Operations Manual - Allen Coding GmbH

Operations
Manual
Thermal Jet
Ink Jet System
5780-649
Revision B
1 Missouri Research Park Drive • St. Charles, MO 63304 • Service Line 1-800-526-2531
Illinois Tool Works Inc © 2016
Thermal Jet
Ink Jet System
Operations Manual
5780-649
Revision B
Ink Cartridge: The TJ Series has been engineered
and designed to work with Diagraph ink cartridges.
The TJ’s Smart Level Ink Detection System, which
provides ink level monitoring to ensure complete ink
usage and product safety, will not be functional if
used with non-Diagraph ink cartridges.
The information contained in this manual
is correct and accurate at the time of its
publication. Diagraph reserves the right to
change or alter any information or
technical specifications at any time and
without notice.
©2016 Illinois Tool Works Inc.
All rights reserved
Printed in the United States of America
Thermal Jet
Warranty:
The TJ Thermal Jet system, including all components unless otherwise specified,
carries a limited warranty.
The inks and conditioners used with the TJ Thermal Jet system carry a limited
warranty.
For all warranty terms and conditions, contact Diagraph an ITW Company for a
complete copy of the Limited Warranty Statement.
Thermal Jet
Section 1: Safety and Ink Cartridge Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2: Quick Start .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 1: Assemble Bracketry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 2: Assemble Bracketry to Conveyor .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 3: Assemble Print Head and Power Supply to Bracketry . . . . . . . . . . . . . . . . . . . . . . 4
Step 4: Adjust Print Head to Substrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Step 5: Insert Pen Cartridge into Print Head .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 6: Cabling, Power, and Serial Port Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 7: Configure the Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 8: Create a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 9: Print a Message .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 3: User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Home Screen: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Message Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Time, Date, and Count Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
User Defined Time Codes .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
User Defined Date Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Product Counts, Variable Fields, Logos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Barcodes, Lines, Product setup, & Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Message Info Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Zoom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Delete Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The Apps Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 4: Maintenance & Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pen Cartridge Maintenance .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Section 5: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Appendix A: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Handheld Serial Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
System Interconnect Diagram .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Appendix B: Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Thermal Jet Print Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Handheld Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Appendix C: File Backup and Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
From a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
File Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Restoring Backed-Up Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
From a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Thermal Jet Operations Manual Rev B
Thermal Jet
Appendix D: Configuring a PC to Communicate with the Handheld . . . . . . . . . . . . . . . . . . 42
Windows XP® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Window 7® .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Appendix E: Font Samples .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix F: Creating Logo Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Appendix G: Controller and Print Head File Management . . . . . . . . . . . . . . . . . . . . . . . . . . 47
File Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Transferring Logo and Font Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Removing a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Appendix H: Communicating Directly to the Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Appendix I: Aligning the 1" (25.4 mm) Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Appendix J: Bulk Ink Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Appendix K: Part Numbers - Consumables and Service Parts . . . . . . . . . . . . . . . . . . . . . . . 58
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Thermal Jet Operations Manual Rev B
Thermal Jet
Section 1: Safety and Ink Cartridge Usage
Section 1: Safety and Ink Cartridge Usage
Following is a list of safety symbols and their meanings, which are found throughout this
manual. Pay attention to these symbols where they appear in the manual.
Wear safety goggles when performing the procedure described!
!
Caution or Warning! Denotes possible personal injury and/or damage to the equipment.
Caution or Warning! Denotes possible personal injury and/or equipment damage due to
electrical hazard.
NOTE: (Will be followed by a brief comment or explanation.)
!
ESD protection should be worn when servicing internal printed circuit boards.
After service to the equipment is completed, replace all protective devices such as grounding cables and covers before operating the equipment.
It is extremely important to:
•
•
•
Clean up all spills with the appropriate solvents immediately and dispose of all waste according
to local and state regulations.
Wear safety glasses and protective clothing, including gloves, when handling all inks and conditioners.
Store inks and solvents under the recommended conditions found on the SDS (Safety Data
Sheet).
Thermal Jet Operations Manual Rev B
Page 1
Thermal Jet
Section 2: Quick Start
Section 2: Quick Start
OPTIONAL HAND
HELD CONTROLLER
TYPICAL INSTALLATION
TYPICAL INSTALLATION
Contents:
•
•
•
•
•
•
Print Head
Bracketry Kit
Power Supply, 15 V
Power Supply Bracket
Power Cord
Software
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Page 2
Thermal Jet
Section 2: Quick Start
Step 1: Assemble Bracketry
Step 2: Assemble Bracketry to Conveyor
Thermal Jet Operations Manual Rev B
Page 3
Thermal Jet
Section 2: Quick Start
Step 3: Assemble Print Head and Power Supply to Bracketry
Ensure bar is
behind front
face of print head
Thermal Jet Operations Manual Rev B
Page 4
Thermal Jet
Section 2: Quick Start
Step 4: Adjust Print Head to Substrate
Adjust print head vertically to meet requirement.
Adjust print head horizontally to set print gap.
.1" (2.5mm) GAP
RECOMMENDED
Thermal Jet Operations Manual Rev B
ADJUST THE PRINT
HEAD TO THE
SUBSTRATE WITH
THIS BRACKET
Page 5
Thermal Jet
Section 2: Quick Start
Step 5: Insert Pen Cartridge into Print Head
PEN STOP
Rotate Cover
Open
Insert Pen Cartridge at an angle up to
Pen Stop
PEN STOP
When inserting cartridge, aim nose at an
angle towards black pogo pin component.
Slide pen cartridge up to Pen Stop.
FINGER RELEASE TABS
Rotate Pen Cartridge
down until it snaps in
place.
FINGER RELEASE TAB
NOTE: The pen is
released by pressing
down on the Finger
Release Tab and pulling up on the rear of
the cartridge.
Close Cover
After pen cartridge
is installed
Thermal Jet Operations Manual Rev B
Page 6
Thermal Jet
Section 2: Quick Start
Step 6: Cabling, Power, and Serial Port Setup
Cabling
CAUTION: Power should be disconnected from the print head prior to connecting or disconnecting any external device, including: PC, controller, or print head daisy chain cables.
Electrical arcing may occur if external cabling is connected or disconnected while power is
supplied to the unit.
Print heads are controlled via a COM port from a PC or a Hand Held Controller. One com
port can control up to eight 1/2" print heads, four 1" print heads, or any combination of the
two totaling eight print cartridges. Using the supplied serial cables, connect the print heads
daisy chain style by connecting the output port of one print head to the input port of the
next. Then connect the COM port of the PC or Hand Held Controller to the daisy chain. A
PC connects to the input port of the first head in the daisy chain, while a Hand Held Controller connects to the output port of the last.
PC OR LAPTOP
COM PORT
Print Head Cable
5780-319-06
DB9 M-F
HH Controller Cable
5780-616-06
DB9 F-F
Thermal Jet Operations Manual Rev B
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Thermal Jet
Power
CAUTION: Power should be disconnected from the
print head prior to connecting or disconnecting any
external device, including: PC, controller, or print
head daisy chain cables. Electrical arcing may occur
if external cabling is connected or disconnected
while power is supplied to the unit.
Install the power plug from the previously mounted
power supply into the power jack on the rear of each
print head.
Press and hold the "PURGE" button on the rear of
the print head while slowly moving a piece of paper,
cardboard, or comparable material in front of the
print head. Print several purge images and validate
that all channels are printing. If not, refer to “Section
4: Maintenance & Shutdowns” on page 26.
NOTE: Do not rub the print cartridge face with the print sample material as this will scratch
the orifice array and affect print quality.
The power supply for the controller or the computer may now be installed.
Serial Port Setup
NOTE: Depending on the InkJet Demo software or controller configuration, this step may
already be complete.
If a computer will be used, install the InkJet
Demo software included with the print head.
Follow the installation prompts, and at this
prompt, select "Interface 1 Serial Print Head".
Launch the program after it has been
installed.
On the Home Screen press the Menu Button, then the Apps Button.
Menu Button
Thermal Jet Operations Manual Rev B
Apps Button
Page 8
Thermal Jet
On the Apps screen, Press the Ports button.
Ports Button
Home Button
On the Ports Setting Screen press the COM1 Function Button, select Serial Print HeadHP, and press OK. Press OK again to exit the Port Settings Screen.
If using a PC, pressing OK after selecting Serial Print Head-HP opens the Serial Port Setup
dialog box. Select the desired COM port (only those ports available are listed) and press
OK. Press OK again to exit the Port Settings Screen.
Press the Home Button to return to the Home Screen.
Thermal Jet Operations Manual Rev B
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Thermal Jet
Step 7: Configure the Print Head
On the home screen, press the More button, and then press Task Settings. On the
Print Heads page, press the Redo Setup button. Select the desired direction.
Set the number of print heads, identify their positions relative to the controller, and select
the appropriate print head type by touching each one and then the drop down box. If using
an external photocell, set the offset.
Check this box if using
5780-261 ink cartridge.
Print head setup complete. Next, select the Encoder tab and choose the desired encoder
type.
External Encoder:
Line speed measured
by an externally
mounted encoder
connected to the last
print head in the daisy
chain
Auto Speed Detect:
Line speed automatically
detected via print head
photo cells.
Fixed Speed:
User enters the
desired line speed
Touch this
box, then
enter the
desired speed
Thermal Jet Operations Manual Rev B
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Thermal Jet
Step 8: Create a Message
From the Home Screen, select the Messages button and then the New button to enter the
message editor.
Messages Button
New Message Button
Create and save the message, and then exit the message editor.
Carton Ruler
Next Field Button
Message Display Area
Field Properties
Date Code
Time Code
Font Selection
Cursor
Zoom
Message Info
Cursor or Field
Coordinates
On-screen
Keyboard
Text
Menu
Quick Save
Delete
Button
Product Setup
Product Side
Count Code
Variable Field
Logo
Thermal Jet Operations Manual Rev B
Line Field
Bar Codes
Page 11
Thermal Jet
Step 9: Print a Message
From the Home Screen, press the Print button.
Print Button
Select the desired message to print, and press the Print button.
Print Button
The message will print on the next photocell trigger.
Thermal Jet Operations Manual Rev B
Page 12
Thermal Jet
Section 3: User Interface
Section 3: User Interface
On-Screen Keyboards & Numeric Keypads
Keyboard
Button
Letters
Layer
Select
Extended Characters
Numbers & Symbols
Language Select Button
Keyboard Button:
•
•
Edit Screen only: Press once to show the keyboard; press again to hide it.
All other screens and dialogs: Keypad or keyboard appears when text or numeric input box is
touched.
Layer Select:
•
Pressing the Layer Select button cycles through; letters, numbers & symbols, and extended
characters.
Language Select Button:
•
Changes keyboard layout to that of the language selected. Changes keyboard layout only; user
interface language does not change.
ESC (Escape):
•
•
Undoes any changes made to any input entry box. If no changes made, hides the keypad or
keyboard.
Edit screen full keyboard: always hides the keyboard.
Arrow Keys:
•
Moves highlighted fields or the cursor around in the Message Editor.
Tab:
•
Shifts focus between fields in the Message Editor.
Backspace:
•
•
Deletes the character to the left of the cursor.
On the edit screen, deletes a highlighted (red) field.
Ctrl (Control) in Message Editor:
•
•
Amplifies the movement of the arrow keys.
Press Ctrl-Enter to insert a new line in a text field.
Shift:
•
•
Press Shift once to make the next character upper case.
Press Shift twice for shift lock. Press Shift again to exit shift lock.
Thermal Jet Operations Manual Rev B
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Thermal Jet
Section 3: User Interface
Home Screen:
Zoom
Message Name
Task Select
Message
Window
{
Connectivity
Indicator
Pause/
Continue
Printing
Print
Cancel Print
Messages
Status
Screen
More...
(Menu)
Message Window:
•
•
•
•
•
Displays the current print message
Updated approximately every seven seconds, so
every print may not be displayed.
Touch and swipe the Message Window to scroll the
message.
White or Beige bars represent the print heads. The
numbers in the left margin correspond to the numbers
assigned to the print heads during system setup.
The window header displays the task number and the
file name of the message being printed. "None" is displayed when no message is being printed.
Task Select Drop Down List:
•
On dual task systems, switches controller operation from one task to another.
Pause/Continue Button:
•
Button appears only when a print message is displayed in the Message Window.
•
Press Pause to halt printing. Any message being printed will finish before printing is halted.
•
Press Continue to resume printing. Print will resume on the next photocell trigger.
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Thermal Jet
Section 3: User Interface
Print Button:
•
•
Press Print to select a message to print.
Select the desired message and press the Print button.
The message will print at the next photocell trigger.
Cancel Print Button:
•
Press the Cancel Print button to remove the current message from the print head(s) and stop print.
Connectivity Indicator:
•
Indicates the controller is electronically connected to and communicating with the print heads.
•
Indicates the controller is electronically disconnected and is not communicating with the print
heads.
Status Button:
•
Press the Status Button to display the Status Screen. The Status Screen displays:
- Controller firmware version number.
- Fonts and Logos present on the selected print head.
- Product Detect status.
- Printing status. Indicates the presence of a print message on the selected print head.
- Ink Type, if applicable.
- Current Date and Time, as reported by the selected print head’s clock.
- Print head firmware version number.
Current Print Head selected
Product
Detect
Print Status
Controller Firmware Version.
Press version number to display
detailed version information.
Ink Type
Date & Time
Fonts and Logos
Selected
Task
Print Head Firmware Version
Return to Home Screen
Zoom:
•
•
Expands the message window to full screen and magnifies the print message so that fine details
may be seen.
Press once to zoom in; press again to zoom out.
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Thermal Jet
Section 3: User Interface
More... Menu Button:
(See “The Apps Screen” on
page 24.)
To turn the controller on, touch
anywhere on the touchscreen.
Fires all jets for a
short period of time
on the selected
print head.
(See“Step 7: Configure
the Print Head” on
page 10.)
Returns to Home Screen
Displays count of all products printed.
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Thermal Jet
Section 3: User Interface
Message Editor
Message Button:
•
•
•
•
Press the Message
Button on the Home
Screen to bring up the
message screen.
To create a new message press the New
button.
To edit an existing
message, select the
message and then
press the Open button.
Both editing a message and creating a
new message will
bring up the message
editor.
Back
Open
Delete Message
Carton Ruler
New Message
Next Field Button
Message Display Area
Field Properties
Date Code
Time Code
Font Selection
Cursor
Zoom
Message Info
Cursor or Field
Coordinates
On-screen
Keyboard
Text
Menu
Quick Save
Delete
Button
Product Setup
Product Side
Count Code
Variable Field
Logo
Thermal Jet Operations Manual Rev B
Line Field
Bar Codes
Page 17
Thermal Jet
Section 3: User Interface
Time, Date, and Count Codes
Expands and
collapses
Count Options
Thermal Jet Operations Manual Rev B
Page 18
Thermal Jet
Section 3: User Interface
User Defined Time Codes
When User Defined is
selected, Define Time
Code button appears.
Sequential format: minute code shown.
Minute 00 = AA, 01 = AB, 02 = AC, etc.
Tabular format: codes printed taken from
table. Use default codes (default Hour
codes shown) or edit table to suit your
requirements.
Thermal Jet Operations Manual Rev B
Periodic format: example above illustrates a shift code implemented by using
a periodic quarter hour code. ’A’ prints
from 23:30 -06:59, ’B’ from 07:00 - 15:29,
and ’C’ from 15:30 - 23:29.
Page 19
Thermal Jet
Section 3: User Interface
User Defined Date Codes
When User Defined is
selected, Define Date
Code button appears.
Sequential format: minute code shown.
Day 1 = A, Day 2 = B, Day 3 = C, etc.
The Fortnight
code type is
available for the
Tabular format
only.
Tabular format: codes printed taken from
table. Use default codes (default Day
codes shown) or edit table to suit your
requirements.
Thermal Jet Operations Manual Rev B
Periodic format: example above illustrates a quarter year code implemented
by using a periodic month code. ’Q1’
prints from Jan 1 - Mar 31, ’Q2’ from
Apr 1 - Jun 30, etc.
Page 20
Thermal Jet
Section 3: User Interface
Product Counts, Variable Fields, Logos
Scroll through
logo images or
select from list
Maximum
9-digit count
Incrementing Count
Count increments when
the ’Start at’ value is less
than the ’Stop at’ value.
Decrementing Count
Count decrements when
the ’Start at’ value is
greater than the ’Stop at’
value.
Variable Field Data Source
User: Print data entered when
print message containing the
variable field is selected to
print.
COM1, COM2: Data is
received through COM1 or
COM2 serial port. Data must
be received before the message is selected to print.
Data 1-10: Data is retrieved
from corresponding system
variable. User has the option to
change the data when the
message is selected to print.
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Thermal Jet
Section 3: User Interface
Barcodes, Lines, Product setup, & Menu
Reverts message
to the last saved
Clears
contents of
message
editor
Calculates
estimated
ink usage for
the contents
of the editor
Exits the editor
to the home
screen
Prints the contents of
the editor on the next
photocell trigger
Quick save
of current
message
Increase or
decrease
barcode
height
Increase or
decrease
barcode
width
Increase or
decrease value
of selected
property
Enter line height
and width
Thermal Jet Operations Manual Rev B
Page 22
Thermal Jet
Section 3: User Interface
Message Info Box
Task number & message name
Estimated prints
per ink cartridge
Product length &
left margin settings
Zoom
•
Increases message size
•
Returns message to original size
Delete Button
•
Deletes the selected field.
Direct Entry of Cursor or Field Position
Direct Entry Box
Field: selecting the
Direct Entry Box
while having a field
selected will allow
the user to manually
input the X & Y
location of the
selected field
Cursor: When no
fields are selected
the Direct Entry Box
will allow the user to
manually input the
X & Y location of the
cursor
Thermal Jet Operations Manual Rev B
Print Head
Number
Page 23
Thermal Jet
Section 3: User Interface
The Apps Screen
See “Time, Date, and
Rollover Time Screen”
on page 25
Return to the
Home Screen
Network Settings
See “User Access”
on page 25
Thermal Jet Operations Manual Rev B
Select Background color
Page 24
Thermal Jet
Section 3: User Interface
Time, Date, and Rollover Time Screen
Set the controller’s time
and time format
NOTE: The 12 hour/24
hour format option applies
to controller functions; it
does not apply to time
codes in print messages.
Press "OK" to
return to the
Apps Screen
User Access
Controls within this box set the user access level.
Buttons outside the box mirror the Home Screen
and indicate which functions are password protected and which are open.
Padlock symbol indicates function
is password protected.
The factory set password is Manager.
Passwords are case sensitive.
Note: Users can either select a pre-defined access level from the list, or they can select
"User Defined" and customize their permissions by touching icons on the User Access
screen.
Thermal Jet Operations Manual Rev B
Page 25
Thermal Jet
Section 4: Maintenance & Shutdowns
Section 4: Maintenance & Shutdowns
Pen Cartridge Maintenance
Porous Inks:
• Daily Maintenance: Prior to shift startup, the cartridge orifice
array should be cleaned of any debris or ink build up. See Daily
maintenance procedure.
•
Shutdowns of one day or more: for extended shutdowns, follow the daily maintenance procedure, remove the pen cartridge
from the print head and store in a cartridge boot cap (5780-208).
•
Bulk Ink System: a properly maintained bulk ink pen cartridge
can maintain acceptable print quality for up to one 350ml ink cartridge. However, there are several factors that can affect print quality:
A. The amount of time it takes to consume 350ml of ink: The
longer it takes to consume 350ml of ink the more difficult it is to maintain acceptable
print quality. Bulk ink is designed for high throughput applications and is not suitable
as a means of reducing ink cost in low throughput application. If ink cost is an issue
then consider printing in draft mode. Draft mode produces a lighter mark but the
resulting ink cost is comparable to using a bulk ink system.
B. Daily maintenance: If daily maintenance isn’t performed, then print quality will
degrade before 350ml of ink has been consumed.
C. Capped during shutdowns: If the cartridge is not properly capped during down
times, then print quality will degrade over time.
D. Environmental conditions: Hot and/or dry environments are the most challenging
to maintain print quality. This is due to low humidity pulling solvent out of the ink,
which leads to a hard plug in the nozzle. No amount of purging or wiping can
recover a hard plug. To combat this scenario, the pen cartridge must be capped
during down times.
E. Air currents around the print head: Air flow across the front of the print head can
contribute to ink drying in the nozzles.
Non-Porous Inks:
• Daily maintenance: prior to shift startup, the cartridge orifice array should be
cleaned of any debris or ink build up. See Daily Maintenance procedure.
•
Shutdowns of one hour or more: For short term or extended shutdowns, follow
the daily maintenance procedure, remove the pen cartridge from the print head and
store in a cartridge boot cap (5780-208).
•
Leading edge print quality: Poor print quality on the leading edge of print can be a
result of the fast drying qualities of non-porous ink. This is caused by the shortened
decap time associated with non-porous ink. To resolve this issue two or more primer
bars (lower case L’s) should be placed at the leading edge of the print message. This
will prime the print cartridge so the necessary message content has acceptable print
quality.
Thermal Jet Operations Manual Rev B
Page 26
Thermal Jet
Section 4: Maintenance & Shutdowns
Daily maintenance procedure
Requirements:
• Deionized or distilled water (DO NOT USE TAP WATER) for POROUS INK ONLY
• Sponge Swabs (p/n: 5760-832)
Procedure:
• For POROUS INK ONLY, lightly dampen sponge swab with deionized water.
• For NON-POROUS INK ONLY, hold sponge swab against orifice array of cartridge. Press and
hold the purge button on the rear of the print head for at least ten seconds. This will fire all channels of the ink cartridge and dampen the swab with ink. The ink will act as its own solvent for
cleaning.
• Rub up and down across the orifice face with light force several times with one side of the
sponge swab.
• Turn the swab over and make one final light rub stroke top to bottom.
• Immediately press and hold the PURGE button on the rear of the print head for 5-10 seconds to
re-prime the orifices. Because ink will eject during the channel purging, a piece of paper, cloth,
or comparable material can be held in front of the orifice array.
Do NOT hold the ink catch material against the orifice array as print quality will be
degraded.
• If print quality becomes unsatisfactory during any shift repeat this procedure.
Before cleaning
After cleaning
Wipe pen
cartridge face up
and down
several times.
Immediately
press and hold
the purge button
for 5-10 seconds.
PEN CARTRIDGE
CARTRIDGE BOOT CAP
Thermal Jet Operations Manual Rev B
Page 27
Thermal Jet
Section 5: Troubleshooting
Section 5: Troubleshooting
NO PRINT
System Symptom
Possible Cause
Actions
No print head power /
green LED on rear of print
head
•
•
Power Supply
AC Source
•
•
Check power supply light indicator.
Check for AC power source between power supply
input limits.
PURGE button on rear of
head does not appear to
work
•
Ink cartridge is damaged
or empty
Print head Board
•
•
Replace with new cartridge and repeat PURGE.
Replace print head printed circuit board or print head.
Print head purges but
won’t print desired message
•
•
Loose or missing cables
Controller or PC software
not configured for Serial
Print Head
Encoder Malfunction
Product not triggering
photocell.
•
•
Tighten or install all cables.
Ensure print heads are configured as serial. See “Section 2: Quick Start”, “Step 6: Cabling, Power, and Serial
Port Setup” on page 7.
Ensure encoder is installed and plugged into the last
print head in the daisy chain.
Ensure the product is within 1/4" of the front face of the
print head.
If an external photocell is installed, then validate the
setting from the Control Panels, System Setup, Task
Options tab.
•
•
•
•
•
•
POOR PRINT QUALITY
System Symptom
Print is foggy or light
Possible Cause
•
Actions
Print head is mounted
greater than an 1/8" away
from the substrate
There are large air currents near the print head
•
Pen cartridge face is dirty
Pen cartridge face is
damaged at the orifice
array
Pen cartridge is not properly seated in the print
head
•
Print that appears
•
smeared and/or debris is
building up on the pen cartridge.
Carton rubbing across the
front of the print head
•
Adjust print head distance or/and use roller retracting
bracketry to insure print head maintains proper distance to prevent damage to pen cartridge.
Unable to recover missing
channels and print quality.
Damaged cartridge
Poorly seated pen cartridge.
Inadequate cartridge
maintenance.
•
•
Replace pen cartridge.
Remove pen cartridge, clean pads of pen cartridge and
pogo pins in print head. Re-insert cartridge.
When a cartridge is not properly cleaned or capped
during down times the solvent in the nozzles evaporate
and can create a hard plug. Once a hard plug has
formed it is impossible to clear and the cartridge needs
to be replaced.
•
Print image is missing
channels or has multiple
fractures
•
•
•
•
•
•
Thermal Jet Operations Manual Rev B
•
•
•
•
Adjust the print head according to “Section 2: Quick
Start”, See “Step 4: Adjust Print Head to Substrate” on
page 5.
Locate print head in an area where there are minimal
currents or provide wind barriers.
Clean the pen face per “Daily maintenance procedure”
on page 27.
Replace damaged pen cartridge with new.
Remove cartridge and reinsert.
Page 28
Thermal Jet
Section 5: Troubleshooting
PRINT HEAD LED FUNCTIONALITY
System Symptom
Possible Cause
Actions
Red LED on steady
•
Pen cartridge ink level is
low.
•
Ready the next pen cartridge for installation.
Red LED is flashing slowly
•
Pen cartridge is out of ink
and significant print degradation is imminent.
A non-recognized cartridge is installed.
•
•
Prepare to install a new pen cartridge.
Install an original recognized cartridge.
Pen cartridge is missing
from print head stall.
Print head is calibrating a
new cartridge.
Print head is in thermal
protection mode.
•
•
Install or re-install the appropriate pen cartridge.
Allow the print head up to 30 seconds to calibrate a
new pen cartridge.
Pen cartridge is out of ink and the print head is self-protecting against excessive heating. Replace the appropriate pen cartridge.
•
Red LED is flashing fast
•
•
•
Thermal Jet Operations Manual Rev B
•
Page 29
Thermal Jet
Appendix A: Specifications
Appendix A: Specifications
1/2" Print Head:
6.23 in
[158.2 mm]
1.32 in
[33.6 mm]
5.30 in
[134.6 mm]
(BULK INK ONLY)
3.65 in
[92.6 mm]
0.87 in
[22.1 mm]
LOWEST
CHANNEL
2X M6 X 1.0 X x.16 in [4.06 mm]
PROVIDED FOR PRINT
HEAD MOUNTING
0.90 in [22.9 mm]
0.90 in [22.8 mm]
1.00 in [25.4 mm]
Weight: 1.3 lbs (.6 kg)
Enclosure: Anodized Aluminum and Stainless Steel
Electrical:
15 VDC from power supply to print head
Power Supply: 90-260 VAC, 50/60 Hz, 1.5 A max. (per power supply)
Print Speed: 200 fpm, 300 dpi continuous
Print Resolution: 300 dpi
Throw Distance:
Recommended Gap:
Maximum Gap:
Porous Ink
.1 in (2.5 mm)
.25 in (6.3 mm)
Non-Porous Ink
.08 in (2.0 mm)
.15 in (3.8 mm)
Print Head Orientation: From horizontal to straight down.
Print Head Tilt:
+/- 45° from vertical for standard print cartridge
+/- 90° from vertical for Bulk Ink print cartridge
45°
45°
Number of Print Fields:
Maximum 5 lines of print per print cartridge at any given point.
Each print line may have at most three (3) 52-character print
fields; number of fields per line increases as the number of
characters per field decreases.
File Storage:
Twenty-seven 256kB sectors per print head are available for
PRINT HEAD TILT
font and logo file storage. Files larger than 256kB use multiple
sectors. Factory installed fonts occupy 8 of the 27 sectors.
Five factory installed fonts: Arial 30, 75, 150, 225, and 300 (0.1 in / 2.54 mm, 0.25 in / 6.35 mm, 0.5
in / 12.7 mm, 0.75 in / 19.05 mm, 1.0 in / 25.4 mm).
Bitmap (logo) files: 150 dots tall max (.5 in / 12.7 mm); 32,767 columns wide max (109 in / 2.79 m at
300 dpi).
Environment:
Ambient operating temperature: 50°F to 104°F (10°C to 40°C); operating humidity: 10% - 80% RH
Ink Type: Dye, Pigmented, or Solvent base hp 45 cartridges
Thermal Jet Operations Manual Rev B
Page 30
Thermal Jet
Appendix A: Specifications
1" Print Head:
2.43 in
[61.8 mm]
6.20 in
[157.4 mm]
5.81 in
[147.5 mm]
(BULK INK ONLY)
4.13 in
[104.9 mm]
1.38 in
[35.2 mm]
0.90 in
[22.8 mm]
1.00 in
[25.4 mm]
2X M6 X 1.0 X.16 in [4.06 mm]
PROVIDED FOR PRINT
HEAD MOUNTING
0.87 in [22.1 mm]
LOWEST
CHANNEL
Weight: 2.1 lbs (1.0 kg)
Enclosure: Anodized Aluminum and Stainless Steel
Electrical:
15 VDC from power supply to print head
Power Supply: 90-260 VAC, 50/60 Hz, 1.5 A max. (per power supply)
Print Speed: 200 fpm, 300 dpi continuous
Print Resolution: 300 dpi
Non-Porous Ink
Porous Ink
Throw Distance:
.08 in (2.0 mm)
Recommended Gap: .1 in (2.5 mm)
.25 in (6.3 mm) .15 in (3.8
Maximum Gap:
mm)
Print Head Orientation: Horizontal to straight down.
Print Head Tilt:
+/- 45° from vertical for standard print cartridge
+/- 90° from vertical for Bulk Ink print cartridge
Number of Print Fields:
Maximum 5 lines of print per print cartridge, 10 total
for the print head, at any given point. Each print line
may have at most three (3) 52-character print fields;
number of fields per line increases as the number of
characters per field decreases.
45°
45°
PRINT HEAD TILT
File Storage:
Twenty-seven 256kB sectors per stall are available for font and logo file storage. Files larger than
256kB use multiple sectors. Factory installed fonts occupy 8 of the 27 sectors.
Five factory installed fonts: Arial 30, 75, 150, 225, and 300 (0.1 in / 2.54 mm, 0.25 in / 6.35 mm, 0.5
in / 12.7 mm, 0.75 in / 19.05 mm, 1.0 in / 25.4 mm).
Bitmap (logo) files: 300 dots tall max (1.0 in / 25.4 mm); 32,767 columns wide max (109 in / 2.79 m
at 300 dpi).
Environment:
Ambient operating temperature: 50°F to 104°F (10°C to 40°C)
Operating Humidity: 10% - 80% RH
Ink Type: Dye, Pigmented, or Solvent base hp 45 cartridges
Thermal Jet Operations Manual Rev B
Page 31
Thermal Jet
Appendix A: Specifications
Bulk Ink Supply:
11.68 [296.6]
11.00in [279.4mm]
1.00in [25.4mm]
1.89in [48.1mm]
3.75in [95.3mm]
1.00in [25.4mm]
6.00in [152.4mm]
3.50in [88.9mm]
3X M8 X 1.0 X .20 in [5.1mm]
PROVIDED FOR INK SUPPLY MOUNTING
.45in [11.4mm]
Weight
4.2 lbs (1.9 kg) without ink cartridge
5.4 lbs (2.5 kg) with ink cartridge
Enclosure
Powder-coat painted steel
Mounting
Modular brackets included
Electrical
15 VDC from power supply to print head
Power Supply: 90-260 VAC, 50/60 Hz, 1.5 A max. (per power supply)
Normal Operating Pressure Range
4 psi to 5 psi
Cable Ports
(1) 15 VDC power supply jack
(1) Handheld controller connector
(1) Print head connector
(1) Photocell connector
(1) Encoder connector
(1) Beacon connector
Plumbing Port
(1) Pressurized ink outlet to print heads
Environment
Ambient operating temperature: 50°F to 104°F (10°C to 40°C)
Operating Humidity: 10% - 80% RH
Tubing Limitations
Maximum horizontal tube length = 10 ft (3 m)
Maximum vertical tube length = 3 ft (1 m)
Print Head Limitations
One daisy chain per Bulk Ink Supply; each daisy chain may have up to 8 print head cartridge stalls (eg: eight 1/2" Print Heads; four 1" Print Heads; four 1/2" Print Heads with two
1" Print Heads)
Ink Type
Dye base
Thermal Jet Operations Manual Rev B
Page 32
Thermal Jet
Appendix A: Specifications
Handheld Serial Controller
Size
Weight: .50kg [1.1lb]
Height: 133.4mm [5.25in]
Width: 240.0mm [9.45in]
Depth: 39.4mm [1.55in]
Enclosure
Black ABS Plastic
Electrical
15 VDC Supplied from print head power
supply: 90-260 VAC, 50/0 Hz, 1.5A max.
Environment
Ambient operating temperature: 40°F to
104°F (5°C to 40°C)
Operating humidity: 10% - 90%, non condensing
User Interface
Type: Graphical User Interface
keyboard: on screen QWERTY
Display
7in [178mm] LCD with touch screen,
800 X 480 pixels
Fonts
Unicode
Storage
512 MB flash memory
Ports
(2) RS-232 Ports, (1) USB Port
(1) 100 base-T Ethernet Port
Thermal Jet Operations Manual Rev B
Page 33
Thermal Jet
Appendix A: Specifications
System Interconnect Diagram
USB
P1
VBUS
1
D- 2
D+3
GND
4
N/C1
N/C6
RX 2
N/C7
TX 3
N/C8
N/C4
N/C9
GND
5
COM 1
P5
Thermal Jet Operations Manual Rev B
ETHERNET
N/C8
N/C7
6
TPRXN/C5
N/C4
3 +
TPRX
TPTX2
TPTX+
1
P7
P3
N/C1
N/C6
RX 2
N/C7
TX 3
N/C8
N/C4
N/C9
GND
5
COM 2
Handheld Controller CPU Board
Page 34
Thermal Jet
Appendix B: Theory of Operation
Appendix B: Theory of Operation
Thermal Jet Print Heads
TIJ Technology
The print head uses Thermal Ink Jet (TIJ) technology as implemented on the hp® 45A cartridge. TIJ technology works by rapidly heating the ink. As the ink heats it expands and is
ejected from the print cartridge orifices. Because the individual orifices are very small,
many more can be compacted in the same amount of space as conventional print technologies. With more orifices per vertical inch / millimeter, a much higher resolution image can
be produced.
Similarities and Differences
A print head can operate stand-alone or in concert with other print heads connected one to
another in a daisy chain configuration. Up to eight 1/2" Print Heads or four 1" print heads
can be daisy chained. Print heads can be controlled by the Handheld controller, from a PC
or laptop using the included InkJet Demo software interface program, or by a user developed application.
Print heads can print up to five lines of print, using any combination of the various print field
types supported, including fixed text, date/time codes, product counts, variable fields,
logos, and a variety of bar codes, including Data Matrix 2-D codes.
Unlike other inkjet technologies, these print heads store and process the currently printing
message internally. This allows the print heads to be disconnected from the controlling
device and operate "stand alone" once the print information has been uploaded to the
heads. However, print head and print message status is unavailable to the the controlling
device once the print heads are disconnected.
Ink Cartridge Ink Status
Each ink cartridge contains approximately 42 mL of ink and has been programmed to make
full use of the Smart Level Ink Detection System. When a new cartridge is snapped into
a print head it is given an identity code so that its ink level may be monitored. As the ink
depletes to 10% ink remaining, an "Ink Low" condition occurs and the red LED on the rear
of the print head turns on steady. The red LED changes to slow flashing, indicating "Ink
Out", when there is minimal ink remaining, and significant print degradation is imminent.
Ink status is reported back to the Handheld controller or InkJet Demo software as long as
they are connected to the print head daisy chain.
Thermal Jet Operations Manual Rev B
Page 35
Thermal Jet
Appendix B: Theory of Operation
Handheld Controller
Functional Description
The Handheld and Thermal Jet System prints text, autocodes (such as product counts or
time and date stamps), bar codes, and/or graphics onto products as they travel by conveyor past stationary print heads. Print can be on any one of, or a combination of, the product's sides. Print speed is controller by a conveyor mounted encoder or a built-in fixed
speed encoder. Products are detected using a photosensor. A graphical user interface with
color LDC, touch screen, and on-screen keypads provides for easy and intuitive system
operation.
Power
The Handheld Controller draws its power through either one of its two serial port connectors from the print head directly attached to the connector, or in applications where the
optional accessory hub or Bulk Ink System is used, from the hub or ink system.
Battery Backup - A 3V battery on the CPU Board maintains the contents of system SRAM
and keeps the real time clock running during power outages or when the Handheld controller is not plugged into a power source.
Please note that power is applied to the Handheld even when it is "turned off." When
turned off, the controller enters a sleep mode where it responds to nothing but a touchscreen touch. All voltages are present while sleeping. The only way to completely remove
power is to unplug the unit.
Handheld Controller Power & Cabling Diagrams
Single Task: The Handheld controller draws its power from the print head, and the COM1
port is connected to the output connector of the last head in the daisy chain.
Handheld Controller
HH Controller Cable
P/N 5780-616-06
DB9 F-F
Print Head Cable
P/N 5780-319-06
DB9 M-F
Thermal Jet Operations Manual Rev B
Power Supply 15V
(P/N: 5760-930)
Page 36
Thermal Jet
Appendix B: Theory of Operation
Single task with accessory hub: The Controller draws its power from the accessory hub,
and is plugged into the ’handheld’ connector on the accessory hub; the accessory hub is
plugged into the output connector of the last print head in the daisy chain.
Handheld Controller
HH Controller Cable
P/N 5780-616-06
DB9 F-F
Print Head Cable
P/N 5780-319-06
DB9 M-F
Thermal Jet Operations Manual Rev B
Power Supply 15V
(P/N: 5760-930)
Power Supply 15V
(P/N: 5760-930)
Page 37
Thermal Jet
Appendix C: File Backup and Restore
Appendix C: File Backup and Restore
From a PC
Use these procedures for making archival copies of the system configuration and print
message files, and for preserving the system's configuration and print messages during
firmware upgrades. File types saved during a backup are .cfg, .prd, .bmp and .alp. These
are the system configuration files, message files, logo files and label files, respectively.
These instructions assume the Handheld Controller is already connected, via Ethernet, to a
PC. If not, please refer to “Appendix D: Configuring a PC to Communicate with the Handheld” on page 42.
1. Obtain the Controller's IP address. Most controllers have an IP address of 10.1.2.3. It
may be different if the controller is networked with other Handhelds or other devices. If
the IP address is unknown, go to the controller, and from the Home Screen:
• Open the menu and touch the Apps button to go to the Apps Screen.
• Touch the Network button on the Apps Screen to open the Network Setup Screen.
• Touch the IP Addresses tab to display the system's IP addresses.
• Record the Controller’s IP address (it's the top one).
2. On the PC, start Microsoft Internet Explorer (must be version 3.2 or higher) or another
web browser.
3. In the browser's address box type in "http://", followed by the controller's IP address.
See the illustration below:
4. Press Enter. The web page shown below should appear.
Thermal Jet Operations Manual Rev B
Page 38
Thermal Jet
Appendix C: File Backup and Restore
File Backup
To backup the system files, click the
Backup files link.
The
dialog
box
shown at right (or a
similar dialog box)
will appear.
Click the Save button. A Save As dialog appears.
The files backed up are compressed and put into a single file, and are given the default
name and file extension backup.tgz. Following normal Windows® conventions, the
backup file may be renamed and given any extension, and saved in any folder desired. To
save the backup file with an extension other than .tgz, open the Save as type combo box
and select All Files.
Thermal Jet Operations Manual Rev B
Page 39
Thermal Jet
Appendix C: File Backup and Restore
Restoring Backed-Up Files
To restore the controller’s backed up system files, click the Restore files from backup
link. The web page shown below appears.
Click the Browse... button to locate and select the backup file to be sent to the controller.
Click the Restore button to send the file to the controller. If the file transfer is successful,
the web page shown below will be displayed.
Thermal Jet Operations Manual Rev B
Page 40
Thermal Jet
Appendix C: File Backup and Restore
From a Controller
Backup
1. Insert a USB jump drive
into the USB port on the
controller.
2. From the home screen
touch Apps Button
then Utilities.
3. From the Utilities
screen select Backup.
4. Enter a file name at the
Backup dialog popup
("Backup"
is
the
default name) and
press Save.
5. From the System Utilities screen select
Safely remove USB
memory.
Apps Button
Utilities
Restore
6. Insert a USB jump
drive into the USB port
on the controller.
7. From the home screen
touch Apps Button
then Utilities.
8. From the Utilities
screen select Restore.
9. Select the appropriate
backup file from the
Restore dialog popup
and press Open.
10. From the System Utilities screen select
Safely remove USB
memory.
11. Restart controller for
new settings/backup to
take effect.
Thermal Jet Operations Manual Rev B
Apps Button
Utilities
Page 41
Thermal Jet
Appendix D: Configuring a PC to Communicate with the Handheld
Appendix D: Configuring a PC to Communicate with the Handheld
This appendix has instructions for setting the IP address and subnet mask of the PC so it
can communicate with the Handheld Controller. Included are instructions for Windows XP®
and Windows 7®.
Windows XP®
1. Open the Start menu; select Settings, then Network Connections.
2. Click Local Area Connection, then open the File menu and select Properties.
Thermal Jet Operations Manual Rev B
Page 42
Thermal Jet
Appendix D: Configuring a PC to Communicate with the Handheld
3. Select Internet Protocol
(TCP/IP) then click the
Properties button.
4. Click the Use the following
IP address radio button.
Enter an IP address of
10.1.2.4, a subnet mask of
255.255.255.0, and click
the OK button.
Thermal Jet Operations Manual Rev B
Page 43
Thermal Jet
Appendix D: Configuring a PC to Communicate with the Handheld
Window 7®
1. Open the Start menu; select Control
Panel; then Network and Sharing Center.
3. Select Internet Protocol Version 4
(TCP/IPv4). Then click the Properties
button.
2. Click Local Area Connection, then click
Properties button.
4. Click Use the following IP address
radio button. Enter and IP address of
10.1.2.4, a subnet mask of
255.255.255.0, and click the OK button.
Thermal Jet Operations Manual Rev B
Page 44
Thermal Jet
Appendix E: Font Samples
Appendix E: Font Samples
Arial 30 - 1/10 in (2.54 mm):
Arial 75 - 1/4 in (6.35 mm):
AaBbCcDdEeFf
1234567890
AaBbCcDdEeFf
1234567890
Arial 150 - 1/2 in (12.7 mm):
AaBbCcDdEeFf
1234567890
For best results printing the next two fonts use an external encoder. The top images were
printed with an external encoder. The lower images were printed using the "Auto Speed
Detect" mode (without external encoder) from the controller or InkJet Demo software.
Arial 225 - 3/4 in (19.05 mm):
Arial 300 - 1 in (25.4 mm):
Thermal Jet Operations Manual Rev B
Page 45
Thermal Jet
Appendix F: Creating Logo Files
Appendix F: Creating Logo Files
Open Paint from a PC by selecting Start, All Programs, Accessories, and then
Paint.
Navigate to the Image Properties dialog box via the
drop down menu.
Thermal Jet: Enter the Width and Height of the logo in
Pixels. For practical purposes the maximum height of a
logo is 150 pixels if the logo is prined with a 1/2" print
head, and 300 pixels if printed with a 1" print head. The
absolute maximum logo height is 1200 pixels, but
logos that cross print head boundaries will likely exhibit
registration problems when printed. Maximum logo
width is 32,767 pixels, or print columns (109.22 in / 2,774 mm when printed at 300
dpi.)
Select Black and white for the Colors.
Draw the pixels of the logo using the drawing tools. See the example below.
Next, click the Rotate button;
Rotate Left 90° (CCW 90°).
From the File Menu, select Save As and save the
logo with a convenient name and directory location.
NOTE: If this logo is imported from another document or software, make sure that the first step
taken is to Save As a Monochrome Bitmap (bmp),
and then Resize to the appropriate height.
Thermal Jet Operations Manual Rev B
Page 46
Thermal Jet
Appendix G: Controller and Print Head File Management
Appendix G: Controller and Print Head File Management
File Manager
NOTE: A .bmp (logo) or .fnt (font) file must reside on both the controller and
print head(s) to be correctly selected, displayed, and printed. Ensure the file
names are less than 15 characters long.
1. If logo or font files are to be transferred, place them on a portable USB storage
device in a convenient location and insert it into the controller USB port.
2. Touch the Apps button on the Home screen menu, and then select the Utilities
button.
Utilities Button
3. Scroll to the bottom of the Select Function list and select File manager. Press
the Do Function button; the File manager screen is displayed.
Scroll Up
Close Folder,
Go Up One
Level
Open Folder
Scroll down
Cut
Copy
Delete
Paste
The home folder contains all folders and files related to controller operation.
The Task:1 and / or Task:2 folders contain all font and logo files resident on the
print head(s) in that daisy chain.
The usb0 folder contains all folders and files resident on the USB storage device.
NOTE: Cut, Copy, Paste, and Delete function the same way as any software.
Navigate to any file in any of the folders and perform the desired function. In
addition, however, files are not allowed to be copied from any task (the print
heads).
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Appendix G: Controller and Print Head File Management
Transferring Logo and Font Files
NOTE: Files cannot be transferred to the print head while printing. Pause
print first.
On the controller, logos are stored in the /home/bmps folder, and fonts are stored in the
/home/fnts folder. Files are automatically placed in the correct folders when transferred to
the controller from a PC using a web browser; they must be manually placed in the correct
folder when being transferred from a USB drive using the copy-and-paste method.
Uploading a file to a print head loads the file on all print heads on the task. A step-by-step
example of uploading a logo file to task 1 print heads follows.
1. As shown in the "File Manager" section, make sure USB storage device is installed and
the File manager selection screen is present on the controller.
2. Select the usb0 folder and press the Open Folder button.
3. Navigate to a previously saved file, highlight the file and press the Copy button. The file
is now stored in temporary memory. In this example, a logo file will be transferred.
4. Press the Close Folder button, then the Go Up One Level button until the File manager selection screen is present.
5. Select the home folder, press the Open Folder button, and select the bmps folder.
Store logos in the bmps folder:
6. The display shows a list of available files. Select
and open the bmps folder:
7. Select the file to be uploaded to the print head(s)
and then touch the Copy button.
8. Close the bmps folder, returning to the home
folder level.
9. Close the bmps folder, returning to the top level.
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Appendix G: Controller and Print Head File Management
10. Select and open the Task:1 folder. The display shows a list of all files on print head #1
only; it is assumed that all print heads have
the same files.
11. Touch the Paste button. The file is uploaded
to all print heads on the task, after which the
file list is updated, showing the newly added
file.
While the file is uploading, an hourglass is
displayed, and the red LED on the back of
each of the print heads on the task’s daisy
chain blinks.
Removing a File
To remove a file from all print heads on a task:
1. Select and open the Task:1 folder.
2. Select the file to be deleted, then touch the
Delete button.
3. The file is deleted and the file list updated.
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Appendix H: Communicating Directly to the Print Head
Appendix H: Communicating Directly to the Print Head
The 1/2" (12.7 mm) and 1" (25.4 mm) print heads can be controlled by direct serial communication. Refer to the serial protocol document 5780-316N when communicating directly to
the print head without the use of a controller or the InkJet Demo software interface.
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Appendix I: Aligning the 1" (25.4 mm) Print Head
Appendix I: Aligning the 1" (25.4 mm) Print Head
NOTE: This procedure assumes that the user has already installed the equipment per the
installation procedure. (See “Section 2: Quick Start” on page 2.) In addition, an encoder
should be used for the best horizontal alignment between both print cartridges.
4. Ensure the front face of the print head is perpendicular to the
substrate being printed.
5. Create a message using the Arial 300 font and run a print sample with the actual product.
6. Observe the vertical overlap or gap between the two cartridges.
If there is significant overlap, loosen the mounting screws and
rotate the print head bracketry counter-clockwise. If there is a
gap between the halves, rotate the bracketry clockwise.
7. Snug the mounting screws and run another print sample. If the
overlap or gap is not acceptable, then repeat the previous step.
8. Repeat the previous two steps until the two cartridges are
matched vertically.
LOOSEN
THESE
SCREWS
9. Fully tighten the mounting hardware.
10. Now observe the horizontal alignment of the characters.
11. Horizontal misalignment can be
compensated electronically
through the controller or InkJet
Demo software program by navigating to Task Settings (System
Setup Screen) and then touching
the print head in question.
12. An adjustment box, labeled as A
to B offset adjustment, is available to compensate for any horizontal misalignment. Increase or
decrease the number in the box
and press Apply. Valid settings
are 310 to 350. The next print will
have adjusted the alignment one
way or the other. Repeat this step
until the desired horizontal alignment is achieved.
Thermal Jet Operations Manual Rev B
Press on this box to
highlight, and then enter
an adjustment value
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Appendix J: Bulk Ink Supply
Appendix J: Bulk Ink Supply
Wear safety goggles when working with industrial inks
and solutions!
WARNING: Disconnect power during installation.
!
!
CAUTION: Sudden impact to the installed print head
(caused by moving the conveyor with the print system
attached or moving the print system from one location
to another) can cause ink to seep out the front of the print cartridge. To keep this
from happening disconnect septum fitting, remove print cartridge, and depressurize
the bulk ink supply before moving the print system.
CAUTION: Failure to properly bleed the air from the ink lines before connecting the
septum fitting to the print cartridge could damage the print cartridge.
System Components
• Print Head
• Regulator
• Bulk Ink Supply
• Controller or PC (Handheld controller requires the optional Hub (below))
• Beacon (optional)
• Hub (optional)
Installation
1. Mount the print head(s), bulk ink supply, and controller (if applicable). Note: The bulk
ink supply can be a maximum of three feet above or below the print head(s). The regulator must be mounted on the same horizontal bar as the print head. See page 64 for
print down application.
Regulator
Print Head
1-1/4"±1/8"
For the system to function properly it is critical that the regulator be positioned appropriately in relation to the print head as shown.
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Appendix J: Bulk Ink Supply
2. Make ink line connections from the bulk ink supply to the regulator per the diagram
below; the trunk line should be made as short as practical. (CAUTION: Do not connect septum fitting to the print cartridge at this time.)
REGULATOR
(P/N: 5780-105)
ORIENT AS SHOWN
TUBING, 1/8" ID X 3/16"
OD (P/N: 1303-563)
FITTING ASSEMBLY, SEPTUM
TO 1/8" BARB (P/N: 5780-393)
BULK INK CARTRIDGE
BULK INK PRINT
HEAD 1
BULK INK PRINT HEAD 2
TUBING, 3/32 ID X 5/32 OD
(1303-564)
3" MAXIMUM VERTICAL
RISE FROM BULK INK
SUPPLY TO PRINT HEAD
FITTING, TEE, REDUCER,
1/8" TO 3/32"
(P/N: 5361-354)
TRUNK LINE
TUBING 1/8" ID X
1/4" OD
(P/N: 1301-468)
VALVE, QD TO
1/8" BARB
(P/N: 1900-757)
INK SERVICE
PORT
(P/N: 1900-757)
3. Make all electrical connections as shown, including all power connections per the
diagram below.
BULK INK CONNECTIVITY
CONTROLLER
INK STATUS
BEACON
(P/N: 5780-214)
CABLE, SERIAL, F/F
(P/N: 5780-616-06)
CABLE, SERIAL
(P/N: 5780-319-10)
ENCODER
(P/N:5760-820-10)
BULK INK
SUPPLY
PHOTOCELL
(P/N: 5760-383)
PRINT HEAD
POWER SUPPLY
(P/N: 5760-930)
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Appendix J: Bulk Ink Supply
4. Insert print cartridges into the print heads and a 350 ml ink cartridge in the bulk ink
supply.
5. Bleeding air out of the ink lines:
Valve
a) At the ink service port of the trunk line, depress the valve
of the fitting in short spurts into a rag or trash can. Continue this until all air has been bled out of the main trunk line.
b) Connect the syringe
(2466-166,
supplied
with the bulk ink system) to the septum fitting. While holding the
syringe and tubing
above the regulator,
slowly draw the air out
of the ink line. Once all
of the air is out of the
ink line and a small
amount of ink is drawn
into the syringe, disconnect the syringe
and plug the septum
fitting into the print cartridge. Repeat for each
regulator.
Syringe
Septum fitting
Regulator
Pressure relief valve
Print head
Bulk Ink Supply
Trunk line
Configuring system for bulk ink supply
At the controller (or PC software) on the Task Settings (System Setup) screen, select the
Task Options tab, and then select the Uses bulk ink supply check box.
Task Options tab
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Appendix J: Bulk Ink Supply
Setup for print down application
The bracketry that comes standard with
the print head does not accommodate a
print down setup. A separate bracket kit
(5780-227) is available to allow for a print
down setup. This kit includes tubing and
fittings for extending the tubing between
the regulator and print head. If only the
tubing and fittings are needed then tubing
kit 5780-211 can be used. This kit
includes enough tubing and fittings to
accommodate five half inch print heads or
two one inch print heads.
1. Mount the print head and regulator. The regulator must be positioned appropriately
in relation to the print head (see figure). If the regulator is positioned too high with
respect to the print head then ink may seep out of the print head. If this occurs simply lower the regulator until it is positioned properly.
Print head
Regulator
5-1/4"±1/2"
5/16"±1/2"
Carton being printed on
Conveyor
2. It will be necessary to splice in a length of tubing between the regulator and print
head (see image below). This should be done before bleeding air out of the ink
lines.
Septum fitting
Fitting, straight through,
1/8" barbs (5361-315)
Regulator
Tubing, 1/8" id x 1/4" od
(1301-468)
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Appendix J: Bulk Ink Supply
90° Tilt Setup
The bulk ink supply allows the print head to be tilted 90° from vertical versus the 45° limitation with a standard print cartridge. The relative positioning between the reservoir and print
head needs to be maintained for the print head to function properly. Standard bracketry
may be used to mount the print head in this orientation, however it may be necessary to
extend the tubing between the reservoir and print head (reference the print down setup for
instructions).
1/ 8±1/ 4
TJ500
TJ1000
Operation
● Operating pressure of the bulk ink supply is 4-5 psi. Once pressure drops below 4 psi the air
pump will turn on and pressurize the ink supply up to 5 psi.
● If the pump can not achieve 5 psi after running for 15 seconds the system goes into an "Ink
Low" state (beacon will turn on solid) indicating the 350 ml ink cartridge is empty. The print
heads will continue to print because there is still ink in the print head cartridges; this allows
ample time to change the 350 ml ink cartridge.
● Changing the 350 ml bulk ink cartridge:
○ Press the pressure
relief valve on the
back of the bulk ink
system to depressurize the ink cartridge.
○ Push in and up
slightly on the cartridge to release it
from the holster.
○ Insert the new cartridge. The system
will detect the new
cartridge and begin
pressurizing automatically.
● Maximum print heads
per ink system: four 1"
print heads, eight 1/2”
print heads, or any combination of the two totaling eight print cartridges.
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●
Appendix J: Bulk Ink Supply
A red LED on the rear panel of the Bulk Ink Supply, and an optional beacon, indicate the system’s operational status:
○ LED/beacon is off - system is operating normally.
○ LED/beacon is on steady - normal system operating pressure (5 psi) was not achieved
after 15 seconds of continuous pressure pump operation and the pump has shut down. It
indicates that the ink cartridge is empty and needs to be replaced. The pump will automatically restart when the cartridge is replaced or power is cycled off and on.
○ LED/beacon is blinking rapidly - the system has experienced a rapid loss of pressure,
possibly due to a break in an ink line, and has shut down.
○ The LED repeatedly blinks rapidly for one second, then goes out for one second, blinks
for one second, goes out for one second, etc.; the beacon continuously blinks rapidly with
one second "off" periods - indicates a missing ink cartridge or the cartridge is not being
detected by the system.
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Appendix K: Part Numbers - Consumables and Service Parts
Appendix K: Part Numbers - Consumables and Service
Parts
Consumables
Ink Cartridge: The TJ print head has been engineered and designed to work with Diagraph ink cartridges. The TJ Smart Level Ink Detection System, which provides ink level monitoring to ensure
complete ink usage and product safety, will not be functional if used with non-Diagraph ink cartridges.
Inks
Part No.
Description
5780-201
5780-201-R
5780-202
5780-212
5780-261
5780-235
5780-220
TJ PM Porous Media, Black
TJ PM Porous Media, Red
TJ PMX Porous Media, Black, Extended Decap
TJ NPM Non-Porous Media, Black
TJ NPMX Non-Porous Media, Black, Extended Decap
TJ PBC Porous Media, Barcode, Black
TJ PM Porous Media, Bulk Ink, Black
5780-219
Package
Shelf Life
1 year
5 Cartridges
6 months
1 year
One 350ml Ink
Cartridge
TJ M Porous Media, Bulk Ink, Black
Service Parts
TJ500
Item
Kit No.
Description
1
5760-302
2
5780-002
Power Supply, Print Head
TJ500 Complete Print Head Kit with Mounting Bracketry, Power Supply, Data Cable, & PC Software
Cover, Enclosure, TJ500 Print Head, Standard
Cover, Enclosure, TJ500 Print Head, Bulk Ink
PCB Replacement Set
Print Head Replacement, Standard
Print Head Replacement, Bulk Ink
Boot, Cartridge Cap
Cable, Print Head, 10’
Extension Cable, Print Head, 25’ (not shown)
Extension Cable, Print Head, 50’ (not shown)
Regulator Replacement, Bulk Ink
Upgrade Kit, Bulk Ink Print Head (Includes Item 3-bottom and Item 10)
3
4
5
6
7
8
9
10
11
5780-203
5780-203BI
5780-226
5780-205
5780-217
5780-208
5780-319-10
2464-182-25
2464-182-50
5780-231
5780-229
2
3
1
6
5
4
7
10
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Appendix K: Part Numbers - Consumables and Service Parts
TJ1000
Item
Kit No.
Description
1
5760-302
2
5780-007
Power Supply, Print Head
TJ1000 Complete Print Head Kit with Mounting Bracketry, Power Supply,
Data Cable, & PC Software
Cover, Enclosure, TJ1000 Print Head, Standard
Cover, Enclosure, TJ1000 Print Head, Bulk Ink
PCB Replacement Set
Print Head Replacement, Standard
Print Head Replacement, Bulk Ink
Boot, Cartridge Cap
Cable, Print Head, 10’
Extension Cable, Print Head, 25’ (not shown)
Extension Cable, Print Head, 50’ (not shown)
Regulator Replacement, Bulk Ink
Upgrade Kit, Bulk Ink Print Head (Includes Item 3-bottom & 2 ea. Item 10)
5780-225
5780-225BI
5780-221
5780-215
5780-218
5780-208
5780-319-10
2464-182-25
2464-182-50
5780-231
5780-228
3
4
5
6
7
8
9
10
11
2
3
4
1
5
7
6
10
BIS350
Item
Kit No.
1
2
3
4
5
6
7
5760-302
5780-216
5780-222
5780-223
5780-224
5780-209
5780-211
1
2
Description
Power Supply, 15VDC, Bulk Ink Supply
Replacement Bulk Ink Supply
Internal Tubing and Fitting Replacement
Vacuum Pump Replacement
PCB Replacement
Septum Fitting Replacement
External Tubing and Fittings (not shown)
3
4
5
6
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Appendix K: Part Numbers - Consumables and Service Parts
IJ3000-HH
Item
Kit No.
1
2
3
4
5780-017
5765-227
5765-228
5780-626
Description
IJ4000-HH Controller
Kit, Replacement Display, IJ4000-HH, 7"
Kit, Replacement CPU, IJ4000-HH
Battery (CR1220)
2
3
Bracketry
Item
Kit No.
1
2
3
4
5780-234
5780-200
5780-227
5780-230
Description
Bracketry, Mounting, Handheld Controller
Bracketry, TJ Print Head Mounting
Bracketry, Print Down
Bracket, Linear, Tool-less
1
2
3
4
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Appendix K: Part Numbers - Consumables and Service Parts
Optional Equipment
Encoder, Photocell, Accessory Hub, and Beacon
Item
Kit No.
1
5760-820-IJ
2
5765-206
Encoder O-ring Replacement
3
5760-383
Photocell
4
5780-010
Accessory Hub with Power Supply
5
5780-214
Beacon
2
Description
Encoder Assembly with Mounting Bracket & 25’ Cable
1
5
3
TYPICAL ENCODER
MOUNTING ON OPEN AREA
OF CONVEYOR BELT
4
TYPICAL PHOTOCELL MOUNTING
TYPICAL BEACON
MOUNTING
CONVEYOR
MOUNTING
BRACKETRY
MOUNTING
TYPICAL ACCESSORY
HUB MOUNTING
ACCESSORY HUB CONNECTIVITY
ENCODER
INK STATUS
BEACON
HANDHELD CONTROLLER
PHOTOCELL
ACCESSORY
HUB
PRINT HEAD
POWER
SUPPLY
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Appendix K: Part Numbers - Consumables and Service Parts
Roller & Retractor Bracketry
Item
Kit No.
Description
1
5780-206
Roller Bracket Only
2
5780-207
Roller and Retractor Bracket
Roller & Retractor Bracketry
Roller Bracket Only
Maintenance
Item
Kit No.
1
1901-398
Hand Cleaner, Reduran
2
5760-832
Sponge Swabs, Qty. 100
3
6600-171
Lint-free Wipe Cloths
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Description
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