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Macrojet 2
Product Manual
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Domino Macrojet 2 Product Manual

Domino Macrojet 2

Product Manual
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(2) 20509 Issue 7 Jan 2018
DOMINO MACROJET 2 PRINTER
PRODUCT MANUAL
For Pocket Terminal operating instructions, refer to Type 64 Terminal User's Pocket Book, Part No 20524.
Users of this printer are warned that it is essential to read, understand and act according to the information given in Part 1 : Health and Safety.
All rights reserved. No part of this publication may be reproduced, stored on a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Domino Printing Sciences plc.
Domino Printing Sciences plc. has a policy of continuous product improvement, the Company therefore reserves the right to modify the specification contained in this manual without notice.
© Domino Printing Sciences plc. 2018.
For sales, service and inks please contact:
Domino UK Ltd. Domino North America
Bar Hill 1290 Lakeside Drive Cambridge CB23 8TU Gurnee IL.60031 England U.S.A. Tel: 01954 782551 Tel: 847 244 2501 Fax: 01954 782874 Fax: 847 244 1421
20509 Issue 7 Jan 2018 (3)
CONTENTS of
EU DECLARATION OF CONFORMITY
No. Doc-0009847_R02
Manufacturers name: Domino UK Ltd.
Manufacturers Address: Bar Hill, Cambridge CB23 8TU
This declaration of conformity is issued under the sole responsibility of the manufacturer.
Object of the declaration: Domino Macrojet, from serial number
L21548
The object of the declaration described above is in conformity with the relevant Union harmonisation legislation:
2014/35/EU : Low Voltage Directive. 2014/30/EU : EMC Directive.
EN 60950-1:2006/A2:2013 Information technology equipment - Safety - Part 1:General requirements.
EN 61000-6-2:2005 Electromagnetic compatibility (EMC).
Part 6-2 Generic standards - Immunity for industrial environments.
EN 61000-6-4:2007/A1:2011 Electromagnetic compatibility (EMC).
Part 6-2 Generic standards - Emission standard for industrial environments.
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20509 Issue 7 Jan 2018 (5)

FCC Notice

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
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CONTENTS
PART 1 HEALTH AND SAFETY
PART 2 DESCRIPTION
PART 3 MAINTENANCE PROCEDURES
PART 4 FAULT FINDING AND REPAIR
PART A INSTALLATION
20509 Issue 7 Jan 2018 (7)

AMENDMENT RECORD

Amendment Date
All Parts at Issue 1 Feb 91 Following pages amended to Issue 2.0: July 91
Preface-7, 1-4, 1-5, 3-32, 4-11, 4-13, 4-17, 5-17, A2, A20. All pages at Issue 3 April 92 All pages at Issue 4 July 95 All pages at Issue 5 April 99 All pages at Issue 6 July 2011 All pages at Issue 7- Changes to voltage regulator Jan 2018
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PART 1 : HEALTH AND SAFETY

CONTENTS
Page
Introduction .......................................................................................... 1-3
Basic Requirements ......................................................................... 1-3
Storage ............................................................................................ 1-4
Fire Risk ........................................................................................... 1-4
Spillages and Disposal ..................................................................... 1-5
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HEALTH AND SAFETY
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HEALTH AND SAFETY
INTRODUCTION
Domino supplies Safety Data Sheets (SDS) giving specific safety information with each of its ink, make-up and wash fluids. There are also warnings on each container. The following notes are for general guidance only.
Basic Requirements
When used correctly, printing inks do not cause problems. However, everybody using them should be familiar with the appropriate safety standards and be aware of the precautions that should be taken. The following are basic requirements:
• Proper standards of industrial practice relating to cleanliness and tidiness must be maintained.
• Inks and their containers must be stored and handled with care.
• Do not smoke or allow naked flames (or other sources of ignition) in the vicinity of any inks or solvents as this is highly dangerous.
• All who come into contact with inks must be properly instructed in their use.
Directions for safe working practices vary according to the environment. The following are broad principles so that necessary precautions may be taken:
• Contact with the mouth must be avoided. Therefore eating, drinking or smoking, or any personal habits or actions which may transfer ink to the mouth, must be avoided.
• Contact with the eyes must be avoided. Suitable eye protection must always be worn whenever there is any risk of splashing or misting. If ink does get into the eyes, first aid treatment is to flood the affected eye for 15 minutes with saline solution, (or clean water if saline solution is not available), taking care not to allow the water to run into an unaffected eye. Medical aid must be obtained immediately.
• Most inks contain solvents which may injure the skin. Good working practice must always be employed and risk assessments carried out. Safety Data Sheets are available that give advice on personal protective equipment. Most gloves only offer limited and short term exposure protection and must be changed after any splashing and on a frequent basis.
• Many inks contain materials which vaporise easily and can be inhaled. Good ventilation and extraction is necessary.
• Any used cleaning materials, e.g. rags, paper wipes, are a potential fire hazard. They must be collected for safe disposal after use.
• After exposure to ink, all possible traces must be washed off as soon as possible at the nearest washing facility.
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HEALTH AND SAFETY
Certain inks are allowed for use where they can be in indirect contact with food. In these cases, the following precautions must be observed in addition to those appropriate to hygiene:
• The inks must only be used in printers supplied from new for use with these inks. Any repairs and replacements must use genuine, new and unused spare parts.
• The inks must not be used in printers which have previously been used, at any time, for any other purpose.
Storage
Printing inks must be stored in well-ventilated buildings, in areas set aside for the purpose, chosen for safety in case of fire. Materials based on volatile, flammable solvents must be stored in accordance with local regulations.
Fire Risk
For an electrical fire, do not use water. If water must be used, such as in the case of a Nitro-cellulose ink fire (see below) the power MUST BE REMOVED first.
Many inks contain Nitro-cellulose as the binder and remain highly flammable when dry. Observe all warnings given on the machine and the following safety instructions:
• If there has been an accumulation of dried ink, do not use metal scrapers to remove it, as they can produce sparks.
• If dry Nitro-cellulose based ink ignites, it will generate its own oxygen and can only be extinguished by lowering the temperature with water.
• If a Nitro-cellulose fire occurs, ENSURE THAT THE ELECTRICAL POWER IS IMMEDIATELY REMOVED FROM THE PRINTER BEFORE water is used to extinguish the fire.
Fire risk is a most important consideration where printing inks are stored and used. The degree of fire hazard will vary considerably from one type of ink or wash to another.
Water-based inks will not burn, although inks based on water-alcohol mixtures may burn if there is sufficient alcohol present. Prolonged exposure of water-based systems to high temperatures may evaporate the water to give a flammable residue.
Solvent-based inks offer a greater degree of hazard depending on the particular solvent or solvent combination. When there is a particular hazard the appropriate information is given on the SDS.
During maintenance, print drops may be collected in a container, such as a beaker. It is essential that this container is made of conducting material and is securely connected to ground/earth.
If there is a fire, there is a likelihood that dangerous fumes will arise from printing inks. For this reason ink must be stored where it can be reached
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HEALTH AND SAFETY
quickly by the fire fighting service, and where it will not spread beyond the store.
Spillages and Disposal
WARNING: Some dried inks are highly flammable. Clean up
all ink spillages immediately. Do not allow the ink to dry or allow any build-up of dried ink spills.
Spillages must be cleaned up as soon as possible with the appropriate solvent materials and with regard to the safety of personnel. Care must be taken to prevent spillages or residue from cleaning up entering drains or sewage systems.
Inks and associated fluids are materials which conduct electricity. Therefore, power to the printer must be switched off while spillages inside the printer cabinet are being cleaned up.
Printing inks and associated fluids must not be treated as ordinary waste. They must be disposed of using approved methods according to local regulations.
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HEALTH AND SAFETY
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DESCRIPTION

PART 2 : DESCRIPTION

CONTENTS
Introduction .......................................................................................... 2-4
Printer Specification ............................................................................. 2-5
Print Heads ...................................................................................... 2-5
Print Characteristics: ........................................................................ 2-5
Cabinet ............................................................................................ 2-5
Print Heads ...................................................................................... 2-5
Environment ..................................................................................... 2-6
Electrical Requirements ................................................................... 2-6
Supply Fuse Rating .......................................................................... 2-6
Inputs ............................................................................................... 2-6
External Alarms ................................................................................ 2-6
Print Head ............................................................................................. 2-7
Control Cabinet .................................................................................... 2-11
Ink System ............................................................................................ 2-12
General ............................................................................................. 2-12
Ink System ............................................................................................ 2-14
Electronic System ................................................................................. 2-16
General ............................................................................................. 2-16
Controls and Indicators ................................................................... 2-17
Universal Serial Interface PCB ......................................................... 2-18
Solenoid Driver PCB ........................................................................ 2-18
Low Voltage Power Supply PCB ..................................................... 2-18
Motherboard .................................................................................... 2-20
Product Detector ............................................................................. 2-20
Shaft Encoder (Optional) .................................................................. 2-20
External Connections .......................................................................... 2-22
Product Detector and Shaft Encoder Connectors (5-pin AXR) ........ 2-22
Power Connector ............................................................................ 2-22
Pocket Terminal Connector (Data Entry 25-way D Connector) ....... 2-23
External Alarms ............................................................................... 2-23
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DESCRIPTION
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Macrojet 2 Large Character Printer
TP1006_1
Ink Box
Control Cabinet
Print Head
DESCRIPTION
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DESCRIPTION
INTRODUCTION
The Macrojet 2 large character printer consists of:
• The print head (up to four can be fitted to one cabinet)
• The control cabinet
• The product detector (one or two can be fitted)
• The disposable ink supply container.
Print messages are normally entered using a Domino Pocket Terminal.
Print heads can be supplied to print with either 7 or 16 ink drops and in a range of character heights (see assembly connected to the cabinet by a flexible conduit and will work in any position. Print heads can be added or changed without difficulty.
The control cabinet contains an ink system supplying ink to the print head(s) and an electronics control system. Controls and external connections are grouped on a panel at the rear.
The product detector is mounted on the line and senses the product as it approaches the print head. There are three optional types: two are infra-red beams and a third works by metal detection.
page 2-7). Each is a separate stainless steel
Ink is supplied in a disposable 5 litre bag-in-box ink container, connected to the printer by a Quick Connect/Disconnect (QCD) connector.
Messages to be printed are normally entered as serial digital data from a Domino Pocket Terminal, but it is also possible to control the printer from a separate computer system (details from Domino).
The printer contains a set of separate auxiliary alarm contacts which can be connected to external indicators or other equipment. An optional alarm beacon is also available to show the printer status.
Another option is a shaft encoder which allows the printer to follow line speed variations. This includes the slowing down and speeding up involved in line stop and start.
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DESCRIPTION
PRINTER SPECIFICATION
Print Heads
7 or 16 drop nozzle heads. Multiple heads in combinations of:
• Up to 4 heads each of 7 nozzle size, or
• Up to 2 heads each of 16 nozzle size, or
• 1 head of 16 nozzle size and 1 head of 7 nozzle size, or
• 1 head of 16 nozzle size and 2 heads of 7 nozzle size.
Print Characteristics:
Character set: 96 ASCII, printed as 7x5 or 16x10 matrix. Character height: 8mm (5x5 matrix 12 and 32 only)
12, 16, 20, (7 x 5 matrix). 12mm Tray Coder 32mm (16 x 10 matrix)
or 2 lines 12mm (7x5 matrix). 50mm (16 x 10 matrix)
or 2 lines 20mm (7x5 matrix). Maximum print speed: 100 metres/second at 12.5mm Character width ch Messages: Up to 40 messages of up to 200 characters length
Cabinet
Dimensions: Width: 394mm (15.51")
Depth: 443mm (17.44") Height: 282mm (11.1")
Weight: 24.5kg (54lb)
Print Heads
Spacing from print surface: 25mm max. Conduit Length: 4m, 8m.
7 Nozzle Head:
Height: 85mm Width: 70mm Depth: 223mm (12, 16 and 20) Depth: 278mm (low level 12mm)
16 Nozzle Head:
Height: 111mm Width: 70mm Depth: 269mm
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DESCRIPTION
Environment
Temperature Range
+5º to +40ºC (42ºF to 104ºF)
(Operating): Humidity: 10 - 90% RH (non-condensing)
Electrical Requirements
Supply Voltage: 110V, 130V, 150V, 220V, 240V, 260V, single
phase with ground. Power: 300VA Supply frequency: 50/60Hz
Supply Fuse Rating
Power switch: 2A (220-260V)
4A (110 - 150V)
Inputs
Product Detector: 12V, 100mA dc supply to sensor, 5 pin AXR
connector. Shaft Encoder (print rate
control):
Data Interface: RS232 or 20mA current loop
suitable for open collectors or TTL encoders.
Encoder power supply link selectable, +5V
or +12V. 5 pin AXR connector.
75-19,200 Baud, selectable.
External Alarms
One output via changeover relay contacts:
2.5A at 260V max. Non inductive.
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DESCRIPTION
TP1290_1
PRINT HEAD
Ink jet printing does not require contact with the print surface. It is therefore particularly suitable for printing on rough, irregular, soft or other "difficult" surfaces.
Macrojet 2 is a valve jet printer. Ink is maintained under pressure behind a closed nozzle or valve. When the valve is opened for a short time, ink emerges as a drop and is propelled by the pressure towards the print surface or substrate. Drops are, therefore, only produced as required in what is known as Drop-on-Demand printing.
Macrojet 2 print heads have either 7 or 16 nozzles producing a line of drops called a stroke on the print surface. As the print surface moves past the head, successive strokes containing different combinations of ink drops build up the character in the form of a dot matrix. This is best understood by studying the illustration below.
The Macrojet print head has, at the front, a nozzle plate with either 7 or 16 nozzles. Ink is supplied under pressure to a manifold behind the nozzle plate. A plunger, fitted with a rubber slug on its tip, is held against each nozzle by a spring. The plunger is connected by a wire to a metal slug sitting part of the way into a solenoid. When the solenoid is energised, the slug is pulled into the centre of the solenoid. This pulls back the plunger, opening the nozzle. When the solenoid is de-energised, the spring pushes the plunger back to close the nozzle.
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DESCRIPTION
TP1291_1
Plunger Slug Slug Return Spring Solenoid
Nozzle Plunger Control Wire Solenoid Slug
TP1380_1
Nozzle Plate
Feed Pipe
Solenoids
Conduit
The Print Head
The ink that emerges from the nozzle forms a drop, ejected onto the print surface by the ink pressure. Drop size, density and quality of the print is controlled by three factors:
• The time for which the solenoid is energized
• The position of the slug when the solenoid is de-energized
• The ink pressure.
Ink flow into the head can be shut off with the print head valve. A purge switch operates all the nozzles to remove any air (see
The print head is mounted at right angles to the print surface, at a distance of 3 to 5mm for best print quality. At distances outside these limits, print quality will be reduced.
Macrojet 2 has a number of print head and print options. The print options are shown in the diagrams (see will print only the single line options. A 16 drop head is required to print the
page 2-9 and page 2-10). A 7 drop head
twinline and large options. Up to four lines of print (7x5), by way of four 7 drop heads or two 16 drop heads, can be supplied from a single control cabinet
page 3-4).
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TP1410_1
Single line 7 x 5 matrix.
Standard Character Printing Styles
TP1412_1
TP1413_1
TP1414_1
Twin line 7 x 5 matrix.
Single line
16 x 10
matrix.
Single line 16 x
10 and 7 x 5
matrix (top or
bottom line).
DESCRIPTION
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TP1415_1
Single line 5 x 5 matrix.
Optional Character Printing Styles
TP1417_1
TP1418_1
TP1419_1
Twin line 5 x 5 matrix.
Single line 5
x 5 and 7 x 5
matrix.
Single line 16 x 10 with single line 7 x 5 and single line 5 x 5
(top or bottom line)
DESCRIPTION
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DESCRIPTION
Control Cabinet
TP1039_3
Accumulator
Bleed
Valve
Pump
Switch
Inhibit
Fan
Solenoid Driver
Serial Interface
Board
Low Voltage
PSU
Power On
Indicator
Ink Container
Empty Indicator
Power Transformer
Vacuum Switch
Pump
Pressure Switch
Manifold
CONTROL CABINET
The control cabinet is moulded in a structural foam material which is extremely strong, light and easy to clean. It is sprayed internally and externally with epoxy paint. A special coating providing RF shielding is also applied to the internal surfaces.
The cabinet consists of a base, holding the ink and electronics systems, and a cover fitted over the top. A panel carrying the controls and connectors is fitted into the rear of the cabinet. The panel is also fitted with a fan that prevents an accumulation of fumes in the cabinet. The air is exhausted out of holes in the base under the transformer.
The ink and electronics systems occupy separate halves of the base and a bulkhead formed in the cover drops between them. Removing four screws and lifting the cover provides access to the whole cabinet.
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DESCRIPTION
Ink System Components
TP1385_2
Vent
Bleed Valve
Priming Port
Ink Manifold
Accumulator
INK SYSTEM
General
The ink system draws in ink from the ink supply container and supplies it under pressure to the print head. The system is governed by switches which control the ink pressure and detect when the ink container is empty.
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Ink System Diagram
M
Accumulator
Bleed
Valve
Vent
Print Head
Valve
Print Head
Main Cabinet
Ink
Container
QCD
Connector
Vacuum Switch
Filter
Spring
NRV
Print Head
Manifold
Solenoids
Pressure Switch
Choke
Bleed
Reservoir
NRV
DESCRIPTION
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DESCRIPTION
INK SYSTEM
The ink system is shown schematically in the diagram opposite. Fresh ink is contained in a 5 litre disposable ink container, which consists of a flexible bag protected by a robust cardboard box. The ink container is connected using a special quick QCD connector.
A gear pump draws ink into the system through a 20 micron filter and spring Non-Return Valve (NRV) and pumps it into the bleed reservoir. Residual air collects in the reservoir and opening the bleed valve allows this air to escape through the vent in the cabinet floor. A by-pass loop, containing a choke to reduce the flow rate, is connected from the bleed reservoir to the inlet side of the gear pump. This ensures that the pump remains primed if air is drawn in through the ink feed pipe.
Ink from the bleed reservoir is forced through a plain NRV into the accumulator which holds the working reservoir of ink for the print heads. The accumulator has a flexible diaphragm clamped between the accumulator body and the mounting flange on the steel frame. The diaphragm is shaped to contain a volume of air. The mounting flange is sealed and the only access into the diaphragm is an air valve provided for maintenance purposes.
As ink is pumped into the accumulator it compresses the air sealed inside the diaphragm. When the ink is pressurised to 7psi (0.48 Bar) the pressure switch trips and switches the pump off. The plain NRV closes to maintain the pressure in the accumulator and re-opens only when the pump next runs. As ink from the accumulator is used up in printing, the pressure drops. At approximately 5psi (0.35 Bar) the pressure switch resets, switching on the pump. The accumulator has a capacity of approximately 70ml, provided by compressing the air behind the diaphragm.
Pressurised ink is fed from the accumulator, through the print head hand valve and the conduit feed pipe, to the print head manifold behind the nozzle plate.
When the pump is running and the ink supply container becomes empty, a vacuum is generated in the feed line. At 8 - 10 inches of mercury (2.76 -
3.45 kilogrammes per sq cm) the vacuum switch trips, switching off the pump and lighting the Ink Container Empty indicator. The spring NRV shuts off, and maintains the vacuum.
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Electronics Components
TP1390_2
Power Transformer
Motherboard
Front Panel
Assembly
Low Voltage
Power Supply
PCB
Universal Serial
Interface PCB
Solenoid Driver
PCB
Fan
Rear Panel
Assembly
DESCRIPTION
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DESCRIPTION
ELECTRONIC SYSTEM
General
The electronic system contains a microprocessor, which controls the message data input, processing and printing. It also contains circuits to drive the solenoids in the print head and to generate d.c. power supplies.
The system consists of the following Printed Circuit Boards (PCBs):
• Universal Serial Interface
• Solenoid Driver (one or two depending on the number of print heads)
•Low Voltage Power Supply
• Motherboard.
The motherboard lies flat in the base moulding. The PCBs are plugged vertically into it and are held in place by a foam strip in the top cover. A single power transformer provides the low voltages required by the power supply circuits.
The product detector is part of the electronics system. It detects the product as it approaches the print head and provides a Print Go signal to the printer. Macrojet 2 is able to use two detectors, with assignment of print heads to detectors being set up with the Pocket Terminal. For details see Pocket Terminal User's Guide, Part Number 20524.
Having been detected, the product still needs time to pass under the head and reach the correct position for printing. The electronics system allows for this with the Print Go delay, which is also set up using the Pocket Term in al .
A shaft encoder is an option which enables the printer to follow line speed variations. It has been explained how characters are printed by strokes, as the product passes the head. If the stroke rate is fixed and the product speed changes, the strokes will become closer or further apart. The result is a change in the character shape. The Print Go delay is also measured in strokes and a fixed stroke rate gives a fixed delay. Changes in the product speed will, result in a change in the position of the printed message.
A shaft encoder is attached to the line and follows the line speed. Using it to control the stroke rate eliminates the variations in character shape and message position.
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