Foxjet SoloSeries 45, SoloSeries 90 Operation Manual

Operations

Manual

Thermal Jet

Ink Jet System

1 Missouri Research Park Drive • St. Charles, MO 63304 • 1-800-369-5384

5780-329

Revision J

Operations Manual

Ink Cartridge: The SoloSeries has been engineered

and designed to work with Foxjet ink cartridges. The SoloSeries’ 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-Foxjet ink cartridges.

Thermal Jet

Ink Jet System

5780-329

Revision J

The information contained in this manual is correct and accurate at the time of its publication. Foxjet reserves the right to change or alter any information or technical specifications at any time and without notice.

Thermal Jet

Warranty:

The SoloSeries Thermal Jet system, including all components unless otherwise specified, carries a limited warranty.

The inks and conditioners used with the SoloSeries Thermal Jet system carry a limited warranty.

For all warranty terms and conditions, contact Foxjet 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 SoloSeries Print Head and Power Supply to Bracketry .. . . . . . . . . . . . 4

Step 4: Adjust SoloSeries Print Head to Substrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 5: Insert Cartridge Pen 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: Marksman HHI or GUI Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Keypad or Keyboard .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Home Screen .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Messages Dialog & the Message Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Control Panels Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Time & Date Setting Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Status Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Section 4: Maintenance & Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Daily Maintenance, Ink Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Weekly to Monthly Maintenance, Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Shutdowns Less Than 3 Days .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Shutdowns More Than 3 Days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Section 5: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Appendix A: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SoloSeries45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SoloSeries90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SoloSeries IS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Marksman HHI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Appendix B: Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

SoloSeries Print Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Marksman HHI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Appendix C: Part Numbers - Consumables and Service Parts . . . . . . . . . . . . . . . . . . . . . . . 39

Consumables .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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Thermal Jet

Appendix D: File Backup and Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

File Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Restoring Backed-Up Files .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Appendix E: Configuring a PC to Communicate with the IJ3000-ES .. . . . . . . . . . . . . . . . . 47

Windows XP® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Windows 2000® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Appendix F: Font Samples .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Appendix G: Creating Logo Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Appendix H: Uploading Files to the Print Head and File Management . . . . . . . . . . . . . . . . 54

Appendix I: Communicating Directly to the Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Appendix J: Aligning the 1" (25.4 mm) Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Appendix K: SoloSeries IS Bulk Ink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5780-329 Operations Manual Rev J

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 ground-

ing 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 MSDS (Material Safety Data Sheet).

Ink Cartridge: The SoloSeries has been engineered and designed to work with Foxjet ink cartridges. The SoloSeriess’ 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-Foxjet ink cartridges.

5780-329 Operations Manual Rev J Page 1

Thermal Jet Section 2: Quick Start

Optional Marksman HHI

controller

Section 2: Quick Start

Contents:

• SoloSeries Print Head

• Bracketry Kit

• Power Supply, 15 V

• Power Supply Bracket

•Power Cord

• Software CD

TYPICAL INSTALLATION

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Thermal Jet Section 2: Quick Start

Step 1: Assemble Bracketry

Step 2: Assemble Bracketry to Conveyor

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Thermal Jet Section 2: Quick Start

Ensure bar is behind front

face of print head

Step 3:Assemble SoloSeries Print Head and Power Supply to Bracketry

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Thermal Jet Section 2: Quick Start

ADJUST THE PRINT HEAD TO THE SUBSTRATE WITH

THIS BRACKET

.1" (2.5mm) GAP

RECOMMENDED

Step 4: Adjust SoloSeries Print Head to Substrate

Adjust print head vertically to meet requirement.

Adjust print head horizontally to set print gap.

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Thermal Jet Section 2: Quick Start

PEN STOP

When inserting cartridge, aim nose at an angle towards black pogo pin component. Slide pen cartridge up to Pen Stop.

PEN STOP

After pen cartridge is installed

FINGER RELEASE T AB

FINGER RELEASE TABS

Step 5: Insert Pen Cartridge into Print Head

Rotate Cover Open

Insert Pen Cartridge at an angle up to Pen Stop

Rotate Pen Cartridge down until it snaps in place.

NOTE: The pen is released by pressing down on the Finger Release Tab and pulling up on the rear of the cartridge.

Close Cover

5780-329 Operations Manual Rev J Page 6

Thermal Jet Section 2: Quick Start

COM PORT

PC OR LAPTOP

Marksman HHI

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 an Marksman HHI controller. One com port can control up to eight SoloSeries45 print heads, four SoloSerie90 print heads, or any combination of the two totalling 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 Marksman HHI to the daisy chain. A PC connects to the first head in the daisy chain, while a Marksman HHI connects to the last.

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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 SoloSeries 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 cartridge. 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 Marksman HHI or the computer may now be installed.

Serial Port Setup

NOTE: Depending on GUI /Marksman HHIstatus, this step may already be complete.

If a computer will be used, install the SoloSeries/ Marksman HHI GUI PC software using the CD included with the print head. Follow the installation prompts, and at this prompt, select "Interface 1 Serial Print Head".

After the GUI program has been installed, launch the program.

Ensure the home screen menu is present via the Hide Menu / Show Menu button, and then press the Control Panels button.

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Press the System Setup button, and then the Serial Ports tab.

To ensure the baud rate is set for 57600, press the button beneath the Port/Baud column and adjust if necessary. Press the OK button to exit the Serial Port Setup screen.

If "Serial Print Head: Task x" is not shown on theCOM1 Function button, press the button and select the Serial Print Head option. Press the OK button to exit the COM 1 Function screen. Press OK again to exit the System Setup screen.

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Step 7: Configure the Print Head

On the home screen, press the Control Panels button, and then press the System Setup button. On the Print Heads page press the Redo Print Head Setup button. Select the desired direction.

Select the number of print heads, identify the first in the daisy chain, and select the appropriate print head type by touching each one and then the drop down box.

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 and connected to the last print head in the daisy chain

Auto Speed Detect:

Line speed automatically detected via SoloSeries

photocells

Fixed Speed:

User types in the desired line speed

5780-329 Operations Manual Rev J Page 10

Touch this box, then type in the desired speed

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.

Create and save the message, and then exit the message editor.

File Menu

Quick Save

Product Setup

Product Side

Message Display Area

Field Selection

Zoom

Font Selection

Field Coordinates

Alpha / Numeric

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Date Code

Time Code

Variable Field

Count Code

Logo

Barcode

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Step 9: Print a Message

From the home screen, push the Print button.

Select the desired message to print, and push the Print It button.

The message will print on the next photocell trigger.

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Thermal Jet Section 3: Marksman HHI or GUI Functionality

POWER

SCREEN BRIGHTNESS

BACKSPACE

Section 3: Marksman HHI or GUI Functionality

Keypad or Keyboard

ESC (Escape):

• Closes the current window, a dialog box, or menu.

• Restores the original contents of any input entry box, if Enter has not been pressed.

Arrow Keys:

• Shifts focus between screen controls.

• Moves highlighted fields or the cursor around in the Message Editor.

Tab:

• Shifts focus between screen controls.

• Shifts focus between fields in the Message Editor.

Backspace in Message Editor:

• Normal functionality as QWERTY keyboard.

• Deletes a highlighted field.

Ctrl (Control) in Message Editor:

• Amplifies the movement of the arrow keys.

• Holding the Ctrl key while pressing the Enter key at the end of a text line enables paragraph functionality.

F4/F8:

The F4/F8 key pulls up the extended characters dialog.

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Home Screen

Print Head Daisy Chain Identifier

Message Window

{

Task 1 Select Button

Task 1, Task 2 Ink Status

Task 1 Print / Pause Button

Quick Print Button

Print Counts Button

Variable Field Button

Zoom Button

Task 2 Select Button

Task 2 Print / Pause Button

Status Screen Access

Button

Show / Hide Main Menu Button

{

Play State

Press to

Pause

Pause State

Press to

Print

Message Window:

• Displays the current print message.

• Updated approximately every seven seconds, so it likely will not show each print.

• Long print messages can be viewed by using the F1 and F2 keys to scroll the message left and right, respectively.

• White or beige bars represent a print head in the daisy chain and are identified by their respective numbering.

• The header displays the task number and file name of the message being printed. If no message is loaded to print, "None" is displayed.

Task Select Button:

• Places focus on the selected task. This allows one to view what is being printed on either task in the home screen. Additionally, items in the main menu vary from one task to the other.

Task Print / Pause Button:

• Starts and Stops print after an operator response to a confirmation popup dialog box.

• If a message is currently printing, pressing the Pause button will discontinue printing after the message completes printing.

• If the Play button is pushed, print will resume on the next product detected.

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Quick Print Menu Button:

• Allows one to access the Print dialog box directly, even with Restricted User Access enabled.

• Simply select the desired message and press the Print It button. The message will print at the next photocell trigger.

Zoom:

• Expands the message window to full screen and magnifies the print message so that fine details may be seen.

• F1, F2, F5 and F6 keys, or the Arrow keys, scroll the message left, right, up and down.

• Press the Zoom button or the ESC key to zoom back out.

Counter:

• Count codes are allowed, but one must select the "Print" button to adjust the count.

Variable Field:

• Variable information fields are allowed, but one must select the "Print" button to change the information being printed.

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Main Menu

Main Menu Collapsed

Print Menu

Main Menu Expanded

Print Menu Button

Cancels print immediately after a confirmation popup dialog box

Closes this menu immediately

NOTE: The Variable Field button is not available. In order to update a variable field, reselect the message to Print.

Fires all jets for a short period of time on the selected print head

Messages Dialog & the Message Editor

Messages Dialog

Returns to Home Screen

Deletes Selected Message

Returns to Home Screen

Message List

Selected Message

Opens Selected Message in the Editor

Starts a new message in the Editor

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Reverts message to the last saved

Clears contents of message editor

Thermal Jet

Message Editor

File Menu

Calculates estimated ink usage for the contents of the editor

Exits the editor to the Home screen

Prints the contents of this editor on the next photocell

trigger

Field or cursor coordinates

Opens Field Properties dialog box for text fields

Quick save of current message

Message display area

Moves from field to field in the display area

Zoom

5780-329 Operations Manual Rev J Page 17

Thermal Jet

Message Editor continued: User Defined Time Codes

When User Defined 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.

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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.

Thermal Jet

Message Editor continued: User Defined Date Codes

When User Defined selected, Define Date Code button

appears

The Fortnight code type is available for the Tab ular format only

Sequential format: in example above Sunday = ’A’, Monday = B, etc

Tabular format: codes printed taken from table. Use default codes (default Day codes shown) or edit table to suit your requirements

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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.

Thermal Jet

Message Editor continued: Product Counts, Variable Fields, Logos

Maximum 9-digit count

Scroll through logo images or select from list

Variable Field Data Source

User: Print data entered when print

message containing the variable field is selected to print.

COM1, COM2: Data is received though COM1 or COM 2 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

Message Editor continued: Bar Codes

Properties dialog for Data Matrix code

Bar Code Data Source

Fixed: Data entered when the

bar code is created. User: Data entered when print

message containing bar code is selected to print. Dummy data entered when the bar code is created acts as a place holder.

COM1, COM2: Data is received though COM1 or COM 2 serial port. Data must be received before the message is selected to print. Dummy data entered when the bar code is created acts as a place holder.

Data 1 - 10: Data is retrieved from corresponding system variable. Dummy data entered when the bar code is created acts as a place holder.

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Thermal Jet

Control Panels Menu

I/O feature not available on Marksman HHI

System Utilities menu for miscellaneous controller tools and file management

Security Access

System Setup:

NOTE: The Product sesnor offset is only available when External product sensor is

selected on the Task Options tab. In addition, External encoder or Fixed Speed must be selected on the Encoder tab.

Controls print head and ancillary equipment configuration

Configures network connectivity via the Ethernet port

Language and unit of measure configuration

Closes this menu immediately

Set print direction, number and type of print heads

External Encoder:

Line speed measured by an externally mounted encoder and connected to the last print head in the daisy chain

Fixed Speed: Enter the desired line speed

System Setup Screen

Auto Speed Detect:

Line speed automatically detected via SoloSeries photocells (disables the external product sensor)

Optional externally mounted photocell connected to the last print head in the daisy chain (disables Auto Speed Detect)

COM port configuration options

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Thermal Jet

Network:

Regional Settings:

Does not apply to Thermal Jet print heads

User Access:

The factory set password is Manager. Passwords are case sensitive.

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

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Thermal Jet

Utilities:

After performing the

Restore default configuration function, the serial

port must be reconfigured for a serial print head.

Time & Date Setting Screens

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Thermal Jet

Status Screen

Note: This set of status screens represents three print heads, two SoloSeries45 and a SoloSeries90, setup in a daisy chain. The first two print heads (Head 1 & 2) are properly connected and detected. The third print head has not been properly connected to the daisy chain.

One button for each print head/print cartridge in the daisy chain. Touch/click button to display status for that print head & cartridge.

Head 3 is a SoloSeries90 - one button for each print cartridge

Controller / GUI version number

Right hand photocell (as seen from front of print head) covered and the left is not

Heads 1 & 2 are SoloSeries45s

Printing is enabled

Ink cartridge type and status - OK

Date (Y-M-D) and time from print head

Print head firmware version number

Ink cartridge not detected

No date & time

List of fonts and logos on the print head

Indications that head 3 is improperly connected or not communicating with the controller

Font and logo list is empty

No print head firmware version number

5780-329 Operations Manual Rev J Page 25

Thermal Jet Section 4: Maintenance & Shutdowns

Section 4: Maintenance & Shutdowns

Daily Maintenance, Ink Cartridge

Prior to shift startup, the cartridge orifice array should be cleaned of any debris or ink build up.

Requirements:

• Deionized or distilled water (DO NOT USE TAP WATER) for POROUS INK

ONLY

• Sponge Swabs (Foxjet p/n: 5760-832)

Procedure:

1. For POROUS INK ONLY cartridges, lightly dampen sponge swab with deionized water.

2. For NON-POROUS INK ONLY cartridges, 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.

3. Rub up and down across the orifice face with light force several times with one side of the sponge swab.

4. Turn the swab over and make one final light rub stroke top to bottom.

5. Immediately press and hold the PURGE button on the rear of the print head for 5-10 seconds to reprime 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.

6. 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.

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Thermal Jet Section 4: Maintenance & Shutdowns

CARTRIDGE BOOT CAP

PEN CARTRIDGE

Weekly to Monthly Maintenance, Print Head

Debris and ink build up on the print head enclosure / cover can be removed using a soft cloth lightly dampened with deionized water.

Take care NOT to wipe the cartridge orifice array.

Shutdowns Less Than 3 Days

The ink cartridge can remain in the print head uncapped. When restarting the print head, follow the Daily Maintenance procedure.

Shutdowns More Than 3 Days

For extended shutdowns, follow the Daily Maintenance procedure, remove the ink cartridge from the print head and store in the optional Cartridge Boot Cap (Foxjet Kit p/n: 5780-208).

5780-329 Operations Manual Rev J 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

PURGE button on rear of head does not appear to work

Print head purges but won’t print desired message

• Power Supply

•AC Source

• Ink cartridge is damaged or empty

• Print head Board

• Loose or missing cables

• Controller or PC software not configured for Serial Print Head

• Encoder Malfunction

• Product not triggering photocell.

• Check power supply light indicator.

• Check for AC power source between power supply input limits.

• Replace with new cartridge and repeat PURGE.

• Replace print head printed circuit board or print head.

• 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 Possible Cause Actions

Print is foggy or light • Print head is mounted

greater than an 1/8" away from the substrate

• There are large air currents near the print head

• Adjust the print head according to “Section 2: Quick Start”, See “Step 4: Adjust SoloSeries Print Head to Substrate” on page 5.

• Locate print head in an area where there are minimal currents or provide wind barriers.

Print image is missing channels or has multiple fractures

• Pen cartridge face is dirty

• Pen cartridge face is damaged at the orifice array

• Pen cartridge is not properly seated in the print head

• Clean the pen face per “” on page 25.

• Replace damaged pen cartridge with new.

• Remover cartridge and reinsert according to “Section 2: Quick Start”, “Step 5: Insert Pen Cartridge into Print Head” on page 6.

SoloSeries PRINT HEAD LED FUNCTIONALITY

System Symptom Possible Cause Actions

Red LED on steady • Pen cartridge ink level is

low.

Red LED is flashing slowly • Pen cartridge is out of ink

and significant print degradation is imminent.

• A non-Foxjet cartridge is installed.

Red LED is flashing fast • Pen cartridge is missing

from print head stall.

• Print head is calibrating a new cartridge.

• Print head is in thermal protection mode.

• Ready the next pen cartridge for installation.

• Prepare to install a new pen cartridge.

• Install an original Foxjet cartridge.

• 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.

5780-329 Operations Manual Rev J Page 28

Thermal Jet Appendix A: Specifications

45°

PRINT HEAD TILT

0.87 in

[22.1 mm]

LOWEST

CHANNEL

3.65 in

[92.6 mm]

0.90 in [22.9 mm]

0.90 in [22.8 mm]

1.00 in [25.4 mm]

2X M6 X 1.0 X x .16 in [4.06 mm] PROVIDED FOR PRINT HEAD MOUNTING

(BULK INK ONLY)

5.30 in

[134.6 mm]

1.32 in

[33.6 mm]

6.23 in

[158.2 mm]

Appendix A: Specifications

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5780-329 Operations Manual Rev J Page 29

PRINT HEAD TILT

45°

0.87 in [22.1 mm] LOWEST

CHANNEL

4.13 in

[104.9 mm]

6.20 in

[157.4 mm]

5.81 in

[147.5 mm]

(BULK INK ONLY)

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1.00 in

[25.4 mm]

0.90 in

[22.8 mm]

1.38 in

[35.2 mm]

2X M6 X 1.0 X.16 in [4.06 mm] PROVIDED FOR PRINT HEAD MOUNTING

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5780-329 Operations Manual Rev J Page 30

Thermal Jet Appendix A: Specifications

11.00 in

[279.4 mm]

1.00 in

[25.4 mm]

5.89 in

[149.7 mm]

1.00 in

[25.4 mm]

3.75 in

[95.3 mm]

6.00 in

[152.4 mm]

3.50 in

[88.9 mm]

.44 in

[11.3 mm]

11.68 in

[296.6 mm]

3X M6 X 1.0 X x.20 in [5.1 mm] PROVIDED FOR INK SUPPY MOUNTING

SoloSeries IS:

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) Communications port

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

Up to 8 print head cartridge stalls (eg: 8 SoloSeries45s; 4 SoloSeries90s; 4 SoloSeries45s with 2 SoloSeries90s, etc.)

Ink Type

Dye base

Ink Cartridge: The SoloSeries has been engineered and designed to work with Foxjet ink cartridges. The SoloSeries’ 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-Foxjet ink cartridges.

5780-329 Operations Manual Rev J Page 31

Thermal Jet Appendix A: Specifications

Marksman HHI:

Weight

1.8 lbs (0.82 kg)

User Interface

Type: Graphical User Interface Keyboard: 70-key, QWERTY style, elastomeric

keyboard 800 X 480 color LCD with touch screen, 7.0"

(177.8 mm) diagonal

Fonts

Arial 30, 75, 150, 225, and 300 (0.1in / 2.5 mm,

0.25 in / 6.3 mm, 0.5 in / 12.7 mm, 0.75 in /

19.05 mm, and 1 in / 25.4mm).

Storage

128 MB flash memory

Print Speed

Up to 200 fpm

Maximum Lines of Print

5 per print cartridge through any given vertical line.

Print Fields per Line

At least 3 52-character fields per print line; more when fields have less than 52 characters.

Maximum Product Length

108 inches (2743 mm)

Maximum Repeat Print Distance

108 inches (2743 mm)

Maximum Number of Print Heads Per Controller

Up to 8 print cartridges per COM port in any combination (eg: 4 SoloSeries45s and 2 SoloSeries90s; 8 SoloSeries45s; 4 SoloSeries90s)

2 COM ports allow for a total of16 print cartridges per controller

Ports

(2) RS-232 ports, (1) 10/100Base-T Ethernet port, (1) USB port

Electrical

15 VDC from power supply to controller Power Supply: 90-260 VAC, 50/60 Hz, 1.5A

max. (per power supply)

Environment

Ambient operating temperature: 40°F to 104°F (5°C to 40°C) Operating humidity: 10% - 90%, non-condensing

Maximum Distance Between Controller and Farthest Print Head in Daisy Chain

100 feet (30.5 m)

Bar Codes Supported

GTIN-12 (UPC-A), EPC-E, GTIN-13 (EAN-13), GTIN-8 (EAN-8), Code 39, GTIN-14 (UCC-128), Code 128, Data Matrix

5780-329 Operations Manual Rev J Page 32

Thermal Jet Appendix B: Theory of Operation

Appendix B: Theory of Operation

SoloSeries Series Print Heads

TIJ Technology

The SoloSeries 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.

SoloSeries Inkjet Similarities and Differences

A SoloSeries print head can operate stand-alone or in concert with other SoloSeries print heads connected one to another in a daisy chain configuration. Up to eight SoloSeries45 or four SoloSeries90 print heads can be daisy chained. SoloSeries print heads can be controlled by the Marksman HHI controller, from a PC or labtop using the included GUI software interface program, or by a user developed application.

SoloSeries Series 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 Foxjet inkjet technologies, the SoloSeries 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 at Foxjet so as to make full use of the SoloSeries Smart Level Ink Detection System. When a new cartridge is snapped into a SoloSeries 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 Marksman HHI controller or GUI software as long as they are connected to the print head daisy chain.

5780-329 Operations Manual Rev J Page 33

Thermal Jet Appendix B: Theory of Operation

Marksman HHI

Functional Description

The Marksman HHI Ink 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 70-key QWERTY keypad provides for easy and intuitive system operation.

Power

The Marksman HHI draws its power through either one of its serial port connectors, either from the print head directly attached to the port, or in applications where the optional accessory hub is used, from the hub. Alternately theMarksman HHI may be powered by an optional 15VDC desktop power supply plugged into its power jack. Marksman HHI/Thermal Jet system cabling requirements differ depending on the power option used; see cabling diagrams below.

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 Marksman HHI is not plugged into a power source.

Please note that power is applied to the Marksman HHI even when it is "turned off." When turned off using the OFF button on the keyboard, the Marksman HHI enters a sleep mode where it responds to nothing but the ON button. All voltages are present while sleeping. The only way to completely remove power is to unplug the unit.

Marksman HHI Power Option Cabling Diagrams

Single Task: The Marksman HHI controller draws its power from the daisy chain, and the COM1 port is connected to the last head in the chain.

5780-329 Operations Manual Rev J Page 34

Thermal Jet

Single task with accessory hub:

The Marksman HHI draws its power from the daisy chain, and is plugged into the ’hand held’ connector on the accessory hub; the accessory hub is plugged into the last print head in the daisy chain.

Single task with optional desktop power supply: The Marksman HHI COM1 port is connected to the first print head in the daisy chain. If the accessory hub is used, it is connected to the last print

5780-329 Operations Manual Rev J Page 35

Thermal Jet

Dual task: The Marksman HHI draws

its power from the task 1 daisy chain; COM1 is connected to the last print head in the task 1 daisy chain, while COM2 is connected to the first print head in the task 2 daisy chain.

Dual task with accessory hub: The Marksman HHI draws its power from the task 1 daisy chain; COM1 is connected to the ’hand held’ connector on the accessory hub, and the accessory hub is then connected to the last print head in the task 1 daisy chain. COM2 is connected to the first print head in the task 2 daisy chain, and the accessory hub is connected to the last print head in the task 2 daisy chain.

5780-329 Operations Manual Rev J Page 36

Thermal Jet

Dual task with optional desktop power supply: The Marksman HHI COM1 port is connected to

the first print head in the task 1 daisy chain, and COM2 is connected to the first print head in the task 2 daisy chain. If either task uses the accessory hub it is connected to the last print head in the daisy chain.

5780-329 Operations Manual Rev J Page 37

Thermal Jet

Interconnect Diagram

Marksman HHI Controller CPU Diagram

5780-329 Operations Manual Rev J Page 38

Thermal JetAppendix C: Part Numbers - Consumables and Service Parts

2

1

3

4

5

6

7

10

Appendix C: Part Numbers - Consumables and Service Parts

Consumables

Ink Cartridge: The SoloSeries print head has been engineered and designed to work with Foxjet ink cartridges. The SoloSeries’ 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-Foxjet ink cartridges.

Inks

Part No. Description Package Shelf Life

5780-201FX Solo 100 Porous Media, Black

5780-201RFX Solo 100 Porous Media, Red

5780-202FX Solo 200 Porous Media, Black, Extended Decap 5780-212FX Solo 300NP Non-Porous Media, Black 5780-235FX Solo 200 Barcode, Porous Media, Black 5780-220FX Solo 100 Porous Media, Bulk Ink, Black

5780-219FX Solo 100 Porous Media, Bulk Ink, Black

Service Parts

5 Cartridges 1 year

One 350ml Ink

Cartridge

1 year

SoloSeries45

Item Kit No. Description

1 5760-302 Power Supply, Print Head

2 5780-002FX

3

4 5780-226FX PCB Replacement Set

5

6 5780-208 Boot, Cartridge Cap 7 5780-319-10 Cable, Print Head, 10’ 8 2464-182-25 Extension Cable, Print Head, 25’ (not shown)

9 2464-182-50 Extension Cable, Print Head, 50’ (not shown) 10 5780-231 Regulator Replacement, Bulk Ink 11 5780-229FX Upgrade Kit, Bulk Ink Print Head (Includes Item 3-bottom and Item 10)

5780-203FX Cover, Enclosure, Standard

5780-203BIFX Cover, Enclosure, Bulk Ink

5780-205FX Print Head Replacement, Standard 5780-217FX Print Head Replacement, Bulk Ink

SoloSeries45 Complete Print Head Kit with Mounting Bracketry, Power Supply, Data Cable, & PC Software

5780-329 Operations Manual Rev J Page 39

Thermal JetAppendix C: Part Numbers - Consumables and Service Parts

2

1

3

4

5

6

7

10

3

2

1

4

6

5

SoloSeries90

Item Kit No. Description

1 5760-302 Power Supply, Print Head

2 5780-007FX

3

4 5780-221FX PCB Replacement Set

5

6 5780-208 Boot, Cartridge Cap

7 5780-319-10 Cable, Print Head, 10’

8 2464-182-25 Extension Cable, Print Head, 25’ (not shown)

9 2464-182-50 Extension Cable, Print Head, 50’ (not shown) 10 5780-231 Regulator Replacement, Bulk Ink

11 5780-228FX

5780-225FX Cover, Enclosure, Standard

5780-225BIFX Cover, Enclosure, Bulk Ink

5780-215FX Print Head Replacement, Standard 5780-218FX Print Head Replacement, Bulk Ink

SoloSeries90 Complete Print Head Kit with Mounting Bracketry, Power Supply, Data Cable, & PC Software

Upgrade Kit, Bulk Ink Print Head (Includes Item 3-bottom & 2 ea. Item

10)

SoloSeries IS

Item Kit No. Description

1 5760-302 Power Supply, 15VDC, Bulk Ink Supply

2 5780-216FX Replacement Bulk Ink Supply

3 5780-222 Internal Tubing and Fitting Replacement

4 5780-223 Vacuum Pump Replacement

5 5780-224 PCB Replacement

6 5780-209 Septum Fitting Replacement

7 5780-211 External Tubing and Fittings (not shown)

5780-329 Operations Manual Rev J Page 40

Thermal JetAppendix C: Part Numbers - Consumables and Service Parts

2

3

4

Marksman HHI

Item Kit No. Description

1 5780-015FX Marksman HHI Controller

2 5780-232 Color Display Replacement

3 5780-233 CPU PCB Replacement

Bracketry

Item Kit No. Description

1 5780-234 Bracketry, Marskman HHI Mounting

2 5780-200 Bracketry, SoloSeries Print Head Mounting

3 5780-227 Bracketry, Print Down

4 5780-230 Bracket, Linear, Tool-less

5780-329 Operations Manual Rev J Page 41

Thermal JetAppendix C: Part Numbers - Consumables and Service Parts

4

2

1

3

5

TYPICAL ENCODER

MOUNTING ON OPEN AREA

OF CONVEYOR BELT

TYPICAL ACCESSORY

HUB MOUNTING

TYPICAL BEACON

MOUNTING

TYPICAL PHOTOCELL MOUNTING

BRACKETRY

MOUNTING

CONVEYOR

MOUNTING

BULK INK

SUPPLY

POWER SUPPLY

INK STATUS

BEACON

ENCODER

PRINT HEAD

PHOTOCELL

ACCESSORY

HUB

ACCESSORY HUB CONNECTIVITY

MARKSMAN HHI

Optional Equipment

Encoder, Photocell, Accessory Hub, and Beacon

Item Kit No. Description

1 5760-820-IJ Encoder Assembly with Mounting Bracket & 25’ Cable

2 5765-206 Encoder O-ring Replacement

3 5760-383 Photocell

4 5780-010FX Accessory Hub with Power Supply

5 5780-214 Beacon

‘

5780-329 Operations Manual Rev J Page 42

Thermal JetAppendix C: Part Numbers - Consumables and Service Parts

Roller Bracket Only

Roller & Retractor Bracketry

Item Kit No. Description

1 5780-206 Roller Bracket Only

2 5780-207 Roller and Retractor Bracket

Maintenance

Item Kit No. Description

1 1901-398 Hand Cleaner, Reduran

2 5760-832 Sponge Swabs, Qty. 100

3 6600-171 Lint-free Wipe Cloths

5780-329 Operations Manual Rev J Page 43

Thermal Jet Appendix D: File Backup and Restore

Appendix D: File Backup and Restore

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 Marksman HHI controller is already connected, via Ethernet, to a PC. If not, please refer to

Marksman HHI” on page 47

1. Obtain the Marksman HHI controller's IP address. Most Marksman HHI controllers have an IP address of other Marksman HHIs or other devices. If the IP address is unknown, go to the controller, and from the

• Touch the

• Touch the Screen.

• Touch the

• Record the Marksman HHI's IP address (it's the top one).

Control Panels button to open the Control Panels Menu.

IP Addresses tab to display the system's IP addresses.

Home Screen:

Network button on the Control Panels Menu to open the Network Setup

.

10.1.2.3. It may be different if the controller is networked with

“Appendix E: Configuring a PC to Communicate with

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.

5780-329 Operations Manual Rev J Page 44

Thermal Jet Appendix D: 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 Marksman HHI files backed up are compressed and put into a single file, and are given the default name and file extension ventions, 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

type combo box and select All Files.

5780-329 Operations Manual Rev J Page 45

backup.tgz. Following normal Windows® con-

Save as

Thermal Jet Appendix D: 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.

Restore button to send the file to the controller. If the file transfer is successful,

the web page shown below will be displayed.

5780-329 Operations Manual Rev J Page 46

Thermal Jet Appendix E: Configuring a PC to Communicate with Marks-

Appendix E: Configuring a PC to Communicate with Marksman HHI

This appendix has instructions for setting the IP address and subnet mask of the PC so it can communicate with the Marksman HHI Controller. Included are instructions for Windows XP®, Windows 2000®, Windows 98®, and Windows 95®.

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.

5780-329 Operations Manual Rev J Page 47

Thermal Jet Appendix E: Configuring a PC to Communicate with Marks-

3. Select Internet Protocol

(TCP/IP)

then click the

Properties button.

4. Click the

IP address

Use the following

radio button.

Enter an IP address of

10.1.2.4, a subnet mask of

255.255.255.0, and click

OK button.

the

5780-329 Operations Manual Rev J Page 48

Thermal Jet Appendix E: Configuring a PC to Communicate with Marks-

Windows 2000®

1. Open the Start menu; select

Network and Dial-up Connections.

2. Click the desired connection, then open the File menu and select Properties.

Settings, then

5780-329 Operations Manual Rev J Page 49

Thermal Jet Appendix E: Configuring a PC to Communicate with Marks-

3. Select Internet Protocol

(TCIP/IP)

then click the

Properties button.

4. Click the

IP address

Use the following

radio button.

Enter an IP address of

10.1.2.4, a subnet mask of

255.255.255.0, and click the OK button.

5780-329 Operations Manual Rev J Page 50

Thermal Jet Appendix F: Font Samples

Appendix F: Font Samples

Arial 30 - 1/10 in (2.54 mm):

Arial 75 - 1/4 in (6.35 mm):

AaBbCcDdEeFf

1234567890

Arial 150 - 1/2 in (12.7 mm):

AaBbCcDdEeFf

1234567890

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 GUI software.

Arial 225 - 3/4 in (19.05 mm):

Arial 300 - 1 in (25.4 mm):

5780-329 Operations Manual Rev J Page 51

Thermal Jet Appendix G: Creating Logo Files

Appendix G: Creating Logo Files

Open Paint from a PC by selecting Start, Programs, Accessories, and then Paint. Bring up the Attributes dialog box by selecting Image and then Attributes.

Enter the Width and Height of the logo in Pixels. For practical purposes the maximum height of a logo is150 pixels if the logo is prined with a SoloSeries45 print head, and 300 pixels if printed with a SoloSeroes90 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 / 2.77 n when printed at 300 dpi.) Select

Choose

Yes at the screen prompt to convert to black and white if applicable.

Black and white for the Colors.

5780-329 Operations Manual Rev J Page 52

Thermal Jet Appendix G: Creating Logo Files

Define the pixels of the logo using the drawing tools, or copy and paste an image from another document.

Bring up the

Select

Rotate by angle, then 270°. Click Ok.

Flip and Rotate dialog by selecting Image, Flip/Rotate.

From the

File Menu, select Save As and save the logo in a directory location that you will

remember.

NOTE: If the print heads are being controlled via a PC using the InkJet Demo software rather than an Marksman HHI controller, then store the logo in

Jet\bmps

5780-329 Operations Manual Rev J Page 53

.

c:\Program Files\Ink-

Thermal JetAppendix H: Uploading Files to the Print Head and File Man-

Appendix H: Uploading Files to the Print Head and File Management

CAUTION: Power should be disconnected from the print head prior to connecting or disconnecting any external devise, including: PC, handheld, 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.

NOTE: Files can

not be transferred while thermal jet print heads are printing. Pause print

first.

Font and bitmap (logo) files are uploaded to the print head via the Marksman HHI controller or PC Inkjet Demo software using the File Manager on the System Utilities screen. In addition to uploading files, the File Manager also allows removal of files from the print heads; however, files cannot be copied from a print head. During the upload process, files are simultaneously added to or removed from all print heads on the daisy chain being addressed. Operations on an individual print head are possible only when it is the sole head on the daisy chain.

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. Refer to “Appendix D: File Backup and Restore” on page 44, step 4. Select the "Transfer file from PC to controller" option. Browse the PC and locate the BMP. Select Ok to transfer the file to the controller.

To access the File Manager utility:

1. Touch the

Control Panels button on the Home screen.

2. Touch the

5780-329 Operations Manual Rev J Page 54

Utilities button; the System Utilities screen is displayed.

Thermal JetAppendix H: Uploading Files to the Print Head and File Man-

3. Scroll to the bottom of the utilities list and select File manager.

4. Touch the

The

home folder contains all folders and files related to Marksman HHI operation; task

folders,

Task:1 and Tas k :2 (not shown), contain the font and logo files present on the print

Do Function button; the File Manager screen is displayed.

heads on their respective tasks. Task folders are present only when one or both of the controller's serial ports are configured for serial print heads. Not shown above are folders

usb0 and usb1, which are displayed when USB drives are plugged into the one or both of

the Marksman's USB ports. The Marksman HHI controller will show only

usb0 as it has

only one USB port. USB folders are not displayed when running the PC InkJet Demo program.

Adding Logo and Font Files

So that they may be correctly selected, displayed, and printed, logos and fonts must be stored on both the controller and the print head(s).

On the controller, logos are stored in the folder

/home/fnts. Files are automatically placed in the correct folders when transferred to

folder 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. The example assumes the file being uploaded is already on the controller.

5780-329 Operations Manual Rev J Page 55

/home/bmps, and fonts are stored in the

Thermal JetAppendix H: Uploading Files to the Print Head and File Man-

1. Open the home folder. The display shows the available folders and files:

2. The display shows a list of available files. Highlight the

bmps folder with the up /

down arrows and open it:

3. Select the file to be uploaded to the print head(s), and then touch the

Close folder, go up one level

Copy button.

4. Close the

5. Close the

5780-329 Operations Manual Rev J Page 56

bmps folder, returning to the home folder level.

home folder, returning to the top level.

Copy

Thermal JetAppendix H: Uploading Files to the Print Head and File Man-

6. Select and open the Tas k :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.

Open

7. 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.

Paste

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

5780-329 Operations Manual Rev J Page 57

Thermal JetAppendix H: Uploading Files to the Print Head and File Man-

To remove a file from all print heads on a task:

1. Select and open the task folder.

Open

2. Select the file to be deleted, and then touch the

Delete

3. The file is deleted and the file list updated:

Delete button.

5780-329 Operations Manual Rev J Page 58

Thermal Jet Appendix I: Communicating Directly to the Print Head

Appendix I: 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 pc GUI software interface.

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Thermal Jet Appendix J: Aligning the 1" (25.4 mm) Print Head

LOOSEN THESE SCREWS

Appendix J: 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.

1. Ensure the front face of the print head is perpendicular to the substrate being printed.

2. Create a message using the Arial 300 font and run a print sample with the actual product.

3. 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.

4. Snug the mounting screws and run another print sample. If the overlap or gap is not acceptable, then repeat the previous step.

5. Repeat the previous two steps until the two cartridges are matched vertically.

6. Fully tighten the mounting hardware.

7. Now observe the horizontal alignment of the characters.

8. Horizontal misalignment can be compensated electronically through the controller or GUI software program by navigating to the

Control Panels from the

Home Screen, pressing System Setup

, and then touching the print

head in question.

9. An adjustment box, labeled as

offset adjustment,

is available to

A to B

compensate for any horizontal misalignment. Increase or decrease the number in the box and press

Apply.

The next print will have adjusted the alignment one way or the other. Repeat this step until the desired horizontal alignment is achieved.

Press on this box to highlight, and then type in an adjustment value

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Thermal Jet Appendix K: Bulk Ink Supply

Print Head

Regulator

For the system to function properly it is critical that the regulator be positioned appropriately in relation to the print head as shown.

1-1/4"±1/8"

Appendix K: 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 (Marksman HHI 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.

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Thermal Jet Appendix K: Bulk Ink Supply

Ink service port

(1900-757)

Fitting, t ee, reduc er, 1/8" t o 3/32" (5361-349)

Tubing, 3 /32 ID x 5/32 OD

(1303-56 4)

Bulk Ink Supply

Trunk line Tubing , 1/8" ID x 1/4" OD (1301-468)

Bulk Ink Print head 2

Reg ulator (5780-1 05)

Tubing, 1/ 8" ID x 3/16" O D (1303 -563)

Fitting assembly, s eptum to

1/8" b arb (5780-393)

Bulk Ink Print head 1

Bulk Ink cartridge

TUBING DIAGRAM

3' Ma ximum vertical

rise from bulk ink

supply to print head

Orient as shown

10' Max imum ho rizontal sepa ration bet wee n Bulk Ink Sup ply and f urtherst Print H ead

Valve, Q D to 1/ 8" barb

(1900-75 7)

BULK INK SUPPLY

POWER SUPPLY 15V (P/N: 5760-930)

BEACON

(P/N: 5780-214)

ENCODER

(P/N: 5760-820-IJ)

CABLE, SERIAL

(P/N: 5780-319-10)

CABLE, SERIAL

(P/N: 5780-319-10)

CABLE, SERIAL, F/F

(P/N: 5780-616-06)

PRINT HEAD 2

PRINT HEAD 1

PHOTOCELL

(P/N: 5760-383)

ACCESSORY

HUB

POWER SUPPLY

15V (P/N: 5760-930)

MARKSMAN HHI

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.)

3. Make all electrical connections as shown, including all power connections per the diagram below.

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Thermal Jet Appendix K: Bulk Ink Supply

Valve

Trunk line

Bul k Ink Su pply

Syr ing e

Regulator

Print head

Septum fit ting

Pres sure re lief valve

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:

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.

Configuring system for bulk ink supply

At the controller (or PC software) in the print head setup, select the "Uses bulk ink supply" check box for each print head in the daisy chain.

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Thermal Jet Appendix K: Bulk Ink Supply

Print head

Regulator

Conve yor

Cart on b e ing p rin te d on

5-1/4"±1/2"

5/16"±1/2"

Regulator

Fitting, straight through, 1/8" barbs (5361-315)

Septum fitting

Tubing, 1/8" id x 1/4" od

(130 1- 46 8)

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.

2. It will be necessary to splice in a length of tubing between the regulator and print

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head (see image below). This should be done before bleeding air out of the ink lines.

Thermal Jet Appendix K: Bulk Ink Supply

1/8 ± 1/4"

SoloSeries45 SoloSeries90

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).

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 car-

tridge. The system will detect the new cartridge and begin pressurizing automatically.

● Maximum print heads per ink system: Four 1" print heads, eight ½" print heads, or any combination of the two totalling eight print cartridges.

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Thermal Jet Appendix K: Bulk Ink Supply

● A red LED on the rear panel of the SoloSeries IS, 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 no one second "off" periods - indicates a missing ink cartridge or the cartridge is not being detected by the system.

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