridge.

2 Press the [ON / OFF]-button and the [INK]-button on the top of the system
simultaneously.

Fig. 7-15: [ON / OFF]-button and [INK]-button on the top of the system

3 Wipe the nozzle plate off carefully to remove excess ink.

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Calculate ink content cartridge

An ink cartridge contains ca. 1,083 bn ink droplets of approx. 24 pl each. The system counts the ink
droplets printed and uses this to calculate the ink consumption.

The number of prints, which can be done with one cartridge, can be read in the menu.

The ink content can also be determined by weighing:

A full LX cartridge weighs ca. 66 g ± 3 g. An empty cartridge weighs ca. 40 g ± 3 g. The rest of an empty
cartridge is max. 3 ml.

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Web-Interface

The WEB Interface can only be called from one terminal at the same time!

If the WEB Interface of a print system should be operated by another terminal, the existing connection
must stop before!

After starting the WEB Interface, the status screen is displayed, from which can be navigate.

Use the arrow keys to scroll through the print image.

By a click on the print image, the print image name, the number of the previously print image and the
number of prints of the selected print image, which can be print with a full cartridge, are displayed.

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The print can pause with .

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The print can start again or another print image can select with .

The selected print image can start with .

The last loaded and paused print image restarts with .

Variable fields are queried each time before a print image starts:

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Parameter settings can be selected and changed with :

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With the button:

 a print image can call up for print start

 a print image can be changed

 a new print image can be created.

Change the ink settings with .

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Call up and change the system settings with :

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Configurable In-/Outputs

Material damage due to short-circuit!

The outputs are open Collector outputs and may load with
max. 100 mA.

The Z1 has at the 15-pole option socket two in- and four outputs. A variety of configurations are
possible and so the connectors for output of status messages (OK, Warning, Error), cartridge level
messages (5% low / empty), print ready and print pulse are possible to use. On the input side signals
for heating, spitting, print direction, upside print, stop and text selection are possible.

The texts for input 1 must be called „!EXT01.00I“ and „!EXT02.00I“ with an external text selection by
the inputs. The texts „!EXT01.00I“ to „!EXT04.00I“ can be assigned if both inputs are used.

The setting can be done with Z1 Remote Manager Software in Functions  System settings 
Advanced settings or via Web-Browser in Settings  Advanced settings.

Fig. 7-16: User interface Software Z1 Remote Manager

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Settings by Z1 Remote Manager software

Following print parameter can set up with the Z1 Remote Manager software (Note the instructions of
the provided Z1 Remote Manager software manual):

 Print start delay

 Print direction

 Zoom

 Fixed speed

 Speed (Only adjustable if fixed speed is adjusted)

 Intensity (Only adjustable if fixed speed is adjusted)

 Shaft encoder

 Shaft encoder resolution (only adjustable if shaft encoder is adjusted)

Fig. 7-18: Set print parameter by Z1 Remote Manager

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8. Z1 Remote Manager
Create a print image

No print images can be created on the Z1 system unit itself.

Print images can be created and processed with the software Z1 Remote Manager software stored on
the USB stick. For this purpose, this must be installed on a commercially available PC (follow the
enclosed Z1 Remote Manager operating instructions).

The diagram below shows the operating surface of the Z1 Remote Manager software

Save Add date Add logo / Delete Decrease Cascade Arrangement

Create Add text
label / time picture selection zoom arrangement on top of
new
each
label

Fig. 8-1: User interface Editor Z1 Remote Manager

Open Save label with a Add Add Add Move Turn Ink Increase
Assign a set of
existing new name variable counter barcode pixel by selection consumpt zoom
parameters to
label pixel through 90° ion a text

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Ethernet Connection establishing

To establish an Ethernet connection to the printer you have to know a free Ethernet address.

Please ask your system administrator.

Instruction
How to set the Ethernet address in the system:

Step Procedure
1 Connect a USB stick to the Z1 and wait that the status LED stops blinking.

2 Connect the USB stick to a PC with Z1 Remote Manager software. The system will
be shown in Z1 Remote Manager.

3 Click in Z1 Remote Manager with the mouse on the system icon and enter the
requested IP address under Functions / Settings / System / IP address.

Confirm the IP address and add the connection to Z1 Remote Manager.

4 Now connect the USB stick again to the Z1.

The Z1 should now be visible under the desired IP address.

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9. Faults
The following chapter describes possible causes of malfunctions and how to remedy these.

In case of frequent faults, reduce the service intervals depending on the actual work load.

Please contact your local distributor with regard to faults that cannot be remedied with the
information provided below.

Safety
Staff

 The fault remediation work described here, unless specified otherwise, can be
performed by the operator.

 Some tasks may only be performed by specially trained specialized staff or exclusively by
the manufacturer; this is specifically pointed out in the description of the individual
faults.

 Work on the electrical system may only be performed by electricians.

Danger to life through electric shock!

DANGER TO LIFE!
Contact with live parts poses imminent danger to life.
Damaged insulation or individual components can be lethal.
Therefore:
– Immediately switch off the power supply and initiate
repairs if the insulation is damaged.
– Work on the electrical system may only be performed by
electricians.
– Before working on the electrical system, disconnect from
the mains (remove mains plug) and check that power is
off.
– Always disconnect mains before performing cleaning and
repair tasks.
– Keep moisture from live parts. Moisture may cause a
short-circuit.

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Risk of injury by improper fault remediation!

WARNING!
Improper fault remediation may cause severe injury to
persons, or material damage.
Therefore:
– Ensure adequate working space before starting any work.
– Keep the working area clean and tidy! Loosely stacked or
scattered components and tools are potential causes of
accidents.

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Table of faults

Faults Possible causes Troubleshooting Recovered by

System unit does No power supply Check power supply Electrician
not start

No 12V/24V DC Check 12V/24V, Electrician

Change power supply Instructed Person

System unit System on Standby Press On / Off button Instructed Person

does not
produce a print
image
Print image not assigned Assign print image Instructed Person

Stop print Start print Instructed Person

Missing start pulse Check photo sensor and Electrician

connection cable

Insert ink cartridge

Missing ink cartridge Instructed Person

Insert new ink cartridge

Empty ink cartridge Instructed Person

Insert new ink cartridge

Defect ink cartridge Instructed Person

Clean ink cartridge

Dry up ink cartridge Instructed Person

Remove and reinsert ink

Ink cartridge not inserted cartridge Instructed Person
correctly

Print parameter incorrect Check print parameter, adjust if Instructed Person

necessary

Fault in the electronics of the Send controller or print head in Manufacturer

controller or the print head for repairs

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Faults Possible causes Troubleshooting Recovered by

Faulty rotary encoder or Check rotary encoder and Instructed Person
incorrect rotary encoder settings encoder settings

Bad and fuzzy The distance between print head Reduce distance to 0 -4 mm …5 Qualified person
print image and product is too big mm

Low intensity Increase intensity Instructed Person

Empty ink cartridge Change ink cartridge Instructed Person

Blocked nozzles Spitting and wipe the nozzle Instructed Person

plate if necessary.

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Trouble shooting tasks

Cleaning the ink cartridge

Material damage due to incorrect cleaning!

Incorrect cleaning may scratch the nozzles of the ink

cartridges, causing blurred print images since the scratches
around the nozzles divert the ink.
Therefore:
– Use only lint-free and absorbent cloths to clean the
cartridges.
– Moisten cleaning cloths with water.
– Wipe slowly without pressure.

 To be done by instructed person.

 To be done if print quality deteriorates during printing or after extended period of non-
use.

During printing the print quality may deteriorate due to dust and ink vapor. In this case, wipe the
nozzle plate of the ink cartridge with a moist, lint-free cloth. The water in the moist cloth dissolves the
ink residues and cleans the nozzles and the ink channels.

Needed tools
Absorbent cloth

Instruction
Please clean the nozzle plate as follows:

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Step Procedure
1 Remove the ink cartridge from the holder.

2 Hold the ink cartridge with the nozzle plate facing downward.

3 Slowly wipe across the nozzle plate in the direction of the arrow, using a moistened
and lint-free cloth.

Do not shake the ink cartridge!

Fig. 9-1: Cleaning the nozzle plate (the image doesn’t show the Funai-Lexmark cartridge)

4 Reinsert the ink cartridge in the holder

A small amount of water may mix with the ink in the channels, rendering the first print a bit grey.

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10. Disassembly
When end of the useful life expires, the system must be disassembled and disposed in an
environmentally-friendly manner.

Safety
Staff

Danger to life through electric shock!

DANGER TO LIFE!
Contact with live parts poses imminent danger to life.
Damaged insulation or individual components can be lethal.
Therefore:
– Immediately switch off the power supply and initiate
repairs if the insulation is damaged.
– Work on the electrical system may only be performed by
electricians.
– Before working on the electrical system, disconnect from
the mains (remove mains plug) and check that power is
off.
– Always disconnect mains before performing cleaning and
repair tasks.
– Keep moisture from live parts. Moisture may cause short-
circuit.

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Risk of injury caused by improper disassembly!

WARNING!
Stored residual energy, sharp-edged components, points and
corners on and inside the apparatus or on the required tools
may cause injuries.
Therefore:

– Ensure adequate space before starting any work.

– Handle exposed sharp-edged components with care.
– Keep the work area clean and tidy! Loosely stacked or
scattered components and tools are potential causes
of accidents.
– Secure components to prevent falling down or falling
over.
– Consult the manufacturer if uncertain.

 Disassembly may only be performed by specially trained specialized staff.

 Work on the electrical system may only be performed by electricians.

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Disposal

Environmental damage due to incorrect disposal!

Electrical scrap, electronic components, lubricants and other

auxiliary materials are subject to hazardous waste treatment
regulations and may only be disposed of by approved
specialized companies!

Unless return or disposal agreements were made, submit disassembled components for recycling:

 Scrap metals.
 Submit plastic components for recycling.
 Dispose of other components according to material composition.

The local municipal authorities or specialized disposal companies provide information on

environmentally compatible disposal.

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11. List of Accessories and Spare Parts

Safety hazard due to incorrect spare parts!

Incorrect or faulty spare parts may affect safety and

cause damage, malfunctions or failure.
Therefore:
– Only use original spare parts from the manufacturer.

Procure spare parts via contracted dealers or directly from the manufacturer.

Ink cartridges

Material damage can be caused by spraying ink!

Spitting results in increased ink consumption and can lead

to undesirable contamination of the environment.

Therefore:
– Hold an absorbent cloth in front of the nozzle plate of the
ink cartridge.

The specified drying times can be reduced by additional heat treatment (hot-air blower, IR
heater). The open time can be extended by spit pulse programming. di.

Please note the ink specific settings for head voltage, fire time, spitting and warming.
There is the possibility to set up the ideally standard values for the respective ink type on the Z1
Remote Manager software or Web interface.
It makes sense to change the values carefully depending on the application.

The settings can be made with the Z1 Remote Manager software below Functions / System
settings / Advanced settings.

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Pos Name Description

.

1 INK ZL01 WD Ink cartridge, color black, 33 ml capacity each.

THERMAL Specially developed water-based ink of Funai-Lexmark.
BLACK

2 INK ZL02 ED Ink cartridge, color black, 48 ml capacity each.

THERMAL Specially developed solvent-based ink of Funai-Lexmark.
BLACK
Well suited for prints on semi-absorbent and non-
absorbent materials, depending on the intensity
Open time without loss of quality:
Up to 8 hours.

3 Ink ZL03 WP Ink cartridge, color black, 33 ml capacity each.

Thermal Black Specially developed, high pigmented, water-based Funai-
Lexmark ink.
Well suited for sharp edged print on poorly
absorbent materials.
Drying:
Immediate drying on absorbent surfaces, no drying on
poorly absorbent surfaces, because the pigments
remain on the surface.
Open time without loss of quality:
Approx. 30 minutes (depending on intensity and print
image).

4 INK ZL04 WP Ink cartridge, color black, 33 ml capacity each.

THERMAL Specially developed, high pigmented, water-based Funai-
BLACK Lexmark ink.

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Settings Spitting and Warming

Fig. 11-1: Z1 Remote Manager advanced settings

Refer to the Z1 Remote Manager Manual.

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Mounting brackets

Pos. Article Description

1 Universal mounting for a fixing on a conveyor from the side, with quick fastener to
bracket take the system unit out of the mounting bracket without
technical tools.

2 Universal mounting for a fixing on a conveyor from the top, with quick fastener to
bracket TOP take the system unit out of the mounting bracket without
technical tools.

3 Flexbracket Kit f o r Z1 flexible bracket to compensate variable distances between

control system and product. Maximum travel length 20mm;
maximum print speed 30 m/min.

Other

Pos. Figure Assembly Description

1 Power supply Power supply Z1 24V

2 Mounting bracket Universal Mounting bracket

3 Mounting bracket Universal Mounting bracket Top

Top

4 Photocell Including 2.5 m connecting cable

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Pos. Figure Assembly Description

5 Encoder Push-pull output, 2,500 pulses/rev.

Splitter cable necessary

6 USB data stick

7 Splitter cable Splitter cable for the connection of

more than 2 options, alarm, RS232,
sensor, encoder

8 Box Box for connecting all the accessories

9 Alarm light Alarm light 3 color

10 Flexbracket kit consisting of:

-Flex bracket deflector
-Flex bracket
-Screws

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12. Appendix
Ink Chart

The Zanasi Z1 has a deposit ink chart. The optimal parameter of an ink will be
automatically adopted by the ink selection.
If the parameters were changed in the Z1 Remote Manager software, the changed
parameters stay active till a new ink type will be select.
The ink tables are stored as excel tables in the HMI account : "InkParLX.csv".

The chart can be adapted customized with an HMI update and can load to the memory of the Zanasi
Z1.

Changes of the ink parameter can cause bad print images and should conduct from
specialized staff.

„InkParLX.csv“:

Set- Fire Spit Spit

No. No. Volume Voltage Time Spitting Rows Delay Warming Warm Temp Warm Time Pre fire
1 1 100 110 190 Off 0 0 No 20 0 33

2 2 80 110 72 Off 0 0 Sì 47 2 25

3 2 80 110 70 Off 0 0 Sì 42 2 25

4 3 80 110 70 Off 0 0 Sì 42 2 25

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Software-Update
Software-update with USB-Stick

 The program directories „HMI“, „Html“ and „SYSTEM“ are copied in the main
directory of an empty USB-stick.

 The Z1 is not connected to the power supply.

Instructions
Please proceed the software-update as follows:

Step Procedure
1 By pressing the [Ink]- button, connect the Zanasi Z1 with the power supply until the
Sensor LED flashes green/red.

2 Connect the USB-stick in the USB socket on the top side of the system.

3 The Sensor LED flashes yellow/red if the program is load.

4 Confirm by pressing the start-button and wait until the system is restart.

5 Remove now the USB-stick.

Software-Upgrade

A software upgrade with costs is comfortably possible.

Please contact your consultant or local distributor to get a software-upgrade

Current software version

Status Date Info

2.0.10.1 Dic.2015

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USB-Stick files

Following files are saved on the USB-stick:

 Z1 Remote Manager Software

 Manual Z1 Remote Manager Software

 Manual Z1

 Leaflet

The required files for software updates:

 HMI-directory

 HTML-directory

 System-directory

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Boot-LED messages

During booting of the system progress can be determined by means of the LED.
If the system stops during booting the cause can be determined by means of the LED.
FC means flashing. An error can be determined on the basis of the number of flashes.

Status-LED Sensor-LED
Description

ye ye Boot BF-Intern

rd — Write 64MB memory

— rd Read 64MB memory

ye — Read/Test 64MB memory

— ye Test ok / Load BootMain from SPI

ye rd Programming and Start of BootMain

— — BootMain Initializzation

rd rd Fatal Error

Boot Error 4x = SPI; 5x = GA; 6x = Displ; 7x = SD-Card; 8x = USB; 9x = RTC;

rd FC: rd
10x = Task

rd FC: gr Init Error 1x = Dev; 2x = FS; 3x= UsrCl

ye gr Read SD-Card

ye rd / gr Wait for stick

ye rd / — No boot data

ye ye / gr Booting of stick

ye ye / rd Copying of stick

ye gr / — Copy ok

gr — Main program loaded and started

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Plug connections
Voltage input

Operating voltage: 12 - 24V direct current, min 1,25A

Connector: Sub-D Plug male 15pin

PIN Description Value Unit

1 GND 0 V

15 Power min 1250 mA +12-24 V

Ethernet

Connection

Network input RJ 45 on the back side of the system.

PIN Description
1 Transmit +

2 Transmit -

3 Receive +

6 Receive -

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USB A

The USB sockets are standard sockets, as used in commercial PCs and USB devices. Insert the USB-stick
without force effect normal to the top side of the system in the USB socket.

PIN Name Color Description

1 VCC Red +5 V

2 D- White Data -

3 D+ Green Data +

4 GND Black Mass

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Option

Option socket: 15 pol Sub-D connector Option socket: 15 pol Sub-D connector

PIN Description Value Unit

1 GND 0 V

2 Output 1 (Alarm) Open Collector,

max 24V / 100mA

3 Input 1 Input Standard: NPN

4 Input 2 Input Standard: NPN

5 Output 3 (OK) Open Collector,

max 24V / 100mA

6 Output 4 (Reserve) Open Collector,

max 24V / 100mA

7 EIA 232 TXD

8 GND 0 V

9 Output 2 (Warning) Open Collector,

max 24V / 100mA

10 Start pulse Input Standard: NPN

11 Shaft encoder Input Standard: NPN

12 Not used

13 Not used

14 EIA 232 RXD

15 Power +12-24 V

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Splitter cable

Pin-configuration:

15 pole Sub-D-connector male 15 pole Sub-D-connector female

(label: Z1) (label: Full)
PIN 1 (GND) PIN 1 (GND)

PIN 2 (OUTPUT 1: ALARM) PIN 2 (OUTPUT 1: ALARM)

PIN 3 (INPUT 1) PIN 3 (INPUT 1)

PIN 4 (INPUT 2) PIN 4 (INPUT 2)

PIN 5 (OUTPUT 3: OK) PIN 5 (OUTPUT 3: OK)

PIN 6 (OUTPUT 4: RESERVE) PIN 6 (OUTPUT 4: RESERVE)

PIN 7 (TX) PIN 7 (TX)

PIN 8 (GND – WITH PIN 1)

PIN 9 (OUTPUT 2: WARNING) PIN 9 (OUTPUT 2: WARNING)

PIN 10 (SIGNAL SENSOR) PIN 10 (SIGNAL SENSOR)

PIN 11 (SIGNAL ENCODER) PIN 11 (SIGNAL ENCODER)

PIN 14 (RX) PIN 14 (RX)

PIN 15 (POWER) PIN 15 (POWER)

15 pole Sub-D-connector male 15 pole Sub-D-connector female

(label: Z1) (label: Power)
PIN 1 (GND) PIN 1 (GND)

PIN 8 (GND – WITH PIN 1)

PIN 15 (POWER) PIN 15 (POWER)

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15 pole Sub-D-connector male 15 pole Sub-D-connector female

(label: Z1) (label: Sensor - Encoder)
PIN 1 (GND) PIN 1 (GND)

PIN 8 (GND – WITH PIN 1)

PIN 10 (SIGNAL SENSOR) PIN 10 (SIGNAL SENSOR)

PIN 11 (SIGNAL ENCODER) PIN 11 (SIGNAL ENCODER)

PIN 15 (POWER) PIN 15 (POWER)

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Sensor

Sensor input:

Standard: NPN (switching to GND)

Voltage: 12V-24V depends on the input voltage

Threshold level: 7V

If switching the input to PNP a resistor of 2kOhm (12V) or 4kOhm (24V) must be connected
between input (Pin10) and ground (Pin1)

Encoder

Encoder input:

Standard: Push-pull or NPN (switching to GND)

Voltage: 12V-24V depends on the input voltage

Threshold level: 7V

Frequency: Max. 150 kHz

If more systems should be connected together the sensor and encoder signal can be connected
parallel. Max. 5 systems because of the power used.
The +12V power should be only connected between one system and sensor / encoder not
between the systems !

15 pol 15 pol Sub- 15 pol

15 pol Sub- 15 pol Sub- Up to 5
Sub-D- D- male Sub-D-
D- female D- male syst em s
male female

PIN 1 – GND PIN 1 PIN 1 PIN 1 PIN 1 PIN 1

PIN 8 – GND PIN 8 PIN 8 PIN 8 PIN 8 PIN 8

PIN 10 – ftc PIN 10 PIN 10 PIN 10 PIN 10 PIN 10

PIN 11 – PIN 11 PIN 11 PIN 11 PIN 11 PIN 11

Encoder

PIN 15 – +12V PIN 15 Not connected Not connected PIN 15 PIN 15

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Input and Output

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Mac Address

The MAC address of the respective Zanasi Z1 can be seen on the name plate of the system. In
addition, the Mac address can be seen in the Z1 Remote Manager software.

Instruction
Please see the MAC address by the Z1 Remote Manager software as follows:

Step Procedure
1 Select the menu Functions on the left side of the Z1 Remote Manager software.

2 If several print systems are connected with the Z1 Remote Manager software, click
on the illustration of the corresponding print system which shall be selected.

3 Click on the button [System Settings].

4 Click on the menu slide „System Config“ to call up the corresponding menu.

5 The MAC address can be seen in the corresponding line.

00:50:C2:A6:5F:6B

Fig. 12-1: Z1 Remote Manager System Config

Range from: to:

00:50:C2:A6:50:00 00:50:C2:A6:5F:FF

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Technical Drawings

System unit Zanasi Z1

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System unit with mounting bracket

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System unit with Flexbracket and mounting bracket

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Parameter List

Current
Parameter After Reset Min. Max. Unit
value
Print Start delay 10 (0.39) 0 (0) 999 (39.33) mm (inch.)

Speed 15 (49.2) 1 (3.28) 300 (984.25) m/min (ft/min)

Divider shaft encoder 4 1 50 -

Intensity 300 50 900 dpi

Print width 100 10 900 %

Direction Dx-->Sx Dx-->Sx Sx--> Dx -

Nozzle row A~B A A+B -

Overhead no no yes -

Sensor Internal Internal Esternal -

Encoder Internal Internal Esternal -

IP-address 0.0.0.0 255.255.255.255 -

IP-mask 255.255.255.0 0.0.0.0 255.255.255.255 -

Gateway 0.0.0.0 0.0.0.0 255.255.255.255 -

Voltage 11,0 4,0 11,2 V

Fire time 190 50 300 s

Fire pause 190 100 300 s

Ink min 5 0 99 %

Spit mode Off Before Interval -

Columns 1 1 99 -

Delay 1 1 999 s

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Current
Parameter After Reset Min. Max. Unit
value
Interval 1 1 999 s

Auto Off 0 1 999 min.

Ripeat Delay 0 (0) 0 (0) 999 (39.33) mm (inch.)

Ripeat Number 0 0 999

Warming No Yes no

Warming Temp. 20 20 80 °C

Warming off timer 0 0 999 s

Language Inglese -

Ink Type ??? -

User 1 0 0 4 -

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Declaration of conformity

We hereby declare under our responsability that the system:

System Description: Ink jet printer

Type: Z1
Identification: from serial number AG-TJ-00001
Manufacturer: Zanasi s.r.l.
via Marche 10, 41049 Sassuolo (Modena), Italy

complies with the requirement:

Directive 2014/30/EU (ELECTROMAGNETIC COMPATIBILITY - EMC)

Directive 2014/35/EU (LOW VOLTAGE)

and has been designed and manufactured in accordance with the harmonized European standards:
EN55022 Interfering voltage
EN55022 Interference field strength
EN61000-6-2 Interference resistance against electromagnetic fields
EN61000-6-2 Interference resistance against high frequency on cables
EN61000-6-2 Interference resistance against ESD
EN55024 Interference resistance against Burst
EN61000-6-2 Interference resistance against Surge
EN55024 Interference resistance against voltage changes and interrupts
EN61000-3-2 Limits of harmonic current emissions
EN61000-3-3 Limits of voltage changes, fluctuation and flicker

The manufacturer keeps information about the system technical construction data.

Person authorised to compile the technical file:

Paolo Zanni (technical manager) - via Marche 10, 41049 Sassuolo (Modena), Italy

Sassuolo (Mo), July 15th, 2016 Gianni Zanasi (Managing Director)

Release 8.150716

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