5600 - Book For Service Engineers Rev 02

Book for service engineers

Version 02 November 2009

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Contents

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Contents SECTION 1 ............................................................................................................................................................................11 SAFETY .................................................................................................................................................................................11 1.1 CERTIFICATION...........................................................................................................................................................13 1.2 AUTOMATIC START UP .............................................................................................................................................13 1.3 SAFETY LABELS...........................................................................................................................................................14 1.4 LOCATION OF SAFETY LABELS..............................................................................................................................15 1.5 FORESEEN USE .............................................................................................................................................................16 1.6 MISUSE............................................................................................................................................................................16 1.7 TRAINING PROGRAMS...............................................................................................................................................17 SECTION 2 ............................................................................................................................................................................21 PRINTER DESCRIPTION / THEORY ..............................................................................................................................21 2.1 BASIC THEORY.............................................................................................................................................................22 2.2 CONTROLLER THEORY.............................................................................................................................................30 2.4 SPECIFICATIONS AND DIMENSIONS ...................................................................................................................142 SECTION 3 ..........................................................................................................................................................................153 PRE INSTALLATION........................................................................................................................................................153 3.1 INSTALLATION POLICY ..........................................................................................................................................154 3.2 PRE-INSTALLATION FORM FOR 5600/5800.........................................................................................................155 3.3 DRY START-UP............................................................................................................................................................163 SECTION 4 ..........................................................................................................................................................................167 ADVANCED INSTALLATION.........................................................................................................................................167 4.1 SCANNERS CLV UTILITY.........................................................................................................................................168 SECTION 5 ..........................................................................................................................................................................183 AFTER SALES SUPPORT ................................................................................................................................................183 5.1 INSTALLATION/START-UP......................................................................................................................................185 5.2 WARRANTY .................................................................................................................................................................187 5.3 SERVICING OPTIONS................................................................................................................................................188 5.4 PM CONTRACTS .........................................................................................................................................................190 5.5 ACCESS CHECKLIST.................................................................................................................................................191 SECTION 6 ..........................................................................................................................................................................203 REMOVE AND REPLACE PROCEDURES ...................................................................................................................203 6.1 NEW HEAD REPLACEMENT ...................................................................................................................................204 6.2 5800 PRINT ENGINE REPLACEMENT PROCEDURE .........................................................................................205 6.3 UPGRADING FIRMWARE FROM THE F.U.U. ......................................................................................................220 6.4 UPGRADING FIRMWARE WITH USB....................................................................................................................223 5600/5800 Service Manual Rev. 02 November 2009 6/339

Contents 6.5 PRINTHEAD CALIBRATION....................................................................................................................................225 6.6 KITS, ETC. ....................................................................................................................................................................226 SECTION 7 ..........................................................................................................................................................................231 TROUBLESHOOTING ......................................................................................................................................................231 7.1 BASIC TROUBLESHOOTING ...................................................................................................................................232 7.2 FAULT AND WARNING TYPES ...............................................................................................................................235 7.3 FAULT AND WARNING LIST...................................................................................................................................235 SECTION 8 ..........................................................................................................................................................................261 ELECTRONICS ..................................................................................................................................................................261 8.1 ELECTRICAL LAYOUTS...........................................................................................................................................262 8.2 SCHEMATICS ..............................................................................................................................................................274 8.3 FLOW BLOCK DIAGRAMS.......................................................................................................................................279 8.3 FLOW BLOCK DIAGRAMS.......................................................................................................................................280 SECTION 9 HYDRAULICS...............................................................................................................................................284 9.1 HYDRAULIC / PNEUMATIC LAYOUT ...................................................................................................................285 SECTION 10 SOFTWARE & CONNECTIVITY............................................................................................................291 10.1 COLOS .........................................................................................................................................................................292 10.2 DOWNLOADING COLOS CREATE FILES TO USB DEVICE...........................................................................300 10.3 WEB USER INTERFACE..........................................................................................................................................308 10.4 SCANNER INTERFACE UTILITIES ......................................................................................................................312 10.5 CONNECTIVITY PARAMETERS ...........................................................................................................................315 10.6 NEXTGEN COMMUNICATIONS PROTOCOL COMPARISON .......................................................................322 SECTION 11 ........................................................................................................................................................................327 INKS & CONSUMABLES .................................................................................................................................................327 11.1 USAGE PER PRINT CALCULATOR ......................................................................................................................328 11.2 INK CAPABILITIES ..................................................................................................................................................328 SECTION 12 ........................................................................................................................................................................331 BAR CODES ........................................................................................................................................................................331 12.1 TBD...............................................................................................................................................................................332 SECTION 13 GLOSSARY .................................................................................................................................................335 13.1 GLOSSARY OF TERMS............................................................................................................................................336

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Section 1 Safety

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Section 1- Safety

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Section 1- Safety The Model 5600/5800 has been designed to meet various safety standards. To alert you to potentially hazardous situations, labels and messages appear on the print system and throughout the guides. CAUTION refers to a potentially hazardous situation which, if not avoided, could result in personal injury.

1.1 Certification The Model 5600/5800 has been designed to meet the following standards and specifications. CE Marked • 98/37/EC • 2006/95/EC • 89/336/EEC • EN 60204-1 • EN 61000-6-4 • EN 61000-6-2 •

UL Listed

Machinery Directive Low Voltage Directive Laws for electrical equipment within certain voltage limits EMC Directive Laws relating to electrical magnetic compatibility Electrical Safety Generic Emission Generic Immunity Complient thru ETL

• EN 292 and 204/108/CE

1.2 Automatic Start Up CAUTION Do not allow an automatic packaging machine startup after a Model 5600/5800 reset. Install the Model 5600/5800 Status Output Signal Option for a manual packaging machine reset. Automatic startup of a packaging machine could kill or seriously maim an operator.

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Section 1- Safety TECHNICAL ISSUE: The Model 5600/5800 has an optional feature which enables it to stop or prevent packaging machine operation when print system conditions prevent marking the packages. These conditions include, but are not limited to, FAULTS, WARMUP PERIODS, and PRINT DISABLED STATUS. Some of these print system conditions are cleared manually by the operator, and some are cleared automatically. In either case, if the Model 5600/5800 has NOT been properly connected, the packaging machine can begin cycling when the condition is cleared. Failure to observe this may result in personal injury. ACTION: There are various ways for the end user to install the Model 5600/5800 Status Output Signal Option to control a packaging machine. Only someone familiar with the packaging machine can determine the best way to signal it with an external device like the Model 5800. If in doubt, consult the manufacturer of the packaging machine. THE MODEL 5600/5800 END USER IS RESPONSIBLE FOR CONFIGURING THE SOFTWARE AND INSTALLING THE STATUS OUTPUT SIGNAL OPTION IN A WAY THAT REQUIRES THE OPERATOR TO MANUALLY RESTART THE PACKAGING MACHINE AFTER A MODEL 5600/5800 CONDITION HAS BEEN CLEARED. Any deviation from this method is unsafe and is not approved by Markem-Imaje or applicable regulatory agencies. Ratings: Each set of dry contacts in the two status relays is rated for a maximum of 30 VDC at 1 Amp.

1.3 Safety Labels Hot Surfaces. To prevent injury from burns, be careful not to touch the jetting assembly surface or hot ink directly. Wear protective eyeglasses when working with hot ink.

Protective Earth. This label identifies a protective earth point.

High Voltage. This label indicates there are high voltages inside the controller. To prevent injury from electrical shock, remove the power cord from the electrical outlet before servicing the controller.

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Section 1- Safety

1.4 Location of Safety Labels

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Section 1- Safety

1.5 Foreseen Use The Model 5600/5800 is an industrial drop-on-demand ink jet print system designed to address the marking and coding requirements of secondary package coding in the fast-moving consumer goods segment. Addressable substrates include coated and uncoated corrugates, rigid plastics, flexible films, and shrink wraps.

1.6 Misuse Using this print system for anything other than the specific application can be a misuse. Contact Markem-Imaje before attempting to use this print system for anything other than the intended use. Misuses include but are not limited to: ƒ

Failing to observe instructions or directives pertaining to the installation, use, and repair of this print system, including the use and disposal of related chemicals.

ƒ

Operating an unserviceable, incomplete, or modified print system.

ƒ

Not observing safety messages and labels.

ƒ

Permitting an unqualified person to operate or repair this print system. See “Training Programs.”

ƒ

Combining or interfacing other equipment with this print system for anything other than the intended use.

ƒ

Using supplies or materials that are not recommended for use with this print system, which may produce unsatisfactory or unexpected results.

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Section 1- Safety

1.7 Training Programs Operators, maintenance personnel, and service technicians are considered qualified when they have gained, through training and experience, an understanding of safe and correct methods of operation, maintenance, or repair. Markem-Imaje conducts training programs. In addition to ongoing courses about current machine models, customers are invited to inquire about any training need.

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Section 1- Safety Notes:

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Section 2 Printer Description / Theory

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Section 2 - Printer Description – Theory 2.1 Basic Theory 5600/5800 Common Controller The 5600/5800 Controller consists of the following sub-assemblies: -

AC Input Filter Power Distribution PCA Transformer Switching Power Supply Controller Main PCA LCD I/O PCA QVGA Color Display

The AC Input Filter incorporates an IEC 60320 (formerly IEC 320) C14 connection. Input voltage to the filter may be configured by selecting the appropriate orientation of the removable fuse cartridge. Configurations for voltages between 110v-120v and 220v-240v may be selected. The device is shipped in the 220-240V configuration. The AC Input Filter supplies voltage to the Power Distribution PCA. - Fuse requirements for the cartridge are: - 110-120V: 8A TD 250V - 220-240V: 4A TD 250V

The Power Distribution PCA supplies and receives power for several different machine functions. This PCA receives AC Main voltage from the AC Input Filter on X10.

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Section 2 - Printer Description – Theory The PCA supplies AC voltage (100/200VAC (X8) or 115/230VAC (X7) depending on which connection is used) to the Primary side of the Transformer. It then receives 24VAC back from the secondary side of the Transformer on X2. The PCA supplies 24VAC to Printhead 1 via X5, Printhead 2 via X6, and to the Switching Power Supply via X9. The PCA receives 24VDC from the Switching Power Supply on X4. It supplies 24VDC to Printhead 1 via X1 and to Printhead 2 via X3.

The Transformer is rated at 400VA. The Primary winding is supplied AC voltage from the Power Distribution PCA. The 24VAC output from the Secondary winding is sent back to the Power Distribution PCA on X2. The Switching Power Supply can supply up to 6.1A @ 24VDC An operating voltage of 24VAC is supplied from the Power Distribution PCA to CN1 of the Power Supply. The Power Supply outputs 24VDC via CN2 which is shared by the Power Distribution PCA and the Controller Main PCA. The Controller Main PCA contains the NVRAM battery, Ethernet port and optional Wi-Fi port, Power PC Microprocessor, and I/O facilities. - The NVRAM Battery is a 3.6V 1.5AA Lithium battery. The battery is replaceable. - Ethernet is available through an integrated RJ45 connection accessible from the I/O panel on the back of the control box. The optional Wi-Fi is facilitated through an integrated RJ45 connection on the board itself. This connection is accessible by opening the Controller enclosure. Both Ethernet options are configured through the machine settings via the User Interface.

- I/O functions are an integral part of the Controller Main PCA and are accessed through the I/O interface panel on the back of the Controller enclosure. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2 - Printer Description – Theory o o o o o o o o o o o

X1: PH1 20 pin / Mini D-Shell X2: PH2 20 pin / Mini D-Shell X3: Scanner 1 / 15 Pin HD X4: Scanner 2 / 15 Pin HD X5: OEU Interface / 15 D-Shell X6: RS232 / NGPCL / 9 Pin D-Shell X7: Fault / Warning / Verification Relays / 15 Pin D-Shell X8: USB Type A Host X9: USB Type B Device X11: Ethernet / RJ45 X14: Status Beacon / 5 Pin Round Amphenol

X14

X11

X7

X6

X5

X4

X3

X2

X1

X9 X8

- Printhead power connections are facilitated through two 5 Pin Round Minifit connectors, each being labeled and assigned to a specific printhead (1 and 2).

-

The LCD I/O PCA is the interface between the Controller Main PCA, the Controller Front Overlay and the QVGA Color Display. The LCD I/O PCA connects to the Controller Main PCA J12 via the X4 50 pin FFC connection. The Front Overlay connects to the LCD I/O PCA via the X5 connector. The QVGA Color display connects to the LCD I/O PCA via X3 (33 pin FFC), X2(Touch screen) and X1 (Back Light).

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Section 2 - Printer Description – Theory The QVGA Color Display is a touch screen interface for the operator. Power, signal, and control for the display are routed through the LCD I/O PCA. A Touch Screen calibration process can be accessed via operator input through the Display.

Printhead The major components of a printhead consist of the Jetting Assembly, Primary Reservoir, Supply Reservoir, Printhead PCA, Statistics Data Module, High pump, Low Vacuum Pump, Pressure Control Solenoids and the enclosure. Model 5600 printheads will also have an Ink Supply cartridge and an Ink Recovery module. Depending on the model configuration, a system can support up to two printheads, each with individual control. *Note: The controller can only operate one printer technology at a time. There is no facility or option to control one 5800 head and one 5600 head at the same time with one controller. *Jetting Assembly The Jetting Assembly consists of a heated jetting array which contains 256 addressable jets. Controlled individual firing of the 256 jets creates the “drop-on-demand” print legend. Ink is supplied to the Jetting Assembly by the Primary Reservoir. • The 5800 uses a faceplate which contains 512 orifices, 2 for each jet, arranged in staggered pairs • The 5600 uses a faceplate which contains 256 orifices, 1 per jet, arranged in a single row. *Primary Reservoir The Primary Reservoir holds ink in a liquid state for use by the Jetting assembly. It contains a heater to maintain the ink in a liquid state. The Primary Reservoir is located behind the black printhead cover. * Together, the Jetting Assembly and the Primary Reservoir are defined as the Print Engine.

Primary Reservoir

Jetting Assembly

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Section 2 - Printer Description – Theory Supply Reservoir The Supply Reservoir receives and holds ink to be pumped on demand to the Primary Reservoir. Ink is inserted into the Supply Reservoir in a solid state through the ink door on the top of the printhead. The Supply Reservoir contains a heating element to heat the ink to a liquid state to enable it to be pumped to the Primary Reservoir as needed. •

5800: Ink is inserted into the Supply Reservoir in a solid state through the ink door on the top of the printhead. The Supply Reservoir contains a heating element to heat the ink to a liquid state to enable it to be pumped to the Primary Reservoir as needed.

•

5600: An ink cartridge is installed on the Ink Interface located on top of the Supply Reservoir. Ink is drawn from the cartridge into the Supply Reservoir using vacuum generated but the High Pump. The 5600 Supply Reservoir has no heating mechanism. Supply Reservoir

The Printhead PCA The Printhead PCA provides the life support functions for the ink management (vacuums, pressures, temperature regulation, ink level management, strobe voltage) as well as the communications interface to the controller. Through the communications interface, it provides diagnostic data, settings management, manual controls, statistical data and language file management.

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Section 2 - Printer Description – Theory Statistics Data Module The Statistics Data Module is an outboard memory device that contains the statistical data for the printhead. It is mounted such that when the Ink Delivery module is sent to Markem-Imaje for repair, the statistical module travels with the IDM.

High Pump The High pump is used to pressurize the Supply Reservoir to pump ink to the Primary Reservoir and to purge ink from the Jetting Assembly. The High Pump resides within the printhead enclosure between the Supply Reservoir and the back panel. On the 5600, the Vacuum side of the high pump is used to pull ink from the Supply cartridge into the Supply reservoir as well as pulling ink from the Waste Ink tray into the waste collection portion of the supply cartridge. Low Vacuum Pump The Low Vacuum Pump is used to maintain a vacuum inside the Primary Reservoir to keep ink from leaking out of the face of the Jetting Assembly. The Low Vacuum Pump resides within the printhead enclosure between the Supply Reservoir and the back panel, just above the High Pump. 5800

5600

Supply Reservoir

Supply Reservoir

High Pump

Low Pump

High Pump

Low Pump

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Section 2 - Printer Description – Theory Pressure Control Solenoids The Pressure Control Solenoids are used to route pressure and vacuum to the appropriate areas within the printhead system. The control of these solenoids is driven by pressure and vacuum requirements determined throughout printhead operation. • •

The 5800 uses 5 solenoids to facilitate pneumatic control for the printhead The 5600 has an added solenoid (S6) to facilitate the waste ink recovery system

5600 only

Printhead Operation The volume of ink in the Supply Reservoir is monitored by comparing the time it takes to reach a specified pressure to a predetermined calibration value. The Supply reservoir is pressurized using the High pump. This pump, once actuated, runs at a constant rate and its pressure is regulated at approximately 7psi by the R1 restrictor. To check ink volume, solenoids S2 and S3 are enabled and the High Pressure pump is turned on. Pump pressure is applied to the Supply Reservoir and its pressure is monitored by the Supply pressure sensor located between restrictor R5 and the Supply chamber. The software uses the value from the sensor to calculate the chamber volume by checking the amount of time it took to reach the predetermined pressure. The Supply Volume Measurement sequence is scheduled on boot-up. After reaching a fully melted state (90 minutes), the sequence is scheduled based on the ink usage rate (primary reservoir fill cycles). Ink Supply volume is indicated on the Color User Interface on the Controller. As ink is pumped to the Primary reservoir and the Supply reservoir volume drops, the current ink supply state will be displayed. •

When ink is required on a 5800, the operator will add ink block(s) through the door on the top of the Supply reservoir. The ink door is locked and will not open until ink is needed. When ink is required, the Ink Door interlock will be disabled and the operator will be able to open the door to add ink.

•

When ink is required on a 5600, the operator will install a new ink cartridge on the Ink Interface located on top of the Supply reservoir.

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Section 2 - Printer Description – Theory As printing occurs, ink will be consumed and the level of ink in the Primary Reservoir will drop. The ILS monitors the reservoir volume and determines when additional ink is to be pumped to the Primary Reservoir. A 100watt Primary Reservoir heater is used to maintain the reservoir temperature to keep the ink in a liquid state. The temperature is monitored by the Primary Reservoir Thermistor. •

The 5800 Print Engine harness contains a Thermal Overload Protection device which will interrupt the Primary Reservoir heater and Jetting Assembly heater circuit if it exceeds 140°c.

•

The 5600 Print Engine harness contains a Thermal Overload Protection device which will interrupt the Primary Reservoir heater and Jetting Assembly heater circuit if it exceeds 70°c.

When ink is required by the Primary reservoir the S2 and S3 solenoids are enabled and the High pump is turned on to apply pressure to the Supply Reservoir chamber. This pressure will force liquid ink from the Supply reservoir through the F3 filter, check valve CV2, and into the Primary Reservoir. Ink is pumped to the Primary Reservoir until the ILS is satisfied. The ink then flows to the heated printhead array where it is chambered into each of the 256 individual jets. The purpose of the Low Vacuum pump is to create a vacuum in the primary reservoir to maintain the proper meniscus on the jets. Without this, the ink would be allowed to weep freely from the jet array. Low Vacuum is monitored by the Low Vacuum sensor at the A2 accumulator. Solenoid S4 is enabled to allow vacuum to be applied to the Primary reservoir. The pump draws through the F4 filter, R2 restrictor, A2 accumulator, R3 restrictor and the A1 accumulator as well as through the S4 solenoid and Primary reservoir. The pump will vent to atmosphere through the R2 restrictor. The input from the Low Vacuum sensor is used by the Controller to adjust the duty cycle of the Low Vacuum pump to regulate the vacuum in Primary Reservoir. When the Printhead receives digital print signals, 200-volt pulses are supplied to the individual piezoelectric transducers (PZT’s). The PZT’s then flex to eject or “fire” a drop of ink. The jetting assembly is kept at operating temperature with a 50w heater. Jetting assembly temperature is monitored by the Jetting Assembly Thermistor. On the rear of the printhead enclosure there are 2 buttons that provide the ability to purge the printhead or test fire all the jets to ensure optimum print performance. Two methods are available to purge the Printhead; Manual or Auto Purge. Manual Purge is initiated by pressing the Purge button on the back panel of the Printhead. The Purge process is then accomplished by enabling the S2 and S5 solenoids and disabling the S4 solenoid. The High pump is actuated and pressure is applied to the primary reservoir, thus forcing ink to flow through the Jetting Assembly which will purge any debris or contaminates. Auto Purge is enabled through the Machine Settings via the Controller’s User Interface. Once enabled, the Printhead will be automatically purged at a preset product count. The operator will define this interval in the Machine Settings, also via the User Interface.

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Section 2 - Printer Description – Theory For both Purge methods, the Purge duration is set by the user in the Machine Settings. The 5600 utilizes a Waste Ink recovery system. As ink is purged, it is collected in the Waste Ink tray. This tray is connected to a waste reservoir within the Ink Supply cartridge via an ink recovery circuit. When ink is purged and collected in the waste tray, S6 will be enabled to allow vacuum to be applied to the waste chamber in the cartridge. This vacuum is generated by the intake side of the High pump. This vacuum draws the waste ink from the tray to where it is stored in the waste chamber of the cartridge. When the Ink Supply cartridge is empty, it is removed and discarded along with the waste ink that was collected from the tray. A Jet Test feature is available for use in Print Quality diagnosis. The Jet Test is initiated by pressing the Jet Test button on the back panel. This will actuate all of the jets in the array by printing a predetermined test pattern. Lines or sections missing from the pattern indicate blocked or inoperative jets. The Jet Test pattern is a fixed program and is printed using a density value of 3 and an internal encoder value of 70 mm/s. The length or duration of the Test Image is determined by how long the user actuates the Jet Test button. A single push of the button will run the Jet Test long enough to satisfy the requirement for the test firing sequence. If the button is pressed and held, it will continue to run and repeat the test sequence until the button is released.

2.2 Controller Theory General The Controller supplies 24VDC for logic power and 24VAC for heater power to the printhead over the yellow power cable. All communications with the controller is done via a multi channel high speed serial interconnect scheme. The single communications cable has discrete LVDS channels for the product sensor output, each of the two encoder channels (A and B quadrature) and the MCPAP protocol serial communications. The controller coordinates the system actions through an implementation of the industry standard PackML 2.2 system state definition as shown in section 2. The controller is responsible for transitioning the printer(s) to the appropriate PackML states.

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Section 2 - Printer Description – Theory Automatic Mode Off State (Boot-up) Printer Hardware initialization The system boots up in the Automatic mode and Off state of PackML. On bootup the printhead initializes the following subsystems in the order of: • • • • • • • • • • • • •

Kernel sequencer Analog to Digital converter Processor ports and other low level outputs and inputs Faults and warnings Ink management hardware including the pumps, heaters, solenoids and strobe voltage power supply SPI communication channel for the language file database memory I2C communications channel for the settings memory, statistics memory and digital potentiometer Language file database XML file database Requests the settings from the non-volatile (NV) memory on the I2C bus Requests the statistics from the non-volatile memory on the I2C bus RS232 serial communications channel for the MCPAP protocol The following state machines: the three heat zones, low vacuum, PackML sequencing, primary reservoir filling, supply reservoir volume measuring, ink door monitoring and purging. These state machines are periodically updated every 50 to 250 milliseconds.

Note: All of the above happens in the first couple of seconds Controller / Printer Synchronization Five seconds after power-up, the controller requests the XML files that define the printer’s Manual Controls, Fault and Warnings, Statistics, Settings and Diagnostics. In addition, the controller requests the currently active language file which contains the strings used by the UI to display the items from the other XML files. The file transfers can take 90 seconds or more.

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Section 2 - Printer Description – Theory Once the XML file transfer is done, the printer performs initialization of several settings in the controller’s FPGA. When the FPGA has been setup, the printer enters the STOPPED state and waits for commands from the printer. After System Boot Up The Status lamp will blink fast in this state. 1. The controller sends a request for the printhead to go to the Ready or Producing state 2. The low vacuum pump and solenoid 4 is turned on to apply low vacuum to the primary reservoir. 3. The primary reservoir and jetting assembly thermal zones are enabled. 4. The printhead waits for the low vacuum to reach its set point 5. The printhead waits for the jetting assembly to reach its temperature set point. 6. The printhead waits for the primary reservoir to reach its temperature set point. 7. 5800 Only - The supply reservoir thermal zone is enabled. If the supply temperature is below 80º C, the supply set point temperature is changed to 125º C and a 30 minute timer is started, otherwise it uses the default set point temperature and no timer. If the timer was started, when it expires the supply reservoir temperature will be restored to the default set point temperature. 8. 5800 Only - The printhead waits for the ink door to be closed. 9. Calculate a dwell time for the ink level sensor. If the printhead is coming up from a cold state, it will wait up to 3.5 minutes after the primary reservoir reaches its set point temperature before allowing a transition to the Ready state. If the system is fairly warm (ink is liquid), the dwell is skipped. 10. The printhead does a supply volume check. 11. The printhead fills the primary reservoir if it is not already full. 12. The printhead enters the Ready state Ready, Producing and Held States The printhead treats the Ready, Producing and Held states the same. The only difference among them is that the "Producing Time" statistic is only incremented in the producing state. Jet testing and purging can only be performed in these states. The Status lamp will be on continuously or, if ink can be added, it will blink slowly. Aborted State If a fault condition is detected on the printer, it will disable any critical outputs and then inform the controller of the fault. The controller will then issue a request for the printer to go to the Aborted state. When the printer receives the request to enter the Aborted state, the printer will:

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Section 2 - Printer Description – Theory • • • • • • • •

Disable purging, aborting any purge in progress Disable jet testing, aborting any jet test in progress Disable ink supplies checking, aborting any supply level check in progress Disable the maintenance of the ink level in the primary reservoir, aborting any primary reservoir fill in progress Disable the strobe voltage The Status lamp on the printer will blink fast The printer will remain in this state until it receives a state change command from the controller (Stopped, Ready, and producing). On transition from the Aborted state, all fault information is cleared. If the controller requests a transition to Ready or Producing, the printer transitions to these states after passing through the Stopped state, turning off all outputs. This has the effect of resetting all state machines and allows the printer to test the fault condition as part of a normal Start-up state sequence.

Stopping State (Shutdown button) When the Shutdown button on the UI is pressed, the controller sends a request to go to the Stopped state. The printer will do sequentially to minimize the ink loss from the jetting assembly until the ink reaches a frozen state. The printer will: • • • • • • • • •

Ensure any primary reservoir fill cycle in progress is allowed to complete Blink the Status lamp fast. Disable all sequences from being initiated, aborting any sequence in progress Disable jet testing, aborting any jet test in progress Disable the strobe voltage Set the operating temperature of the jetting assembly to 75ºC Disable the primary reservoir heater 5800 only: Disable the supply reservoir heater. Turn on the low vacuum pump and solenoid 4.

The printer will then wait for the temperature of the jetting assembly to reach the new 75ºC set point. When this temperature is reached, the jetting assembly thermal zone is disabled, the low vacuum is disabled and the printer enters the stopped state.

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Section 2 - Printer Description – Theory Stopped State • In the stopped state, no outputs are on with the exception of the fast blinking status lamp. • All automated sequences (jet testing, purging, filling, supply volume checking) are prevented from running. The printer will remain in this state until it receives a state change command from the controller. Manual Mode • The Manual mode is entered when the operator opens any Manual Control menu on the UI. The controller will send a Manual mode request to the printer at that point. • Jet testing and purging are allowed in this mode. • Ink supply volume checking is not performed automatically in this mode although there is a manual control sequence that causes a supply volume check. • Most faults are not reported in the manual mode, the exceptions being the very low level hardware failures such as Software faults, database faults, brownout warnings, etc. Even though these faults are sent, the system will remain in the Manual mode, there will be no transition to the Aborted state. • The Manual mode philosophy is that one should know what they are doing when they enable and disable the various devices. The printer will prevent the flooding of the primary reservoir by disabling solenoid 3 if the high pump is on and the ink level in the primary reservoir is sensed. All other combinations of outputs may be made without intervention of the printer. • When exiting the Manual mode (entering the Automatic mode by exiting the UI Manual Control menu), the printer will always enter the Stopped state, disabling all outputs with the exception of the fast blinking Status lamp. The controller will then issue a request for the printer to go to the Ready or Producing state. Primary Reservoir Fill Sequence This sequence is performed to replace the ink in the primary reservoir that has been used through either purging or printing. There is a level sensor (thermistor) that detects if the ink has reached the level of the sensor. If the ink is not detected, the sequence is started based on the requirements below. • The primary reservoir fill sequence is only allowed in the Ready, Producing and Held states. • If the primary reservoir ink level sensor is invalid, the fill sequence request will be ignored. The ink level sensor is tested periodically for having a valid output. Any voltage measured at the sensor less than 2VDC or greater than 7VDC is considered invalid. • If the primary reservoir is in an Ink Present state, the fill sequence request will be ignored. • If a supply reservoir measurement sequence is active, the fill sequence will be delayed until it completes. • If the supply reservoir is in an Ink Out state, the sequence will be delayed until it detects ink was added. • 5800 only: If the ink door is open, the sequence will be delayed until it is closed. If the ink door is opened during the sequence, the sequence is aborted. • 5800 only: If the supply reservoir is not at the set point temperature, the sequence will be delayed until it reaches the set point temperature. • 5600 only: If an Ink Recover sequence is active, the sequence will be delayed until it completes. • 5600 only: If a Supply Reservoir Fill sequence is active, the fill sequence will be delayed until it completes. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2 - Printer Description – Theory If all of the above conditions are met and the ink level in the primary reservoir is low, the fill sequence will be run as follows: 1. 2. 3. 4. 5. 6.

Read the current low vacuum duty cycle to be used for detection of a flood condition later. Turn off solenoid 5 Turn on solenoid 1 Turn on solenoid 3 Turn on the high pump Start a 60 second timer that will set the maximum time for the primary reservoir to fill before throwing a fill fault. Monitor the low vacuum duty cycle during the actual filling. If the duty cycle changes 10% or more from the duty cycle in step 1, set a flag that indicates the system is not flooded. Monitor the ink level sensor. When it indicates the ink is present, disable the high pump, solenoid 1 and solenoid 3. Test the flooded flag and generate a low vacuum flooded warning if the flag indicates the system is likely flooded. If the timer expires before the primary reservoir is filled, the sequence is terminated (high pump off, solenoid 1 off and solenoid 3 off) and a fill fault is thrown.

7. 8.

9.

Supply Volume Measurement Sequence The basis for the measurement scheme is to measure the time it takes to pressurize the supply reservoir at a constant air flow rate to a known pressure. This time will be inversely proportional to the ink volume in the supply reservoir – the longer it takes, the lower the ink volume. Adjustments for system variations are accomplished using two calibration settings that get modified after the operator performs a calibration procedure. The sequence is scheduled on boot-up, when transitioning from the Starting state to the Ready state. After reaching the Ready, Producing or Held states, the sequence is scheduled based on the ink usage rate (primary reservoir fill cycles). • • • • • • •

This sequence is allowed in all states except the Off and Aborted states This sequence will not be automatically scheduled in the Manual mode. However there is a Manual control sequence that may be selected to perform a volume measurement This sequence will not execute with the ink door open. If the door is opened during this sequence, this sequence is aborted This sequence will not execute when a purge sequence is active. If a purge sequence is activated during this sequence, this sequence is aborted This sequence will not execute when a primary reservoir fill sequence is active 5600: If a supply reservoir fill sequence is active, the supply measurement request will be delayed until the supply reservoir fill completes. 5600: If an ink recovery sequence is active, the supply measurement request will be delayed until the ink recovery completes.

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Section 2 - Printer Description – Theory When this sequence starts, the following will occur: 1. 2. 3. 4. 5. 6.

7.

Disable the high pump Disable solenoid 2 Disable solenoid 3 Disable solenoid 5 Start a 60 timer that sets the maximum time allowed for the supply reservoir to reach zero pressure Wait for the supply reservoir pressure to reach zero millibars. This is necessary because the measurement sequence could have been requested immediately after a primary reservoir fill sequence which would have pressurized the supply reservoir If the timer times out, a supply zero pressure fault is thrown and the sequence is aborted

Once the supply pressure reaches zero, the following is performed: 1. 2. 3. 4.

Enable solenoid 2 Enable the high pump Start a three second timer to allow the pressure to reach a high level Wait for the timer to expire

Once the timer expires the following is performed: 1. 2. 3. 4.

Enable solenoid 3 to apply the pressure to the supply reservoir Start a 20 second timer to limit the maximum time allowed to reach the set point pressure of 82.7 millibars (1.2 PSI) The printer waits for the supply reservoir pressure to reach 82.7 millibars If the timer times out, the sequence is aborted and a Supply Reservoir Pressure Leak fault is thrown. It is assumed that the pressure could not build up because of a leak in the ink door gasket although other failures can account for the failure

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Section 2 - Printer Description – Theory Once the supply pressure reaches the set point pressure, the following occurs: 1. 2. 3. 4. 5.

The timer is stopped Disable the high pump Disable solenoid 2 Disable solenoid 3 The supply volume is calculated using the calibration settings. If the supply volume is abnormally high, it is assumed that the pressurizing orifice is plugged. This would cause a high volume value because the printer would be measuring the volume of just the hoses leading to the supply reservoir. An abnormally high value will cause a Supply Reservoir Orifice Blocked fault 6. The supply status is determined and sent to the controller for updating of the supply bar graph on the Home menu 7. Using the ink usage rate, a timer is started to trigger the next supply volume measurement sequence 8. If the measured volume has increased, the ink supplies used statistic is incremented On the 5600 system: 1. If the supply reservoir measures less than full, a supply fill sequence is initiated. 2. Following the supply fill sequence, another supply measure sequence is performed to determine if the supply is now full. 3. If the supply isn’t full, steps 1 and 2 are repeated two more times in an attempt to fill the supply. 4. If the supply isn’t full after these three attempts at filling from the ink cartridge, an Ink Out fault is thrown and the assumption is that the ink cartridge is empty. 5. It is only after the supply is full or three attempts to fill it are completed that the ink status is sent to the controller. Supply Fill Sequence (5600 Only) This sequence is the means of replenishing the ink that has been pumped to the primary reservoir from the supply reservoir. It is accomplished by applying a vacuum to the supply reservoir which will pull ink from the ink container through Filter F2 and check valve CV1 into the supply reservoir. • • • • • • •

This sequence is allowed in all states except the Stopping, Stopped and Aborted states. This sequence will not be automatically scheduled in the Manual mode. However there is a Manual control sequence that may be selected to perform a supply reservoir fill. If the supply reservoir is full, the fill request is ignored. If the ink cartridge missing, the fill request is ignored. If the cartridge is removed during this sequence, this sequence is aborted. If a purge sequence is active, the supply fill request will be delayed until the purge completes. If a purge sequence is activated during this sequence, this sequence is aborted. If a primary reservoir fill sequence is active, the supply measurement request will be delayed until the primary reservoir fill completes. If an ink recovery sequence is active, the supply measurement request will be delayed until the ink recovery completes. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2 - Printer Description – Theory When this sequence starts, the following will occur: • • • • • •

Enable the high pump Disable solenoid 1 Disable solenoid 3 Disable solenoid 6 Enable solenoid 2 Start a 60 second timer that sets the time that the pump will generate the vacuum to pull the ink from the ink container to the supply reservoir.

Once the fill timer times out, the following is performed: • • •

•

Disable solenoid 2 Disable the high pump Start a 50 second timer to allow the vacuum in the supply reservoir to dissipate. This must be done because a supply measure sequence is initiated following each supply fill sequence. The first step of the supply measure sequence is to wait for zero pressure before starting but there is a one minute timeout for this step. By placing the delay in this supply fill sequence, the Zero Pressure timeout fault is avoided. Empirically it has been determined that one minute is required for the vacuum to dissipate. Wait for the timer to expire.

Once the vacuum dissipation timer times out, the following is performed: • •

Increment the Supply Fill Count statistic If in the Automatic mode, a Supply Reservoir Fill sequence is requested.

Purge Sequence A purge is designed to force ink from the jetting orifices in an effort to remove air pockets or contamination from the face of the jetting assembly. In either case, it is typically done as a reaction to a low quality print (missing jets). • •

•

• •

This sequence is only allowed in the Ready, Producing and Held states because the primary reservoir is up to temperature in those states There are two types of purges: auto and manual. Each of these has its own associated purge time. In addition, the purges can be triggered from two modes: Manual mode and Automatic mode If the primary reservoir is filling when the purge request arrives, the purge request is delayed until the fill sequence is completed. If this was a manual purge request (purge switch pressed), the printer status lamp will flash at a fast rate for five seconds to indicate the request cannot be honored at this time A manual control purge request will be done regardless of the volume of ink in the primary reservoir A non-manual control purge request will only be honored if either the primary reservoir is full or there has not been more than 5 mL of ink purged from the primary reservoir since the last primary reservoir fill sequence 5600/5800 Service Manual Rev. 02 November 2009

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Section 2 - Printer Description – Theory •

If a supply reservoir volume check sequence is active when manual purge request is activated, the volume check sequence will be terminated and the purge sequence will proceed

5600 only: If a supply reservoir fill sequence is active, the purge request will be ignored. 5600 only: If an ink recovery sequence is active, the purge request will be ignored. When a purge sequence starts, the following will occur (in order): 1. The controller is informed a purge is in progress so that it can evaluate any bad prints that might occur due to the purge. 2. Solenoid 2 is disabled 3. Solenoid 3 is disabled 4. Solenoid 4 is disabled 5. Solenoid 5 is enabled 6. The high pump is enabled 7. The purge duration timer is started using the UI menu setting appropriate for the type of purge (auto or manual) 8. The printer then waits for the purge timer to expire When the timer expires the following occur: 1. Turn off the high pump 2. The purge count statistic is incremented 3. If the purge was triggered from the Manual mode, the sequence is done so the following is done: a. Disable solenoid 5 b. Enable solenoid 4 to reconnect the low vacuum to the primary reservoir c. The purge sequence is now complete 4. If the purge was triggered from the Auto mode, the printer waits an additional three seconds. This allows the pressure created by the added ink in the primary reservoir to dissipate through solenoid 5 and restrictor R1 5. Once the three second timer expires the following is done: a. Disable solenoid 5 b. Enable solenoid 4 to reconnect the low vacuum to the primary reservoir c. The purge sequence is now complete

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Section 2 - Printer Description – Theory Waste Ink Recovery Sequence (5600 Only) This sequence is the means of recovering the waste liquid ink from the ink tray. This ink would have accumulated from any purges that have occurred. Waste ink recovery is requested whenever an ink container is inserted and whenever the amount of purged ink exceeds 12 mL. Recovery is accomplished by applying a vacuum to the ink cartridge which will pull the ink from the ink tray into the cartridge waste area. This sequence is allowed in all states except the Stopping, Stopped and Aborted states. This sequence will not be automatically scheduled in the Manual mode. However, there is a Manual control sequence that may be selected to perform a waste ink recovery. If the ink cartridge is missing, the request is ignored. If the cartridge is removed during this sequence, the sequence is aborted. If a purge sequence is active, the request is delayed until the purge is done. If a supply reservoir volume measurement sequence is active, the request is delayed until the supply reservoir volume measurement is done. If a primary reservoir fill measurement sequence is active, the request is delayed until the primary reservoir fill is done. If a supply reservoir fill sequence is active, the request is delayed until the supply reservoir fill is done. When this sequence starts, the following will occur: • Disable solenoid 1 • Disable solenoid 2 • Disable solenoid 3 • Disable solenoid 5 • Enable solenoid 6 • Enable the high pump • Start a 20 second timer that sets the time waste ink is recovered When the waste ink timer times out, the following occurs: 1. Disable the high pump 2. Disable solenoid 6 3. Increment the Waste Recovery Count statistic 4. Clear the purge volume variable 5. The sequence is done Jet Test Sequence A jet test is performed to check the printing status of all jets in the printer jetting assembly. It is done at a fixed density of 3 and will print in the current print direction assigned to the head (direction viewed from the cable end of the printer). It prints using the internal encoder at a speed of approximately 70 millimeters per second. The jet test sequence is only allowed in the Ready, Producing and Held states of the Automatic mode The sequence may be performed in the Manual mode (while in any Manual Control menu) The printer does not directly control the jet testing; it simply monitors the jet test switch and reports the status to the controller • The jet test pattern is automatically created by the FPGA in the controller • The controller will log missed prints if the jet test is performed during active label printing • The jet test pattern will be printed as long as the operator presses the switch 5600/5800 Service Manual Rev. 02 November 2009

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Section 2 - Printer Description – Theory Ink Cartridge Monitor (5600 only) The ink cartridge is monitored to determine if it has been removed too long. There is a 3 second delay between cartridge state transitions so it will take three seconds for the cartridge state to display as Present once the operator install the cartridge. • • • •

The ink cartridge is monitored in all but the Stopping and Stopped states. The installation of the cartridge will activate a supply reservoir measurement sequence if the current supply volume is not Full. Upon completion of this sequence, the state of the door lock is evaluated. If the ink cartridge is removed, a one minute warning timer is started and the printhead waits for the cartridge to be installed. If the warning timer times out, an Ink Cartridge Missing warning is thrown.

If the ink cartridge is installed, the following occurs: • Any Ink Cartridge Missing warning is cleared. • Any Ink Cartridge Empty warning is cleared. • If not in the Manual mode, a supply reservoir volume measurement sequence is requested. • If not in the Manual mode, an ink recovery sequence is requested. • The Ink Supplies Used statistic is incremented. Heat Zones This section describes how each of the heat zones (supply reservoir, primary reservoir and jetting assembly) is controlled while they are enabled. The thermal zones are updated periodically (currently every 50 millisecs) to determine if their respective heater should be enabled based on a comparison of the heat sensor (thermistor) to the set point temperature. 5800 Only: Due to limited power being available, the three zone heaters cannot be on at the same time. Because of this, priority is given to the jetting assembly and primary reservoir so if all are requesting power; the supply reservoir must wait until one of the other two zones has reached its set point and no longer needs power. This priority scheme is implemented within U16 (CPLD) on the printer board so the microprocessor does not know how or when it is active. The U16 (CPLD) also implements a heater watchdog feature. The microprocessor requests power for a zone by periodically pulsing the respective heater request line on the CPLD. If the CPLD does not get a pulse in 370 millisecs, it will disable the respective heater. This prevents a heater from being left on if the microprocessor or control code fails. •

The 5600 does not use a Supply Reservoir heater as the ink is already liquid and does not need to be melted.

If the set point is changed while the zone is enabled, the zone state will be set to Disabled and the Enable flag set. The next time the zone is serviced, the zone will transition through the states as if it were enabled for the first time.

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Section 2 - Printer Description – Theory There are four zone states: Disabled, Warming, Cooling, and Stabilized. In all zone states, the periodic update will first check if the thermal sensor is outputting valid values (temperature is between -20ºC and 150ºC). If it is not a valid value, the zone’s thermal sensor fault is thrown. Secondly, it will check if the zone is still enabled. If not enabled, it will disable the heater, stop the Stabilize and Change timers and set the state to Disabled. The actions occurring in each state are defined as follows: 1. Disabled State a. This is the default power-up state for all zones and is the state the zone returns to when it is disabled by other control logic. When a zone is enabled, it starts from this state. When a zone’s temperature set point is changed, it re-starts from this state. b. Once enabled, a zone is only in this state once since the state will change to either Warming, Cooling or Stabilized based on the logic below. c. The current temperature is read and saved for comparison later to see if the zone is heating or cooling as expected. d. If the zone is cooler than the set point: i. Enable the heater. ii. If the temperature is within the set point range (+/- 3ºC of the set point), the zone state is changed to Stabilized else the zone state is set to Warming. iii. If the temperature is outside the set point range, two timers are started. a. The Change timer is set for two minutes. If it expires the zone is disabled and the zone’s temperature fault is thrown because no change in temperature has been detected. b. The Stabilized timer is set for 30 minutes. If the zone does not reach the Stabilized state in this time, the zone is disabled and zone’s temperature fault is thrown because something must be wrong (bad heater, low or absent heater voltage, abnormally cold environment, etc). e. If the zone is warmer than or equal to the set point: i. The Change timer is set for four minutes. If it expires and the zone’s temperature has increased, the zone’s temperature fault. Since it can take a very long time in a hot environment for a system to cool, there ii. is no fault if the temperature does not change when in the Cooling state. iii. The Stabilized timer is set for 60 minutes. If the zone does not reach the Stabilized state in this time, the zone’s temperature fault is thrown because something must be wrong (bad heater, low or absent heater voltage, abnormally cold environment, etc).

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Section 2 - Printer Description – Theory 2. Warming State a. If the zone is warmer than or equal to the set point temperature: i. Disable the heater ii. Stop the Change and Stabilize timers iii. Change the zone state to Stabilized b. Pulse U16 (CPLD) to let it know the microprocessor has enabled the heater. 3. Cooling State a. If the zone is cooler than the set point temperature: i. Enable the heater ii. Stop the Change and Stabilize timers iii. Change the zone state to Stabilized 4. Stabilized State a. If the current temperature is at or above the set point temperature, disable the heater. b. If the current temperature is below the set point temperature, enable the heater. c. If the zone is outside the set point range (+/- 3ºC of the set point) but previously was inside the range, start the Stabilize timer, set for 100 seconds. If this timer expires, it indicates the zone could not return to the set point range after the allotted time so there must be a fault. The zone will be disabled and a fault thrown. d. If the zone is inside the set point range, stop the Stabilize timer. Low Vacuum Low vacuum is necessary to counteract the tendency for the ink to drip from the face of the jetting assembly. The vacuum is applied to the primary reservoir and is sensed using a vacuum sensor (U5) on the printer board. A vacuum of 43 mm of water must be maintained while the ink is liquid, including when ink levels are being restored (fill cycle), a purge is made or through loss of ink during printing. Low vacuum is generated from a 24VAC 60Hz diaphragm pump using a simulated AC waveform. The basis of the control is to sample the current vacuum using sensor U5 and adjust the microprocessor PWM output’s duty cycle accordingly. The higher the duty cycle value, the stronger the pump stroke and the higher the generated vacuum. The duty cycle is updated every 42 milliseconds. The output from the microprocessor is a variable duty cycle 1200 Hz square wave. This is divided by 10 in CPLD U16 to generate 120 Hz, the time for each half cycle of the 60 Hz pump. The low vacuum must be maintained within the range of +/-10 mm of water about the set point, otherwise a low vacuum fault will be thrown.

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Section 2 - Printer Description – Theory The duty cycle is expected to be within the range of 12 – 35 mm of water and normally will be close to 20. If it is below 12, the printer assumes that filter F4 is plugged so a Plugged Filter warning is thrown. If the duty cycle is above 35, the printer assumes that there is a leak in the low vacuum system so a Primary Reservoir Leak warning is thrown. The low vacuum control is disabled while purging by disabling solenoid 4. While filling the primary reservoir with ink, the low vacuum is maintained as the printer could be in the Producing state. Encoder A quadrature encoder may be connected to the printhead. The standard LCIJ encoder produces 5.9 pulses per millimeter using the standard encoder wheel. The printhead serves only as a connection point; all encoder processing is done in the controller. Product Sensor A product sensor may be connected to the printhead and it will accommodate either active high or active low signals. The printhead serves only as a connection point; all product sensor signal processing is done in the controller. Controller Subsystems The Controller uses a PowerPC-based processor board following the NGE (NextGen Embedded) architecture. The Controller software consists of the Common Ink Jet Controller specific software built on top of the NGE Core software. The Controller is responsible for the following system functionality: PackML State Behavior Imaging Printing Job Management Barcode Scanning File Management Logging Settings Diagnostics

Localization Statistics Local User Interface Manual Control Web User Interface Faults & Warnings Firmware Upgrade Security Host Communications Localization Local User Interface Web User Interface Imaging

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Section 2 - Printer Description – Theory External Communications The following optional external communication channels will be available for use with external devices attached to the Controller: • • • • •

One 10/100 Ethernet port used for DCP communications One 10/100 Ethernet port dedicated for the optional plug-in wireless Ethernet module used for DCP communications One Host Port multiplexed for use with NGPCL over RS232, data entry scanning (via NGPCL commands), or pass-thru barcode scanner programming Three scanner ports (used for verification scanning or TU Lookup) Two USB ports (One ‘A’ style for memory sticks and one ‘B’ style for DCP or NGPCL)

Inter-Module System Communications Controller-Printhead Communications: The communications between the printhead and the Controller will be implemented using the MCPAP protocol over a high speed hardware link. Encoder pass-through: The signal of the encoder attached to the printhead will be passed to the Controller via the high speed serial link. The microprocessor on the printhead board will not have access to this signal. The encoder signals will go directly to the FPGA on the Controller so the Controller microprocessor will only have indirect visibility of these signals through querying the FPGA. Jetting Assembly Communications: The clock, data, & strobe signals generated by the Controller will be passed to the printhead via a high speed serial link. The microprocessor on the Printer board will not have access to this signal. The jetting assembly signals will go directly from the FPGA on the Controller to the jetting assembly. Product Sensor (Print Trigger) pass-through: The signal of the Product Sensor attached to the printhead will be passed to the Controller via a high speed serial link. The microprocessor on the Printer board will not have access to this signal. The Product Sensor signals will go directly to the FPGA on the Controller so the Controller microprocessor will only have indirect visibility of these signals through querying the FPGA.

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Section 2 - Printer Description – Theory Beacon All lamps on the beacon should be lit for five or more seconds every time the system powers up to serve as a lamp test. Fault Lamp (Blue) Off = No fault is active On = Fault is active (PackML Aborted state) Warning Lamp (Amber) Off = No Warnings On = Warning is active Fast Blink = Ink Low warning is active Producing Lamp (Green) Off = Any PackML state other than the Producing state On = PackML Producing state

Pushbuttons: Green Button: Start-Producing button Red Button: Stop-Producing button Top Right Button: Job-Select button Bottom Right Button: Print-Adjust button

Relays The Controller supports three internal dry contact relays and they each have a dedicated functionality: -Fault Relay -Warning Relay -Reject Relay Printer Technologies The Controller is designed generically so that various printhead ink technologies may be adapted without significant changes to the Common Controller firmware. As well, the Controller will support up to two printheads simultaneously. In a dual printhead configuration, the 2 printheads must be of the same print technology.

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Section 2 - Printer Description – Theory Purge Management by Controller Software Triggered Remote Purge A software triggered remote purge is triggered via a software command on one of the supported protocols (NGPCL or DCP). When triggered, it uses the purge duration associated with an Auto purge. If Timed Auto Purge or Product Count Auto Purge is activated, the associated time or count is reset when a remote purge is performed. Note: The onus is on the customer to synchronize a remote purge with production so that products do not have corrupted prints. The system will count a print as a bad print if a print is triggered while the purge is being performed (including the time to clear the jetting assembly of purged ink). Hardware Triggered Remote Purge A hardware triggered remote purge is triggered via a digital input on FlexIO. When triggered, it uses the purge duration associated with an Auto purge. If Timed Auto Purge or Product Count Auto Purge is activated, the associated time or count is reset when a remote purge is performed. Note: The onus is on the customer to synchronize a hardware-triggered remote purge with production so that products do not have corrupted prints. The system will count a print as a bad print if a print is triggered while the purge is being performed (including the time to clear the jetting assembly of purged ink). Print Count Based Auto Purge The Controller will initiate (via an MCPAP message to the print heads) an automatic purge each time a set number of products have been printed. The interval for this auto-purge will be defined via a user programmable setting. When the user programmable auto-purge interval setting is set to zero, this feature will be disabled. The Controller will initiate the purge upon completion of the print on the printer in an attempt to perform the purge in between prints. Note: The onus is on the customer to ensure there is enough time between products to ensure printed images are not affected by the purge. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2 - Printer Description – Theory In case the customer fails to ensure there is enough time between products to ensure printed images are not affected by the purge, upon initiating an auto-purge and receiving notification from the print head that the purge is in process, the Controller will count and handle a print as missed or failed as appropriate just as it would any other purge if it interferes with the print cycle. System Initialization Controller-Printhead Boot-Up Process On power-up, the controller will compare the MCPAP versions for each of the attached printheads and raise a non-recoverable fault if an incompatibility is detected. In order to allow the Common Ink Jet controller to be generic enough to support multiple print technologies, at system boot-up the printhead is required to upload configuration files to the controller. These files define print-technology-specific “personality” of the user interface. The following files are required: • • • • • •

Settings Diagnostics Statistics Manual Control Operations Faults & Warnings Language Strings

The Controller will be able to simultaneously support printheads of the same technology type with different configuration files as long as the MCPAP schema supported by the 2 printheads is the same. The Controller will not support 2 print heads of different technology types simultaneously (i.e. LCIJ Hot Melt and Liquid or LCIJ and SCIJ). At boot-up the print head is required to upload the image file used to program the controller-resident FPGA specifically for the print technology requirements. If the Controller supports multiple print heads but only one print head is connected, the Controller is able to control a single print head on any available print head port/connection (there is not a designated port/connector required to be used for single print head connections). In order to optimize boot-up time, the Controller will cache “personality” files and their versions in nonvolatile memory. At boot-up, the Controller will request the versions of files from the print head(s) and will only upload the actual files if there are new versions available.

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Section 2 - Printer Description – Theory System Control Modes & States PackML The Controller conforms to the state model as mandated by PackML V2.2. Power-Up The system will power-up in the AUTOMATIC mode. The Controller automatically transitions from OFF to STOPPED when the power is turned on. The Controller must send a PackML PREPARE or START command to start the printhead warm-up process. Within the STARTING state, the printhead enables all requisite modules and validates that all machine settings and start-up conditions are met. Once all the system production conditions have been met (temperatures, vacuum levels, ink levels), the printhead transitions to READY. The Controller supports a setting that will allow a user to configure 1 of 2 possible PackML states that the system will transition to on power up (READY or PRODUCING). The Controller will default to READY. For systems using the Print Queue feature, the operator must remove any products between the upstream product sensor and the trailing printhead prior to pressing the START button. Start Button When the operator presses the Start Producing button while a printhead is in the READY state and the Printer’s trigger has not been disabled through a menu selection, the Controller will send a START command. At this point the printhead will transition to the STANDBY/PRODUCING state. Printing will commence when a Product Sensor is activated. When the operator presses the Start Producing button while the printhead is in the HELD state, the Controller will send a START command and the printhead will transition to the STANDBY/PRODUCING state. Printing will commence when a Product Sensor is activated. For dual Printer installations, the operator must clear all products between the upstream product sensor and the trailing printhead or scanner prior to pressing the Start Producing button or the dedicated Start Producing pushbutton. Failure to do so will cause the print queue to be mismanaged and can result in incorrect data being printed on the product. Stop Button

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Section 2 - Printer Description – Theory When the operator presses the “UI Stop Producing” button or the dedicated Stop pushbutton while the printhead is in the STANDBY/PRODUCING state, the operator is presented with a dialog box to ensure they really meant to do this. This will provide for a selection of a YES / NO response. This warning will also explain that any product in the queue will be mislabeled because printing stops immediately. Answering “NO” to the query will cause the STOP button depression to be ignored, leaving the system in the STANDBY/PRODUCING state. The Stop query message can be disabled. Answering "Yes" to the query will cause the Controller to send a STOP command to the Printer and the printhead will transition to the READY state. While in the READY state, the Product Sensors are ignored and no printing will occur; otherwise the printhead remains fully functional. Transitioning from the STANDBY/PRODUCING state to the READY state will immediately cause printing to stop. Any partially printed product, including those in the print queue, will be counted as Failed Prints. This includes any products that have activated a product sensor. For systems using the Print Queue feature, the logical print queue will be cleared. This requires the operator to remove any products between the upstream product sensor and the trailing printhead (or scanner) prior to pressing the Start Producing button. All verification data will be cleared for product in the queue. Hold Event The Controller may get an external request to stop printing via a DCP command or Flex I/O input in order to service a condition on the production line. This will cause the Controller to command the Printers to transition to the HELD state.

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Section 2 - Printer Description – Theory While in the HELD state, the Product Sensors are ignored and no printing will occur; otherwise the printhead remains fully functional. A Hold event will cause all printing to immediately stop. Any partially printed product, including those in the print queue, will be counted as Failed Prints. This includes any product that that have activated a product sensor. For systems using the Print Queue feature, the logical print queue will be cleared. This requires the operator to remove any products between the upstream product sensor and the trailing printhead prior to pressing the START button. All verification data will be cleared for product in the queue. Faults When the machine experiences a fault condition, the printhead will transition to the ABORTED state. Any partially printed product including those in the print queue, and product being registered will be counted as Failed Prints. Manual Shutdown and Startup The Shutdown command is designed to place the printhead(s) in a state where it is safe to move (ink frozen) or safe to power off (no ink dripping from jets on conveying system). It ensures the various thermal zones do not pose serious burn hazards to operators / service personnel. It also minimizes ink leakage from the jetting assembly when the ultimate goal is to power down the machine. When the “Shutdown” UI button is pressed, the Controller will issue a PackML STOP command and the printhead will transition to the STOPPED state in a controlled fashion. Once the printhead(s) properly shutdown and notify the Controller that they are in the STOPPED state, the system will transition to the STOPPED state. Shutdown may be cancelled at any time by the operator through a menu selection (Cancel button). At this point the Controller will command the printhead to go to the Ready or Producing state. Automatic Startup & Shutdown A menu is provided to allow the user to select the hour and minute that the printheads will be auto-started and auto-shutdown in 24 hour format. The start-up and shutdown time settings are available for each day of the week.

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Section 2 - Printer Description – Theory Each day of the week has an “Enable” setting to determine if the auto start-up and shutdown feature is active that day. The operator may cancel a start-up or shutdown sequence by pressing the Start-up/Shutdown button on the UI. If the Start-up and Shutdown times are identical, the Shutdown function takes priority. If a start-up time is specified after the shutdown time, the system will not shutdown the system that day. When the 5800 powers up, the auto start-up/shutdown settings must be tested to determine what the appropriate state of the printheads should be. Manual Mode The system will power-up in the AUTOMATIC mode. Entering the “Manual Control” menu on the local user interface will place the system in MANUAL mode where Manual Control commands can be issued to the printhead. Closing the Manual Control Menu will cause the system to transition back to the AUTOMATIC Mode and into the READY or PRODUCING State. Printhead Modes The main menu of the UI indicates the mode of each printhead. Each printhead has four states that it can be in, three of which are user selectable via its Printhead Mode setting. Not Connected – The printhead is not connected to the communications port or the communications channel is not functional. The Settings and Diagnostics for a “Not Connected” printhead are not visible to the operator. This state is detected by the Controller on power-up. Disabled – This mode is selected via the Printhead Mode setting. Communications to the printhead have been established and the printhead will respond to all MCPAP messages. In this mode, all menu items relating to the printhead are available. Upon being set to “Disabled”, the Controller will issue a Stopped state transition request and the printhead will respond as if the Stop button were pressed on the UI. The printhead will remain in the PackML Stopped state regardless of the state of the Controller or the other printhead. Pressing the Start button on the UI will not affect a printhead whose Mode is set to Disabled. Standby – This mode is selected via the UI Printer Mode setting. The Standby mode disables a printhead from printing but the printhead behaves normally in all other respects. Conceptually it is as if the jetting assembly voltage were turned off. The printhead will transition through all of the PackML states as described in the PackML state model above, it just won’t print. This mode allows a customer to keep a second printhead always ready in case the primary printhead fails. The production line can be returned to a 5600/5800 Service Manual Rev. 02 November 2009

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Section 2 - Printer Description – Theory normal state by simply transitioning the Standby printhead to the Online mode and setting the failed printhead to the Disabled mode. Online - This printhead mode is selected via the UI Printer Mode setting. This is the normal mode for a functioning printhead that will be actively printing. Replacing Printers When a customer decides to replace a printhead from either a single or double-headed system, these are the steps that should be required: 1. 2. 3. 4. 5. 6.

7.

8.

9.

Turn the power to the controller OFF and wait for it to cool down. Remove the current printhead. Install the new printhead. Turn the power ON. At power-up, the controller will identify that the printhead is different from when the controller was powered off (based on the printhead serial number). The UI will show a prompt notifying the operator that the controller recognizes that a different printhead is connected and ask the operator if the prior printhead’s settings should be pushed to the new printhead or if the default settings should be sent. If the operator chooses to use the machine settings from the prior printhead, these settings will be pushed down to the new printhead. This will allow operation of the machine with the machine settings that were active before the printhead was replaced. If the operator chooses not to use the settings from the prior printhead or the default settings, the UI will show a warning that the settings may need to be modified before printing. To implement this behavior, the Controller will have to keep a local copy of both printhead settings. This, in turn, means that every time a printhead setting changes, the Controller will save this in its local copy of settings.

Imaging Resolution Vertical resolution • •

5800 Hotmelt - The system uses 256 jet, dual column, 2.56" print swath jetting assembly giving a vertical (cross-track) dot density of 100dpi 5600 Liquid - The system uses 256 jet, single column, 2.56" print swath jetting assembly giving a vertical (cross-track) dot density of 100dpi

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Section 2 - Printer Description – Theory Horizontal Resolution Each horizontal line of new image data will be printed at 5.9 dots/mm (150 dots/inch). Do not confuse Horizontal Resolution with the Density feature. The Horizontal Resolution is specified for printing "new" data whereas the Density feature re-prints current data. Horizontal Resolution is the Dots Per-Inch; Density is the amount of ink per dot. Image The minimum length of an image is one encoder line or 0.17 mm (0.0067 inches). The maximum length of an image is 1000 mm (39.37 inches). The height of an image is fixed at 65.02 mm (2.56 inches). The system will only support image rotations of 0 and 180 degrees The system will not support image mirroring Field Types The Printhead will print all fields types defined in the Image Data Model specification. Image Definition Files A Job is a named set of all files required by the system to create the bitmaps that will be printed. For the purposes of this, a label is defined as the total height and width of the bitmap that may be printed by a system and is composed of a minimum of one and a maximum of two images. An image is defined as that portion of the rendered label printed by a single printhead. At label composition time the images will be pre-assigned to the printheads. Image 1 (upper image) will be assigned to Printer 1 and Image 2 (lower image) will be assigned to Printer 2. The Controller may override the label composition image assignment using an image re-mapping menu item. Two printheads may be assigned to print the same image. Any printhead may be assigned to print either image regardless whether a second printhead is attached. When two printheads are assigned to the same image, the printed images will be exactly the same (time fields, incremental fields, etc) for a given printed product regardless of printhead positioning on the conveying system (see Printer Arrangement on Production Line).

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Section 2 - Printer Description – Theory Barcode Symbologies The Common Controller supports printing of the following list of Dynamic barcodes: • • • • • • • • • • • • • •

PDF 417 ITF EAN 8 UPCE UPCA QR Code 39 Code 128 EAN 128 EAN 13 Data Matrix GS1 DataBar Omnidirectional GS1 DataBar Composite GS1 DataBar Expanded

The following symbologies are supported as Static codes only; created with CoLOS software: • • •

GS1 DataBar Expanded Composite GS1 DataBar Expanded Stacked GS1 DataBar Expanded Stacked Composite

Image Localization The Controller supports printing of static text for any language that uses discrete characters. Note: The phrase “discrete characters” is used to refer to characters where there is a space between characters as opposed to having each character in a word connected to the one before it as in a scripted language such as Arabic or Indian. In the case of languages that are written from right-to-left, the text needs to be presented to the Controller in the reverse order so that it is rendered correctly. Through the use of logo-ized fields, any foreign language text that is supported by CoLOS can be printed by the Controller. This can be used to print static versions of text in languages that use complex composition algorithms such as Arabic.

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Section 2 - Printer Description – Theory The Controller supports printing of User Input text for any language that uses discrete characters. In the case of languages that are written from right-to-left, the text needs to be entered at the user interface to the Controller in the reverse order so that it is rendered correctly. Dynamic Time\Date fields with 3-letter month abbreviations are support for the following languages.

English German Spanish Dutch Brazilian Swedish Norwegian Danish Finnish Russian Polish Greek Turkish Mandarin Japanese Arabic Hebrew French Italian

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Section 2 - Printer Description – Theory QR barcodes are the only barcode symbology supported by the Controller that can encode Kanji characters. Local Image Manipulation The Controller allows for local changes in the aspect ratio of a loaded image from 50% to 200% via the Color UI.

Printing Encoder There is one external encoder per printhead supported, each of which may be assigned to either printhead via a menu selection. Alternately there is an internally generated encoder signal that may be selected for applications where the product speed is constant. The internal encoder option should not be chosen for applications where the product speed is variable. This is especially true when printing bar codes due to the critical nature of bar spacing. Where two printheads have selected the internal encoder, each may have a different internal encoder speed selected. A single external encoder can be assigned to both printheads. Print Triggers Product Sensors There is one physical product sensor per printhead supported by the system. Each product sensor may be set to trigger a print on the positive or negative edge of the signal. Each product sensor has an associated debounce value that causes the trigger to only go active when the signal has been active for the full debounce distance. One product sensor can be logically assigned to both printheads. This is typical when the printheads are located in close in-track proximity. The different registration values would then determine the start of printing for each printhead.

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Section 2 - Printer Description – Theory Assigning a different trigger to each printhead is typically done in applications where there is a relatively large distance between the two printheads or if the product transitions to a second conveying system before the second printhead prints. A bump and turn configuration is typical of this where the product makes a 90º turn when transitioning from one conveyor to another with a printhead on each conveyor. Having the second trigger eliminates any accumulated registration error that may be caused by product slippage on the conveying system(s). If the Print Queuing feature is required, the system must use two product sensors. This is because there may not be multiple products between a product sensor and the start of printing. If the system is not in the STANDBY/PRODUCING state, print triggers will be ignored. There will be a means of triggering a print for a specific printhead via NGPCL, DCP, and Flex I/O. There will not be a means of triggering a print from the UI. If the printhead is in the registration phase and it receives another trigger, a fault will be raised because this indicates the product is spaced too close together. The system does not support multiple products between the print trigger and the start of printing. A printhead may enter the registration phase while actively printing as long as the printing completes on that printhead before that printhead registration counts down to zero. Fixed Spacing Selecting Fixed Spacing as the trigger for a particular printhead causes the printhead to be automatically triggered after a fixed distance has passed rather than using an external product sensor. If one printhead in a two printhead installation is set to Fixed Spacing mode, they both should be set to this mode but the system will not enforce this. If enabled, Fixed Spacing Distance setting determines the distance between print triggers. The Fixed Spacing Distance setting must be greater than the image width plus the registration distance to avoid causing a Print Overlap Fault. Both printheads should have the same Fixed Spacing Distance but the system will not enforce this. The registration setting is used to offset the start of the print while using fixed spacing.

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Section 2 - Printer Description – Theory Dual Printer Arrangement on Production Line • • • • • • •

Either print head may be the first to print the product in a sequential system. Once the system is placed into the Producing State, the order that the print heads print cannot be altered (either physically or by changing settings). Both print heads may be used to print on the same side of a box with overlapping print times. Both print heads may be used to print on the same side of a box with sequential print times. Each print head may be used to print on the opposing sides of a box with overlapping print times. Each print head may be used to print on the opposing sides of a box with sequential print times. Each print head may be used to print on adjacent sides of a box with sequential print times (bump and turn).

When two print heads are arranged sequentially on the conveying system separated by some distance, there will be support for having up to eight products between the leading product sensor and the trailing edge of the second print (or after the trailing scanner if a verification scanner is positioned after the second, downstream printhead). Reference the section on Print Queuing for more details concerning the print queue. In this arrangement, the prints applied by each printhead to a box must maintain the same variable data (time fields, incremental fields, etc). This is referred to as Print Queuing. • • • •

Each printhead must have its own product sensor when print queuing is required. The product sensors must be arranged such that for their respective printhead, all printing is completed before the printhead gets another print trigger. The separation distance of printheads in a sequential setup is limited only by the length of the cabling connecting the print heads to the Controller. In a two printhead configuration, both print heads will be driven from the same job, image, and settings files.

Printing Setup Faults & Warnings Missed Print: Occurs when a product passes a print head without being printed on. A missed print will occur when a print trigger fires during registration or when an allocation completes and the previous job is not finished printing. Print Overlap: Occurs when the registration phase of a print occurs before the previous print completes. Due to the possibility that the product sensor and printhead could be configured some distance apart, the Controller will accept a print trigger while a previous product is still being printed.

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Section 2 - Printer Description – Theory Allocations An allocation is associated with a specific job and allows the user to tell the system how many times the job should be printed. For example, if the allocation for a job is set to 1000, then the job will be printed exactly 1000 times. An allocation can be initiated via a new job selection using DCP or NGPCL. When an allocation is set, two extra counters are made available; Allocation Total and Allocation Current. Allocation Total contains the total allocation quota, and Allocation Current contains the number currently completed. The allocation is incremented at the start of each print cycle. The system will not allow a print to be made after the allocation has been completed. After the allocation is complete, if a print signal is received before the allocation is cleared or updated, a fault will be raised in a single print head configuration. In a 2-headed configuration; if Box A, being the last necessary box to satisfy the current allocation, has passed print head 1 and not yet passed print head 2, and Box B triggers product sensor 1, an Allocation Warning will be raised initially and a missed print will be raised each time a product passes this sensor. Once Box A subsequently passes print head 2, an Allocation Fault will be raised. When the allocation fault is raised the job is unselected so the user will have to select a new job to continue printing. Missed or failed prints will be counted towards the total allocation. If they were not counted and the machine was set to print 1000 items of job A and then 500 items of job B, the machine could print the wrong image on some of job B’s items. Therefore the Allocation Current count is actually the number of products which have triggered the first product sensor, not the number of good prints. If a shutdown, stop producing, or fault occurs in the middle of producing a job with allocation, the allocation will not reset or clear but stay in its current state. In other words, if a job set for 1000 prints has printed 500 products and then a shutdown, stop producing, or fault occurs, the current allocation will stay at 500 and the total allocation will stay at 1000. If a user wishes to print a job with infinite allocation, allocation is simply not used. In other words, do not specify an allocation upon job selection.

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Section 2 - Printer Description – Theory A new job cannot be selected from the Color UI when an allocation is currently active. The current allocation must be allowed to complete or be explicitly cleared by the operator before a new job can be selected. When an allocation is active and not complete, pressing the select job button brings up a "Clear Allocation" menu screen. The Allocation fault is clearable by the user and when raised the current job will be un-selected, requiring the user to select a job to start printing again. An allocation may be explicitly cleared via DCP or through the Color UI. The operator will be prompted to confirm the action as part of the initiation process. When an allocation is cleared via the Color UI, the UI will return to the Home Screen and the batch count will be reset to zero. Examples Involving 1 Print Head, Allocation of 2, Direction Left-To-Right: Allocation Fault raised on print go signal for product C.

Direction of product flow

Missed Print Warning raised on print go signal for product C. Allocation Fault raised on print complete signal for product B.

Direction of product flow

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Section 2 - Printer Description – Theory Missed Print Warning raised on print go signal for product C. Allocation Fault raised on print complete signal for product B

Direction of product flow

. Missed Print Warning raised on print go signal for product B. Allocation Fault raised on print go signal for product C.

Direction of product flow

Missed Print Warning raised on print go signal for products B and C. Allocation Fault raised on print complete signal for product A.

Direction of product flow

Examples Involving 2 Print Heads, Allocation of 2, Direction Left-To-Right: Allocation Fault raised on print go signal at PH1 for product C.

Direction of product flow

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Section 2 - Printer Description – Theory Missed Print & Allocation Warnings raised on print go signal at PH1 for product C. Allocation Fault raised on print complete signal at PH2 for product B.

Direction of product flow

Missed Print & Allocation Warnings raised on print go signal at PH1 for product C. Allocation Fault raised on print complete signal at PH2 for product B.

Direction of product flow

Missed Print & Allocation Warnings raised on print go signal at PH1 for product C. Allocation Fault raised on print complete signal at PH2 for product B.

Direction of product flow

Missed Print Warning raised on print go signal at PH1 for product B. Missed Print & Allocation Warnings raised on print go signal at PH1 for product C. Allocation Fault raised on print complete signal at PH2 for product A.

Direction of product flow

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Section 2 - Printer Description – Theory

Direction of product flow

Job Queuing Job Queuing is an extension of the allocation mechanism. It allows automatic job selection during batch printing. A user could choose to print 1000 items for Customer A, followed by 2000 items for Customer B, etc. At the 1000th print for Customer A, the system would automatically select the job for Customer B and production would continue seamlessly. When Job Queuing is enabled, if the next job is not defined when the current allocation is completed, the allocation warning and allocation fault will be raised as described in the above section. A Job Queuing setting is used to enable and disable job queuing. Job Queuing does support jobs with associated settings. When a particular job in the job queue completes, the new job is selected. If the new job selected has new settings, these are applied per print head as needed to avoid changing settings prematurely and effecting the last prints of the previous job on the second print head. • • • • • • •

The job queue can hold up to 8 jobs, 1 currently selected job and 7 queued jobs. Queued jobs are viewable on the CUI on the print preview screen. DCP provides a mechanism to view information on queued jobs as well. The job queue should be retained through power cycles. A job may be added to the queue at any time via a job selection and these jobs are added to the end of the queue. The only time this will fail is if the job queue is full. There is no mechanism to add a job in the middle of the queue. Jobs may be deleted from the job queue via DCP. The job queue may be cleared via the CUI or via DCP.

If a job selection is performed with no specified allocation, the selected job will print continuously (regardless of whether queuing is enabled or not) until a “Stop Production” command is initiated. When allocation completes (whether at the end of a job queue or just a single job with allocation without job queuing) and the allocation fault is raised, the job will be unselected. See the allocation section above for more details on the allocation fault.

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Section 2 - Printer Description – Theory

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Section 2 - Printer Description – Theory Digital Job Select Digital Job Select allows the user to select which job is printed on a print-by-print basis. Also called “switch on the fly,” this is often used in applications such as lane identification, or identifying pockets on a heat-sealing apparatus. The Controller supports up to eight different jobs that may be selected via three (binary coded) Flex I/O input lines. The system will continue to print a selected job until a new digital job selection request is received. Digital Job Select may be used in conjunction with Print Queuing (see below). Digital Job Select with allocations is not supported.

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Section 2 - Printer Description – Theory Print Queuing Print Queuing accommodates installations where two printheads are used and their arrangement is such that they could be printing on different products simultaneously. The print queue is defined to encompass all products that reside between the very first and the very last connected peripheral in the system (including product sensors, print heads, scanners, and the reject mechanism). The size of the queue refers to the number of products between the printheads and includes any products registering or currently being printed. In the example below, if neither printhead has finished its current print, the queue count would be five. The maximum print queue size is 8 products. Print Queuing requires the use of two product sensors – one for each printhead. There is no provision for registration queuing. Once a product sensor is activated, the respective printhead must start printing that product before the product sensor may be activated by the next product. Any transition out of the Producing State while print queuing will cause the logical print queue to be cleared. This includes pressing the Stop Producing Button, system faults, and power downs as well as any other event which might cause a transition out of the Producing State. This requires the operator to remove any products between the upstream product sensor and the trailing printhead (or scanner) prior to pressing the Start Producing button. When the machine is powered down, faults out, or the Stop Producing Button is pressed while in the Producing State with items in the print queue, upon re-entering the Producing State the system will move on to print the next serialized number regardless of whether the previous print has been completed by both heads and verified by a scanner or not. If a Jet Test is performed by the operator while the Controller is printing with a queue, the current print will be classed as a failed print and the failed print count will be incremented.

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Section 2 - Printer Description – Theory If a Jet Test occurs while the product is being printed by the 1st printhead, the Controller will treat the product in the same way as if the 1st printhead registered a missed print and will not print when the product reaches the 2nd printhead. If a Purge is performed by the operator while the Controller is printing with a queue, the system will react in the same way as described above for the Jet Test.

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Section 2 - Printer Description – Theory Job Selection The Controller is NOT required to check that a job has all the required files before selection. It is the responsibility of the system that sends the job. If during selection a file is found to be missing, a message will be displayed to the user and the selection will fail. The following interfaces will provide the facility to perform job selection: • • • •

Local User Interface Web User Interface DCP NGPCL

The Controller may be placed in Host Database Mode via a system setting. When the Controller is in Host Database Mode, job selection via the Color UI will cause the job to be loaded and selected via CoLOS. When a job selection is initiated via DCP using the SelectJob command, the files associated with the job are expected to be downloaded from the host. When a job selection is initiated via DCP using the SelectLocalJob command, the files associated with the job are assumed to be local to the Controller. When a job selection is initiated via NGPCL, the Controller will first look for the associated files in the local file system and then, if not found, will attempt to cause the job to be loaded via CoLOS. Any time a new job is selected, the Controller will send a Job Selected DCP event to CoLOS. If CoLOS is in group mode and the files associated with the new job reside in the CoLOS database, CoLOS will then perform a job selection on the other nodes in the group to match. If the associated job files are not local to CoLOS, CoLOS will not be required to upload the job files from the Controller and download them to the other Controllers in the group for selection.

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Section 2 - Printer Description – Theory Default Jobs Default jobs may be deleted by the user. Default jobs will be restored to the file system following a firmware upgrade or a restoration to factory defaults. Barcode Scanning The Controller will support up to two 15 pin scanner ports on the base system and a 15 pin scanner port on the OEU. In addition, the OEU port will accept a TU scanner with an adapter cable. Note that there can only be two verification scanners per system and one Traded Unit scanner per system. Traded Unit (TU) Lookup Scanner The system supports a single scanner to provide TU functionality. TU is a feature where a scanner is placed upstream of the first printhead and reads a pre-printed barcode on the product to select the job that will be printed on that single product. For every product to be printed, a new job selection is initiated via the scanner. Since each selection is new and the Controller has no way to know what the next job will be, no serialized state information will be maintained for a given job between job selections. The TU scanner may be triggered by two sources – a FlexIO input going active, or the customer can choose to handle all triggering and registration independent of the Controller. A setting allows the selection of the FlexIO trigger input or NONE. If FlexIO is selected, the system must provide menu items to select the Encoder, Trigger Delay Distance and Scanner ON Distance. If NONE is selected, the customer is responsible for all connections and timing associated with triggering the scanner. In this case the controller has no knowledge of the scanner trigger. The scanner may be attached directly to an external device (such as a PLC or host PC) that would handle triggering the scanner and then passing the data up to the controller via the controller scanner port. If NONE is selected, the 5800 will simply receive a data stream from the scanner when it finishes each scan. The TU scanner enable output will go active based on a sensor attached to a physical input to the system.

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Section 2 - Printer Description – Theory There is a diagnostic feature where the raw ASCII data from the scanner can be displayed. Through a menu selection on the UI, the Host Serial Port is logically tied to the respective scanner port in a pass-through arrangement, allowing the customer to modify the scanner settings using the manufacturer’s setup program. The Controller will not be used to directly modify a scanner’s internal settings. Note that the only ports that support this mode are the two Scanner ports on the Controller since they are the only scanner ports that provide two serial ports. The TU scanner may be attached to either of the two Controller scanner ports, the scanner port on the OEU or the OEU port on the Controller (requires a custom cable). The data output by the scanner will be a Start character (defined in the settings menu) followed by the ASCII job name and terminated by the Stop character (defined in the settings menu). Optionally, multiple data for variable fields may be included in the scanner output. If it is, it is inserted between the job name and the End character and is separated from the job name by a ‘|’ (0x7C) character. Each succeeding variable data item is separated from the prior variable data item using the ‘|’ character. Verification Scanners The system supports the Sick Inc. scanner protocol. Markem-Imaje buys scanners pre-programmed for use with our systems as verification scanners. A generic scanner protocol is available for customers that do not use a supported scanner protocol. It will include a Start and End character setting on the menu. The data stream from a generic scanner will consist of only the characters read from the barcode bracketed by the Start and End characters selected on the Verification Settings menu. It will not include the ability to have multiple barcode strings, character counts, barcode type or any other fields in the data stream. There are two levels of verification: Readability and Data. When using a Sick scanner, both levels of verification will check for the correct barcode type and length. Readability mode will only test if a barcode is readable without testing if the data read is identical to the data printed.

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Section 2 - Printer Description – Theory Data mode will test if the scanned barcode type and barcode data matches the barcode that was rendered. • • •

The system will support two scanners to provide verification of the printed barcodes. Each printhead can be assigned to a single scanner. Two printheads cannot be assigned to the same scanner.

You can enable or disable verification for each printhead individually. When disabled, any barcodes printed by the associated printhead are ignored and not considered when the overall success of verification is determined. The system provides a means of triggering the scanner. Verification scanners are activated based on either a sensor attached to a physical input or based on the start of print for the associated printhead. These are referred to generically as the scanner trigger. When using “Start of Print” as the scanner trigger, the system must be configured such that there will never be more than a single product between the print head and its associated scanner. If it necessary to have more than a single product between the print head and its scanner, an external scanner trigger must be used. A delay distance must be provided to allow offsetting the actual activation of the scanner from the point the scanner trigger goes active. The scanning distance (distance the scanner is on) is a system parameter. The system also supports a trigger mode of NONE where the customer is responsible for the triggering of the scanners including all registration and ON times. In this mode, the system asynchronously receives the scanned data stream. The Controller scanner delay and scanner ON time settings are not used for this mode of triggering. Each printheads' image may contain up to two barcodes. A job may contain a maximum of four barcodes, two per printhead.

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Section 2 - Printer Description – Theory A fault may optionally be activated after a series of failed verifications. The number of successive failed verifications before raising a fault is a user specified menu item. If the operator chooses to deactivate this fault, the system will act as though verification is disabled. The dry contact Reject relay may optionally be activated on unsuccessful verification. The Reject relay is a standard feature within the Controller. The reject mechanism may be setup to activate a set distance after the trigger of Product Sensor 1 or Product Sensor 2. Product Sensor 1 indicates the product sensor that is physically attached to Print Head Port 1 on the Controller. The amount of time that the reject relay remains active is defined by a user editable setting. This setting is defined in units of time rather than distance. It is possible to program the verification scanners while they are attached to the Controller. A computer running a program supplied by the scanner manufacturer may be connected to the Controller Host PC serial port. Using a menu selection on the UI, the Host PC port is logically tied to either of the Controller Scanner ports in a pass-through arrangement, allowing modification of the scanner settings using the manufacturer’s setup program. The Controller will not be used to directly modify a scanner’s internal settings. Note that only ports that support this mode are the two Scanner ports on the Controller since they are the only scanner ports that provide two serial ports. Verification scanners may only be connected to either of the two scanner ports on the Controller. The string sent by a generic scanner must conform to the following: <STX><Start Char><+><End Char><ETX>. The items in red are optional and will only be present if the scanner decodes multiple barcodes. STX is the ASCII control character 0x02 and ETX is the ASCII control character 0x03. Start Char and End Char are defined by the user via a scanner setup menu item. The default string sent by the Sick scanners when purchased from Markem-Imaje is as follows: <STX><[><+><+><]><ETX>. The items in red are optional and will only be present if the scanner decodes multiple barcodes.

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Section 2 - Printer Description – Theory For the Number of Codes and Code Data Length fields, if the number is less than 10, the leading digit will actually be the character ‘_’. Code Type is one of the following: {'x'} - No code returned {'e'} - ITF (Interleaved 2 of 5) {'b'} - Code 39 {'j'} - Code 128 {'d'} - EAN 8 {'d'} - EAN 13 {'a'} – Codabar {'c'} - UPC-A {'c'} - UPC-E {'f'} - ITF Industrial (Interleaved 2 of 5) (standard) {'q'} - ITF Industrial B (Interleaved 2 of 5) (modified) {'i'} - Code 93 {'c'} - UPC-x 2 Digit Add-On {'c'} - UPC-x 5 Digit Add-On {'n'} - EAN128 Data Entry Scanner (Wedge Scanner) A data entry scanner can be connected to the Host Port on the Controller directly and used to scan a barcode at the operator station that identifies the job to select. The scanned data is then incorporated into an NGPCL packet, either by configuring the scanner itself to do so, or by using a scanner in concert with custom host PC software. The NGPCL job selection packet is then sent to the Controller via the NGPCL Host Port. This approach removes the need for the operator to use the soft keyboard on the UI for hand typing the job name. The barcode and resultant NGPCL packet sent to the Controller may include user input field data. In this scenario, the Color UI is not be involved in the job selection process and all user prompted data would be expected to be updated via NGPCL. A data entry scanner can be connected to the USB Host port and will serve as a keyboard substitute for the Color UI. This will allow the user complete flexibility to navigate the Color UI and either manually enter fields via the soft keyboard or use the scanner to enter field information by scanning a barcode.

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Section 2 - Printer Description – Theory The data entry scanner required to be supported by the controller is the Welch Allyn 3800G04E Handheld Barcode Scanner (Markem-Imaje p/n 0672538). A data entry scanner can be connected to a host PC running CoLOS and CoLOS can use scanned barcode data to select jobs by name as well as to input user prompted data fields.

File Management Flash File System The Controller: • Supports a Flash based file system. • Stores job and image files to its local Flash file system. • Stores supported settings files to its local Flash file system. • Stores supported language translation files to its local Flash file system. USB File System The Controller: • Supports a USB FAT file system. • Transfers job and image files to and from a USB Flash memory drive. • Transfers any supported settings files to and from a USB flash memory drive. • Transfers any supported language translation files to and from a USB flash memory drive. Restore to Factory Defaults The Controller: • Provides the ability to initiate a restoration to factory defaults from the local user interface. • Formats its Flash memory & NVRAM when restoring to factory defaults. • Writes the following default files to Flash when restoring factory defaults Custom Code Shift Code Job Image and Font LUI Chars MASP Security • Clears all log files when restoring to factory defaults. Note: The ability to initiate a restoration to factory defaults from the Color UI is restricted to security level 3 and above.

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Section 2 - Printer Description – Theory Logging Event Log Event Log entries are time-stamped. This log has a finite size. If an entry is about to exceed the size, the Controller will overwrite the oldest entry with the new data. This log is non-volatile (retained between power cycles). The printhead has the ability to log its own data in the Controller Event Log using the MCPAP Log Maintenance Event message. The Controller is able to transfer the event log to a host via DCP. The following table lists events that are logged: Event All Faults All Warnings System PackML Final and Quiescent states Auto / Manual Mode Changes All System Settings Changes Job Selection Printhead Maintenance Events

Responsible Module Controller Controller Controller Controller Controller Controller Printhead

The Controller is able to transfer the current event log to a USB FLASH drive. This will be initiated via the Color UI. This file will be named “event.log” and when the Controller is prompted to “Copy Logs To USB”, any file with this name that already exists on the USB stick will be overwritten.

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Section 2 - Printer Description – Theory Variable Data Log This log contains a time-stamped listing for the jobs selected as well as the variable data printed relative to these jobs (job names and field data for fields tagged as Logged). This log has a finite size. If an entry is about to exceed the size, the Controller will overwrite the oldest entry with the new data as the default. Optionally, a warning to the operator is issued stating that the oldest data is about to be over-written. This allows the operator to extract and clear the existing log if they desire. This log is non-volatile (retained between power cycles). The Controller is able to transfer the variable data log to a host via DCP.

Settings Controller Cached Printer Settings The Controller requests specific setting values from the printhead when it requires them for display at run-time. Printhead settings will be cached by the Controller only for the purpose of providing a feature where the Controller recognizes a new printhead has been attached on power-up (via printhead serial number) and provides the operator the option download the previous printhead settings. Job Settings Files All settings changed through a job settings file when a job is selected are saved and become the current settings. Every job settings file will define new current settings that will be used until either the operator changes a setting or another job with another job settings file is selected. All jobs selected after selecting a job with a job settings file inherit the settings modifications dictated by the job settings file. Changes made to settings by an operator after a job is selected will not change a job settings file associated with the currently selected job.

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Section 2 - Printer Description – Theory As part of applying job settings, default settings will never be applied automatically. Settings changes applied by a job settings file are permanent and the next job selected will build off of the previous settings. If an invalid setting is detected when applying settings associated with a job settings file, a system fault will be raised to indicate this to the user. It is not a requirement for the system to fail to allow the job to be selected in this case. The above is true regardless of whether settings are being applied at job selection time, as part of job queuing, or during print queuing.

Controller Settings Category Machine

Setting Database Job Queuing

Description

Default

Database that supplies the job files Job queuing modes

DB_LOCAL JQ_OFF

PH1 Direction PH2 Direction Audible Alarm PH1 Image Area Mapping

PH2 Image Area Mapping

L-R L-R Disabled Print head 1 could get the top area of the image or lower area of the image. It is also possible to map the same image area to both print heads Print head 2 could get the top area of the image or lower area of the image. It is also possible to map the same image area to both print heads

Range

Units

DB_LOCAL, DB_HOST JQ_OFF, JQ_STANDARD, JQ_BINARY_SELE CT L-R, R-L L-R, R-L Enabled, Disabled

ENUM

Access Level 3

ENUM

3

AREA_ONE

AREA_ONE, AREA_TWO

1

AREA_TWO

AREA_ONE, AREA_TWO

1

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Section 2 - Printer Description – Theory Category

Setting Units Scheme

Default

Imperial (inches, inches / sec), Metric (mm, mm/sec)

Range

Metric

Imperial, Metric

Online

0

Disabled, Standby, Online Disabled, Standby, Online 0-10000

Machine ID

Machine000

-

Line ID

Line001

-

Japanese Emperor Year offset to use when computing relative years to print. Offset from midnight determining when time/date fields rollover.

1

Date Rollover Minute

PH1 Printer Mode PH2 Printer Mode Auto-Purge Count

Imaging

Description

Online Number of printed products between autopurges. A setting value of zero disables print count based auto purge.

Units

Access Level 3 2 2 2

2

0-3000

Text string Text string Years

0

0-11

Hours

3

Offset from midnight determining when time/dates rollover.

0

0-59

Minutes

3

Date Rollover Direction

Direction to apply Rollover Hour and Rollover minute offsets.

After Midnight

Before Midnight, After Midnight

Enum

3

BBE Rollover Hour

Offset from midnight determining when time/date fields rollover.

0

0-11

Hours

3

BBE Rollover Minute

Offset from midnight determining when time/dates rollover.

0

0-59

Minutes

3

BBE Rollover Direction

Direction to apply Rollover Hour and Rollover minute offsets.

After Midnight

Before Midnight, After Midnight

ENUM

3

Relative Year Offset

Date Rollover Hour

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Section 2 - Printer Description – Theory Category

Setting Local Image Aspect Ratio Side Jetting Imaging Mode

Comms

IP Address IP SubNet IP Gateway DCP Actor Name

Description

Default

Range

Units

Access Level Percentage 3

100%

50%-200%

SCIJ only setting to support mirroring the image during side jetting applications Fixed IP address to listen for connections on Subnet to use when listening for connections Subnet to use when listening for connections Actor name within DCP network

DISABLED

ENABLED, DISABLED

Enum

3

010.000.000.015

15 chars

Text string

3

255.255.255.0

15 chars

Text string

3

010.000.000.001

15 chars

Text string

3

Actor1

16 chars max

Text string

3

Defines length of field names in NGPCL Defines length of field names in NGPCL Defines if the Pass/Fail field should be included in Request Responses Determines whether a checksum will be included, and expected, on NGPCL packets Serial port speed

0

0-100

3

0

0-100

3

Yes

NO_TYPE, YES_TYPE

ENUM

3

No

NO_TYPE, YES_TYPE

ENUM

3

BAUD_19200

BAUD_9600, BAUD_19200, BAUD_38400, BAUD_57600, BAUD_115000 , BAUD_115200 CHARSET_AS CII, CHARSET_UN ICODE

ENUM

3

ENUM

3

NGPCL Field Name Length Field Data Length Request Success Code Field Checksum Enabled

NGPCL Port Baud Rate

RS232 Char Set

Character set to assume on RS232 comms

CHARSET_ASCI I

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Section 2 - Printer Description – Theory Category

Setting

Description

Default

Range

Units (as saved)

Security Access Level

VDL_NONE, VDL_JOBSEL ECT_UPDATE , VDL_PERPRI NT VDFA_STOPL OGGING, VDFA_DELET E_OLD_DATA, VDFA_STOP_ PRINTING ENABLED, DISABLED

ENUM

3

ENUM

3

ENUM

4

DISABLED

ENABLED, DISABLED

ENUM

4

DISABLED

ENABLED, DISABLED

ENUM

4

Logging Variable Data Log Level

Sets when entries are made into the variable data log

VDL_JOBSELEC T_UPDATE

Data Log Full Action

Determines what to do when the event log is full

VDFA_STOPLO GGING

Controller Debug Output

Enables and disables the controller trace output Enables and disables image data output from the FPGA Enables and disables image data output from the FPGA

DISABLED

PH1 Image Data Output PH2 Image Data Output

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Section 2 - Printer Description – Theory

Category Serial Ports

Verification

Setting

Description

Default

Host Port Mode

None

Scanner Port 1 Mode

None

Scanner Port 2 Mode

None

Verify Both

Determines whether scanners for both printheads must succeed in verification or not

Enable

Range NGPCL, Scanner Port 1,2,3, Wi-Fi Program, None PH1 Verif. Scanner, PH2 Verif. Scanner, TU Scanner, None PH1 Verif. Scanner, PH2 Verif. Scanner, TU Scanner, None Enable, Disable

Unit s EN UM

Access Level 3

EN UM

3

EN UM

3

3

Consecutive Failures VS PH1 Baud Rate

1

1 – 10

3

9600

3

VS PH1 Scanner Type VS PH1 Start Char. VS PH1 Stop Char VS PH1 Trigger

Sick

9600, 19200, 38400, 57600, 115200 Sick, Generic

Generic Type only Generic Type only

‘[‘ ‘]’ Start of Print

Any ASCII Any ASCII None, FlexIO, Start of Print

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Section 2 - Printer Description – Theory

Category

TU Lookup

Setting

Description

Reject Relay Encoder

Ext. Encoder 1

Reject Relay Delay Distance Reject Relay On Time TU Baud Rate

0

TU Scanner Type TU Start Char. TU Stop Char

Generic Type only Generic Type only

TU Trigger TU Trigger Edge

Print Initiation

Encoders

Default

When FlexIO selected

Range

Ext. Encoder 1, Ext. Encoder 2 0 – 2000

Units

Access Level

3 Mm

3

Ms

3 3

500 9600

0 – 10000 9600, 19200, 38400, 57600, 115200

Sick ‘[‘

Sick, Generic Any ASCII

3 3

‘]’

Any ASCII

3

Flex I/O (dedicated sensor) Rising Edge

None, FlexIO

3 3 Mm Mm

3 3 3

Mm

3

TU Encoder TU Delay Distance TU ON Distance

PH1 0 0

Rising Edge, Falling Edge PH1, PH2 0 – 1000 0 – 1000

Product Sensor 1 Debounce Product Sensor 1 Edge Product Sensor 2 Debounce Product Sensor 2 Edge External Encoder 1 Scaling Factor

1

0 – 10

Rising Edge

Rising Edge, Falling Edge 0 – 10

1 Rising Edge 100

Rising Edge, Falling Edge 20 – 500

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3 Mm

3 3

%

3

Section 2 - Printer Description – Theory Category

Startup / Shutdown

Print Position

Setting External Encoder 2 Scaling Factor Measure Speed using Box Input Box Length Machine Startup State

Description

Default

Range

Units (as saved) %

SecurityAccess Level 3

100

20 – 500

Disable

Enable, Disable

0

0 – 2000

3

Repeat this for all other days of the week

Disable

Start In Ready, Start In Producing Enable, Disable

Repeat this for all other days of the week

0

0 – 23

3

Repeat this for all other days of the week

0

0 – 59

3

Repeat this for all other days of the week

0

0 – 23

3

Repeat this for all other days of the week

0

0 – 59

3

0

0, 180

3

Up

Up, Down

ENUM

1

Up

Up, Down

ENUM

1

PH1 Vertical Offset

Direction to shift image the number of mm specified in PH1 Vertical Offset Direction to shift image the number of mm specified in PH2 Vertical Offset Resolution must be at least jet/jet spacing

0

0 – 650

10ths of mm

1

PH2 Vertical Offset

Resolution must be at least jet/jet spacing

0

0 – 650

10ths of mm

1

Sunday Auto Warm-up / Shutdown Enable Sunday Auto Warm-up / Shutdown Start Hour Sunday Auto Warm-up / Shutdown Start Minute Sunday Auto Warm-up / Shutdown Stop Hour Sunday Auto Warm-up / Shutdown Stop Minute Rotate Image (0 and 180 degrees) PH1 Vertical Shift Direction PH2 Vertical Shift Direction

Measure conveyor speed using a known box length

2 Mm

3

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Section 2 - Printer Description – Theory Category

Setting VS PH1 Trigger Edge VS PH1 Mode VS PH1 Delay Distance VS PH1 ON Distance VS PH1 Max Barcodes VS PH2 Baud Rate VS PH2 Scanner Type VS PH2 Start Char. VS PH2 Stop Char VS PH2 Trigger VS PH2 Trigger Edge VS PH2 Mode VS PH2 Delay Distance VS PH2 ON Distance VS PH2 Max Barcodes Reject Relay Trigger

Description

Default

When FlexIO selected

Range

Units

Access Level

Rising Edge

Rising Edge, Falling Edge

Data 0

Readability, Data 0 – 1000

Mm

3 3

300

0 – 1000

Mm

3

1

2

3

9600

3

Sick

9600, 19200, 38400, 57600, 115200 Sick, Generic

3

Generic Type only

‘[‘

Any ASCII

3

Generic Type only

‘]’ Start of Print Rising Edge

Any ASCII None, FlexIO, Start of Print Rising Edge, Falling Edge

3 3 3

Data 0

Readability, Data 0 – 1000

Mm

3 3

300

0 – 1000

Mm

3

1

2

3

Product Sensor 1

Product Sensor 1, Product Sensor 2

3

When FlexIO selected

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Section 2.0 Printer Description - Theory Printhead Settings All numeric values will be in metric units when received from the Controller or sent to the Controller. Restore Settings to Factory Defaults When a restoration to factory defaults is initiated by the user, system settings will be selectively restored to the default values as defined in the Settings Constraint Files that are compiled into the Controller and print heads. An optional element is available in the Setting Constraints schema to define whether each individual setting will be protected against restoration to factory defaults. Using this mechanism, the Controller and each print head are able to define the settings that should and should not be restored to factory values when a Restore to Factory Defaults is initiated. Diagnostics Diagnostic information reports the current state of the machine and its inputs and outputs. It would typically be used by a service person to identify the cause of faults within the machine. Diagnostic information may be displayed on the machine UI or via a web browser. Diagnostic Information The information captured by the Controller covers both external and internal diagnostics. External diagnostics can be defined as signals from devices external to the Controller but part of the installation as a whole such as scanners. Internal diagnostics are the signals within the Controller and are used to find faults within the system such as heated reservoirs. Diagnostic information is presented at the UI or web browser and is often used in conjunction with manual controls to allow an operator, at the Controller, to request the machine to take an action and to then be able to monitor the state of the resulting signal. All numeric values will be sent in metric units. Controller Diagnostics See table on next p

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Section 2.0 Printer Description - Theory UI Diagnostics Category Configuration

Item Control Board Serial # FlexIO Map

States / Value

*.io filename

FPGA Version Controller FUU Version Printer FUU Version Printer Software Version Controller States

PackML State

Stopped, Starting, Ready, Producing, Holding, Held, Stopping, Aborting, Aborted

I/O

Flex I/O Inputs and Outputs (16) Conveyor Speed (Encoder 1, Encoder 2)

On / Off

Encoder Speed (Encoder 1, Encoder 2) Scaling Factor

Product Sensor (2 – Printer 1, Printer 2) Beacon Lamp (3 – Green, Amber, Blue) Relay (3 – Fault, Warning, Reject)

Timing Analysis

Audible Alarm Scanner 1 Data Scanner 2 Data Scanner 3 Data Product to Product Time Product Print Time Job Select Time Image Update Time

Responsibility

Controller – Version Screen Controller – Version Screen Controller – Version Screen Controller – Version Screen Printer – Version Screen Printer – Version Screen Controller – Home Screen Controller

Current speed of the product. This is the speed of the product based on the standard encoder wheel (generates 150 encoder lines per inch) with the scaling factor applied. Units = mm/sec Current speed of the encoder wheel when using the standard encoder wheel (generates 150 encoder lines per inch). Suggested percentage for the scaling factor setting when calibrating using the Measure Speed setting and an external encoder. This is based on the standard encoder wheel. Units = mm/sec On / Off

Controller

On / Off

Controller

On / Off

Controller

On / Off Last read data from scanner port Last read data from scanner port Last read data from scanner port (if OEU is installed) Time from the print trigger for the first head until the next print trigger on the first head on the latest print. Units = milliseconds Time (ms accuracy) from the start of printing on the first head to the end of printing on the last head. Units = milliseconds Time to select the current job. If from the Host, includes the time to pass files. Time to do image updating on a print to print basis and includes incremental and time field updates

Controller Controller Controller Controller Controller

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Controller Controller

Controller

Controller Controller Controller

Section 2.0 Printer Description - Theory Statistics Statistical parameters represent a record of how the machine has performed over a period of time. Statistical parameters are presented at the UI or web browser. Controller Counts and Statistics "Batch" counts are reset by selecting a job. Controller counts and statistics descriptions: Statistics Grouping Counts

Statistic Name Allocation Current Allocation Total Batch Failed

Batch Good Batch Missed Batch Verification Prints Batch Verify Failed Prints Total Failed Total Good Total Missed Total Verification Prints Total Verify Failed Prints Statistics

Average Product Throughput

Details The number of images that have been printed since the current allocation was set The maximum number of images that the selected job will be allowed to print before the user is prompted or a new job is selected The number of images that have failed to complete printing since the current job was selected. In these instances the print started but failed to finish successfully The number of successful prints since the current job was selected The number of print signals that failed to cause a print to begin since the current job was selected The number of images which have had all barcodes verified successfully since the current job was selected The number of images with barcodes that failed to verify since the current job was selected The total number of images that have failed to complete printing. In these instances the print started but failed to finish successfully The total number of successful prints The total number of print signals that failed to cause a print to begin The total number of images which have had all barcodes verified successfully The total number of images with barcodes that failed to verify When producing, prints per hour

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Responsibility Controller Controller Controller

Controller Controller Controller Controller Controller Controller Controller Controller Controller Controller

Section 2.0 Printer Description - Theory Printhead Statistics Printer statistics are defined by the print head and uploaded by the Controller at system boot-up. Printer statistics are displayed on all system interfaces supported by the Controller but are maintained by the printhead and are requested periodically for display. Manual Control Controller Manual Control MANUAL mode allows manual manipulation of system hardware to aid in installation and to diagnose faults. It is not possible to use Manual Controls while the machine is in AUTOMATIC mode. Manual Control operations are accessible from the local user interface. Manual Control operations are accessible from the web-based user Interface. Table of Controller Manual Control operations:

Grouping I/O

Manual Controls Control Description Relays (3) On / Off Beacon Lamps (3) On / Off Audible Alarm On / Off

Location Controller Controller Controller

Printhead Manual Control Printer manual control operations are defined by the printhead and uploaded by the Controller at system boot-up. Faults & Warnings See "Troubleshooting Section" Faults and Warnings Suppression The Controller provides a mechanism to suppress any fault. When a fault is suppressed the fault will not get raised or displayed by the UI/Web UI but the fault will get logged. The faults and warnings which can be disabled must be identified and placed in a Fault Suppression File used by the Controller. Fault and Warning Priorities Faults and warnings are split into 4 categories which denote the priority of the condition. The levels can be identified by the final digit of the fault or warning number. The levels range from 0-3 with 3 being the most severe. Level 3 conditions are classified as faults that require the customer to contact Markem-Imaje for a resolution. Level 2 conditions are classified as faults that can be dealt with by a technician. Level 1 conditions are classified as faults that can be dealt with by an operator. Level 0 conditions are classified as warnings.

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Section 2.0 Printer Description - Theory Firmware Upgrade Upgrade Process There are two methods for updating the firmware on the system: from a USB stick or via the DCP protocol using CoLos Tools. The upgrade process is initiated using a combined upgrade file containing both the printer and controller application images with the extension .nge. The NGE upgrade file must contain the Controller application. The printhead application is optional. If the printhead application is not present, only the Controller will be upgraded. Printheads cannot be upgraded without first upgrading the Controller. The following actions are taken to reset the system as part of a firmware upgrade: • • • • • • •

Firmware version numbers updated Batch counts reset Total counts remain unchanged Settings returned to default values No job selected on reboot The file system cleared of any non-system files Any deleted system files restored to file system

Upgrade from USB The Controller provides a mechanism at the local user interface to allow a technician to upgrade the Controller firmware and that of any attached printheads from a USB flash memory drive connected to its USB port. The user must copy the required NGE file to a USB memory stick, making sure there are no other NGE files on the stick. The memory stick must be inserted into the USB slot in the controller and then the user has to select the ‘Upgrade from USB’ option on the UI. The Controller is responsible for carrying out the following process: 1. Automatically back-up settings and files to the USB stick prior to performing the upgrade. This does not include default files (i.e. default jobs). In a case where there is not enough space available for backup on the USB stick, the user will be notified, told how much additional space is required, and provided the option to continue anyway or cancel. 2. Reboot into FUU mode and upgrade the main application firmware using the file on the memory stick. 3. Reboot into the main application code which will check the NVRAM section to see that the firmware has been upgraded from the USB stick. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2.0 Printer Description - Theory 4. Connect to each of the print heads in turn and update the firmware in each. 5. Continue with the standard boot up process of the system. 6. When the Controller's firmware gets updated the Controller will restore the file system to factory defaults (prior to re-applying backed up files). 7. Backed-up settings and files are automatically restored as part of the boot-up process with no user interaction required. If the USB key is not present during the reboot following firmware upgrade, or has no configuration files to copy, the controller will continue to bootup but will notify the user that default settings and files will be used. 8. If the controller has a new board with no application code programmed in it the user can activate the FUU using a hardware jumper, insert the USB stick, and when the Controller is powered on it will load the new firmware automatically. The jumper must be moved back to its original position in order for the controller to reset and boot-up normally following the upgrade process. Upgrade over DCP The Controller provides a mechanism to allow a technician to upgrade the Controller firmware and that of any attached printheads from a PC running CoLOS Tools via DCP. Using CoLOS Tools, the user will select to upgrade the firmware and then select the required NGE file when prompted. CoLOS Tools will provide the facility to backup and restore system files as part of the firmware upgrade process. The following set of actions will happen between CoLOS and the controller: 1. Firmware Upgrade DCP message is sent from CoLOS to the controller. 2. The controller then reboots into the FUU application. 3. CoLOS reconnects to the controller and upgrades the controller application using the FUU protocol. 4. When the upgrade is complete the controller will reboot. 5. CoLOS reconnects to the controller and sends the UpdatePrinterFirmware DCP message with the printhead firmware file included in the message. 6. The controller puts each connected printhead into FUU mode. 7. The controller downloads the new firmware into each connected printhead using the Printhead FUU protocol. 8. The system reboots. 9. When the Controller's firmware gets updated the Controller will restore the file system to factory defaults and then request new configuration files from the printheads as part of the standard boot-up process.

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Section 2.0 Printer Description - Theory Security Access Levels Operator 1111 Supervisor 2222 Service 3333 Markem-Imaje (Password of the day) Note: Security needs to be enabled to be prompted for password entry Default Access Level • The system supports a Default Access Level feature (setting). • The Default Access Level is set-able only at the highest customer access level (Service). • The Default Access Level sets the level of access that is active at every power-up. All menu items at this level and at lesser levels will be available without a password being required. All menu items above this access level will require a password. • The Default Access Level may only be changed from the Service access level. Multiple User Interface Access Levels Access to the Color UI and the Web UI is handled independently to prevent unintended access to secure features. Logging on to one user interface will not inherently allow access from the other. Instead, users will be required to explicitly log on using the user interface they wish to access. Host Communications DCP The Controller: • Allows communication with any other DCP enabled application using a 10/100BaseT Ethernet port. • Allows communication with any other DCP enabled application using the 2nd (spare) 10/100Base-T Ethernet port which may be used to communicate to an external Wireless (Wi-Fi) module. • Allows communication with any other DCP enabled application using a USB serial port. Note: The Controller will NOT support DCP over a RS-485 or RS-232 network. NGPCL The Controller is able to communicate with any other NGPCL enabled device: • Using a 10/100BaseT Ethernet port. • Using a RS232 Serial port. • Using a USB serial port. Note: The Controller will NOT support NGPCL over a RS-485 network.

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Section 2.0 Printer Description - Theory Localization Language Files The Controller uses language files conforming to the MachineLanguageFile.xsd schema file in order to display localized strings on the local user interface. The Controller uses language files conforming to the MachineLanguageFile.xsd schema file in order to display localized strings on the web-based user interface. The Controller has the capacity to store all of its specific supported language files. The Controller has the ability to send down printhead specific language files to the printhead in order to update translations or add new language files. The Controller has the ability to request printhead specific language files from the printhead and provide it to the user in order to update translations. If the user selects a language that is present on the Controller but not on the printhead(s), the Controller displays Controller strings in the selected language and default printhead strings to ENGLISH. For the currently loaded language, the Controller provides the ability to upload the [language name].language file via DCP. This file provides a complete listing of all language IDs and associated translated strings for use in displaying localized strings. This file contains strings for multiple print heads if applicable in the format they would be displayed (i.e. PH1 Density). The [language name].language file is hidden from the user when displaying the list of files that are currently in the file system. This file is intended for use by CoLOS or other DCP enabled applications only and is not used to upload or download custom translations. For the currently loaded language, the Controller provides a [language name].trans file in the file system that contains a listing of all the unique strings that are translated by the system. This file will not contain multiple strings for multiple print heads and will not pre-pend print head strings with PH1 or PH2. This file is intended to be uploaded, edited, and downloaded to support custom language translations. When using the Color UI mechanism to copy all files to USB, the [language name].trans file will be copied while the [language name].language file will not. When deleting files at the Color UI, the user has the option to delete [language name].trans files. [language name].language files can not be deleted. Custom [language name].trans files are automatically backed-up and restored as part of a firmware upgrade.

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Section 2.0 Printer Description - Theory The default english.trans file is not to be editable by the user and therefore its download to the Controller will be prevented. Handling Translation Files Translation files ([language name].trans) are xml files conforming to the MachineLanguageFile.xsd schema. All files begin with the version information consisting of the following: • • • • • • •

A schema version which defines the format of the remainder of the file. The language file version. The machine type (i.e. “NGE Controller” for the Common Controller). The minimum machine software version. This is followed by the presentation name and the font information. The presentation name is used to display the name of the language on the user interface. The majority of a translation file consists of entries which contain a text ID used to index strings to display and a text string to be displayed by the user interface. While the text strings should be translated into the language of choice, the text IDs should not be modified by a user.

In addition to the above, each entry contains additional information to help formulate new entries in a given language: • •

• •

A Length Guideline defines the maximum length of the translated string. A More Info element defines additional translated text that relates to the string in the "Text" element. For example, in the case where the string entry defines an error string, "MoreInfo" contains a description of the error and some information on how to correct it. A More Info Length Guideline defines the maximum length of the translated more info string. A Usage Info element defines how the string will be used by the user interface.

Translation files can be edited in any Unicode file editor. It is important that the language file is saved as Unicode (little endian) rather than other encoding variants (such as UTF-8). Better editing support is provided by dedicated XML editors, such as XMLSpy, within which each entry is displayed and can be modified in tabulated form. If possible, translation files should be validated against the schema to ensure that it can be parsed by the system correctly.

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Section 2.0 Printer Description - Theory Supported Languages (For Display of Static UI strings) English (Default) Polish Germany Czech French Hungarian Italian Greek Spanish Turkish Dutch Chinese Brazilian Japanese Swedish Arabic Norwegian Danish Finnish Russia Local User Interface Units The Controller supports both Metric and Imperial units for the display of settings and diagnostics. There is a setting provided to transition the machine between Metric and Imperial Units. In the case of displaying settings units, the underlying setting value will not change as a result of rounding when the display units are change from Metric to Imperial or vice versa. It is expected and acceptable that there will be some loss of precision due to rounding when the units display setting is changed. It is expected that this setting will be changed very infrequently (as part of initial system setup). The conversion formulas from Metric to Imperial units are the following: mm * 0.0393700787 = in in * 25.4 = mm oz * 29.5735296 = ml ml * 0.0338140227 = oz mBar * 0.0145037738 = psi psi * 68.9475729 = mBar (celsius * 1.8) + 32 = fahrenheit ((fahrenheit - 32) / 9) * 5 = celsius

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Section 2.0 Printer Description - Theory The Units used to display and increment values are the following: Displayed and Incremented in Metric Units 1.0 mm 0.1 mm 0.01 mm 0.01 mm\sec 1.0 C 1.0 mm H2O 0.1 mm H2O 1.0 mm Hg 1.0 mBar 1.0 ml

Displayed and Incremented in Imperial Units 0.01 in 0.001 in 0.0001 in 0.001 in\sec 1.0 F 0.01 in H2O 0.001 in H2O 0.01 in Hg 0.01 psi 0.01 oz

Color UI Localization The Common Controller’s local user interface has been based around the Unicode 16 character set. Given the correct resources and configuration files, the Common Controller is capable of displaying at the user interface any Unicode character inside the range U+0020 to U+FFFF. However, full support for all 60,000 characters is not practical. The number of characters would be prohibitively large for users to scroll through when entering the data. It is also difficult to find a font containing support for all 60,000 characters which provides an acceptable display quality in all cases. Similarly, including foreign language support for all languages would be impractical. Meeting the demands of a specific locale may require the Common Controller to be reconfigured from the out-of-box state. The user interface may be configured to use new languages by downloading new translation files (*.trans) as described in Section 19 above. The font used by the user interface can be modified to suit particular character sets. The font to use in order to display characters used for text entry at the user interface is specified in the language file. This must contain the desired set of characters you wish to be displayed. The specific xml used to define the user interface font is as follows:

NGE Swiss WGL4 NGE Swiss WGL4.ttf 12 To update the Common Controller configuration, the new translation file should be downloaded using Colos or a USB device and then selected. Before the new language is selected, the user must ensure that the specified font in the language file is already in the file system. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2.0 Printer Description - Theory Web-Based User Interface Web UI offers remote user interface functionality via a networked PC. Refer to section * for detailed use.

2.3 Printhead Theory System Overview Printhead Subsystems: PackML State Behavior Printhead / Controller Communications Ink Management Purge Management Jet Test Management Strobe Voltage Management Language File Management Logging Settings Diagnostics Statistics Manual Control Faults & Warnings Firmware Upgrade Support Encoder Pass-through Product Sensor Pass-through Debugging Support Communications Printhead-To-Controller Communications The communications between the printhead and the controller is implemented using the MCPAP protocol over a high speed serial link. Encoder pass-through. The signal of the quadrature encoder attached to the printhead is passed to the Controller via the high speed serial link. The microprocessor on the printhead does not have access to this signal. The encoder signals go directly to the FPGA on the Controller. Two diagnostic lamps are available to determine if the two channels of the encoder are functional (see the Lamps section). 5600/5800 Service Manual Rev. 02 November 2009

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Section 2.0 Printer Description - Theory Jetting Assembly Communications ƒ The clock, data, and strobe signals generated by the FPGA on the Controller are passed to the printhead via a high speed serial link. ƒ The microprocessor on the printhead does not have access to these signals. ƒ Product Sensor (Print Trigger) pass-through ƒ The signal of the Product Sensor attached to the printhead is passed to the Controller via a high speed serial link. ƒ The microprocessor on the printhead does not have access to this signal. ƒ The Product Sensor signals go directly to the FPGA on the Controller. Lamps Printhead Status Lamp (#1, Green) Off State Power is not applied to the printhead Slow Blink State • The printhead Supply Reservoir is able to accept more ink • There is less than 30 minutes of production time left based on ink usage history • The printhead must be in the PackML Ready, Standby/Producing, Holding or Held states for this to be determined Fast Blink State • The printhead is in the PackML Manual mode • The printhead is in the PackML Stopping, Stopped, Starting, Aborting or Aborted states • The printhead is in the Producing, Ready, or Held states and the operator pressed the Purge button when the printhead had a low level of ink in the Primary Reservoir. For this situation, the lamp will blink for five seconds to indicate that the purge cannot be performed at this time Continuously On State The printhead is in the PackML Ready, Holding, Held or Standby/Producing states (at its set point temperatures, vacuum levels are ok and the Supply Reservoir and Primary Reservoir ink levels are ok). The printhead is ready to print but the Controller may not be (Ready, Held states) The Supply Reservoir is full to the point that no more ink can be added

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Section 2.0 Printer Description - Theory FUU Lamp (#2, Red) Three fast blinks on boot-up FUU present Printhead application present and running Many slow blinks on boot-up (several seconds) FUU present Printhead application absent. The application space is being erased in preparation for an application download. Once this is done, the lamp is left on. Many fast blinks This state occurs when an application is being downloaded. It remains in this state until all application bytes have been received and stored. Once this is done, the application starts automatically and the lamp will be off. Product Sensor Lamp (#3, Green) Off State The product sensor is not activated On State The product sensor is activated. This only indicates a properly functioning sensor if the state changes to OFF when the sensor is de-activated. Encoder Lamp Channels (#4 and #5, Green) Off State This encoder channel is inactive Blinking State This indicates the encoder is turning at a slow rate and encoder pulses are being generated. At higher turning rates, this will appear to be On continuously. On State This encoder channel is active. It will also appear On if the encoder is turning at a fast rate.

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Section 2.0 Printer Description - Theory Jet Test Management When pressed, the Jet Test button will cause a fixed pattern to be printed. The jet test feature will only be allowed if the printhead is in the PackML Ready, Producing, or Held states (at temperature and there is sufficient ink in the Primary Reservoir. The repeated printed pattern is as follows: • All jets on for 150 encoder lines • All jets off except the topmost and bottom most jet for 30 encoder lines • All jets for jetpack A on for 150 encoder lines • All jets off except the topmost and bottom most jet for 30 encoder lines • All jets for jetpack B on for 150 encoder lines • All jets off except the topmost and bottom most jet for 30 encoder lines • All jets for jetpack C on for 150 encoder lines • All jets off except the topmost and bottom most jet for 30 encoder lines • All jets for jetpack D on for 150 encoder lines • All jets off except the topmost and bottom most jet for 30 encoder lines The pattern will be printed as long as the button is pressed Jet testing uses the internal encoder at a fixed printing speed of 70 mm per second Jet testing uses a density of 3 (of 8) Other active specialty printing modes (mirror, inverse, upside-down, etc.) which may be enabled at the time are ignored The print direction will be the same as that chosen for normal printing A functioning connection to the Controller is required for Jet Testing since the bit pattern will be output by the FPGA in the Controller The FPGA generates the Jet Test pattern when commanded by the Controller. This pattern is not a “canned” label that the Controller must build for the purpose of Jet Testing. The FPGA automatically adjusts the settings specified above so that the printhead will only have to issue a Jet Test Start and a Jet Test Stop command to activate this feature If the jet test button is pressed while printing on a product, the product print will be aborted, causing a failed print During a jet test, all print triggers will cause a missed print while the jet test is active. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2.0 Printer Description - Theory Purge Management General A purge sequence is designed to force ink out all array orifices in an attempt to remove air bubbles from the ink path and to flush debris from the array faceplate. Multiple purge sequences may be initiated by holding the Purge pushbutton active. The operator is not required to release the purge pushbutton between purge sequences. The number of consecutive purges is limited to those that can be done while no more than 0.1” of ink is removed from the Primary Reservoir after it enters a low ink condition. A purge will only be allowed if the printhead is in the PackML Ready, Producing or Held states. The Controller will log all Purge requests in the Event log. Pushbutton Manual Purge Pressing the Purge button will cause ink to be forced out the array orifices for a user defined time. The onus is placed on the operator to choose an appropriate time to purge. If the operator purges while printing, the printed image would very likely be corrupted. The Controller has no influence on the manual pushbutton Purge request. If the Purge button is pressed while printing on a product, the product print will be aborted, causing a failed print. All print triggers will be ignored and cause a missed print while the Purge Button is active. Purges may be requested from the Controller if the Controller receives a NGPCL or DCP Purge command (software triggered remote purge) or receives a Flex IO hardware input (hardware triggered remote purge). Details of these purge requests may be found in the Common Controller Theory of Operation. Count-Based Auto Purge A count-based purge will perform a purge after a set number of products have been printed. A value of ‘0’ will disable this feature. The system will request the purge upon completion of the print on the printhead. Note: The onus is on the customer to ensure there is enough time between products to ensure printed images are not affected by the purge.

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Section 2.0 Printer Description - Theory The system will count a print as a bad print if a print is triggered while the purge is being performed (including the time to clear the jetting assembly of purged ink). If Time-Based auto purge is enabled, the timer will be reset when a Count-Based auto purge is performed Software Triggered Remote Purge This purge is triggered from the Controller when it receives a NGPCL or DCP Purge command. Details of this purge request may be found in "Purge Management by Controller" section of this manual. When triggered, the purge duration will be set by manual purge duration setting. Hardware Triggered Remote Purge This purge is triggered from the Controller when it receives a Flex IO hardware input. Details of this purge request may be found in "Purge Management by Controller" section of this manual Ink Door (5800) The ink door has a sensor to indicate the latch is locked. As well, it will have an active lock to ensure the door cannot be opened when the supply reservoir ink level is FULL. It will otherwise be unlocked. There is a mechanical means of overriding the door lock solenoid. The door lock state is set by the door latch switch state when the printhead exits the Manual mode. The door lock state equals the first value of the door latch switch state while the system is booting up (PackML Off state). Whenever the door is closed, it is locked and will stay locked until the ink level is such that it should be unlocked. The door lock follows the supply reservoir ink level state in the Automatic mode once the first supply reservoir ink level reading is made. If the door lock is mechanically overridden, the printhead will not cause the lock solenoid to be retracted. It is expected the user will also have to override the solenoid to lock the door again. Ink Management See Printhead Theory document. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2.0 Printer Description - Theory System Initialization At system boot-up the printhead is required to upload the following printhead specific configuration files to the Controller: • • • • • • •

Print technology settings file (DevCaps) Settings file Diagnostics file Statistics file Manual Controls file Faults & Warnings file Language file (strings to display each of the above items on the local user interface for the currently selected language).

At system boot-up, the printhead is required to upload the file used to program the Controller-resident FPGA.

Controller-Printhead Boot-up Sequence 5600 vs. 5800 software detection The printhead is able to determine if the software that it is running is compatible with the ink technology that the printhead supports. The statistics module will contain a flag that is set at manufacturing time or at ARC refurbish time which identifies the ink technology the printhead is built for.

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Section 2.0 Printer Description - Theory System Modes & States PackML State Model:

The printhead conforms to the state model as mandated by PackML V2.2. The Controller is responsible for transitioning the printhead to the various terminal PackML states via MCPAP state transition commands. Off State (Power-Up) The printhead will power-up in the PackML AUTOMATIC mode. The printhead automatically enters the OFF state once all internal modules are initialized. In the OFF state, the Controller requests all XML and FPGA image files. It also requests any other information it needs to complete its initialization. Once the Controller finishes initialization, it commands the printhead to execute any initialization the printhead needs to perform over the communications channel. When the printhead completes its system initialization, it informs the Controller. The Controller will then inform the printhead that all initialization is complete, at which point the printhead enters the STOPPED state. Once the printhead enters the STOPPED state, the Controller is responsible for all printhead PackML state transitions. When requesting a printhead state change, the Controller only requests a transition to a terminal PackML state (STOPPED, READY, PRODUCING, HOLD, ABORTED). It is the printheads’ responsibility to get to that state in an efficient manner. The printhead informs the Controller when it reaches the requested terminal PackML state. Stopped State • All pumps are off. • All solenoids are off. • All heaters are off. • The strobe voltage is off. • The Status lamp is blinking at the fast rate.

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Section 2.0 Printer Description - Theory When transitioning to the terminal STOPPED state, the printhead will perform a controlled shutdown as follows (STOPPING state): • •

Disable the Primary Reservoir heat zone Disable the Supply Reservoir heat zone (5800 Only)

Set the Jetting Assembly heat zone to the lowest temperature that will keep the ink liquid. This is done to prevent the freezing ink in the Primary Reservoir from creating large pressures on the jetting assembly. 1. 2. 3. 4. 5. 6.

Disable the strobe voltage Prevent Purging Prevent Jet Testing Disable Supply Reservoir ink volume testing Disable Primary Reservoir ink level maintenance. Enable the Low Vacuum so the ink does not drip from the Jetting Assembly while the printhead is cooling down 7. The Status lamp will blink at the fast rate. 8. Wait for the Primary Reservoir and Supply Reservoir to reach a solid ink temperature then transition to the STOPPED state. 9. Once the Primary Reservoir and Supply Reservoir reach the solid ink temperature, the low vacuum and jetting assembly heat zone will be disabled. The STOPPED state will then be entered. 10. If a request to enter the READY or PRODUCING states arrives while in the STOPPING state, the printhead will abort the cool-down process, disable the low vacuum and Jetting Assembly heat zone and enter the STOPPED state. The printhead will then transition to the newly requested state. Ready State All thermal zones are at their set point temperatures and any dwell times have expired. All vacuums have been established and are stable. All ink levels have been determined and corrected if not valid. The strobe voltage has been enabled. The Status lamp is ON continuously if the Supply Reservoir is full or it is slowly blinking if the Supply Reservoir can accept more ink. Jet Testing and Purging may be performed Supply Reservoir ink measurement is enabled. Primary Reservoir ink level maintenance is enabled. Producing State Same as the Ready State 5600/5800 Service Manual Rev. 02 November 2009

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Section 2.0 Printer Description - Theory Hold State Same as the Ready State Aborted State When the system experiences a fault condition, it will transition to the ABORTED state. A transition to the ABORTED state may occur from any transitory or terminal state. If a fault is detected on the Controller, it will send a request for the printhead to enter the ABORTED state. If a fault is detected on the printhead, the printhead will send the controller a message stating a fault condition has been detected. The Controller will then issue a command for the printhead to enter the ABORTED state. Exiting the Aborted state may only be done via operator acknowledgement on the UI. There are only two printhead fault exceptions to this. One is the addition of ink during an Ink Out fault because the act of adding ink is interpreted as fault acknowledgement. The other is the Door Open fault because the act of closing the door is interpreted as fault acknowledgement. If transitioned to the ABORTED state from the READY, PRODUCING or HELD states, the system will maintain the normal vacuums and thermal zones with the exception of those that may be directly related to the fault. This will allow a faster recovery from most faults, especially Ink Out. Purging and Jet Testing are not allowed in this state. Supply Reservoir ink measurement is disabled in this state. Primary Reservoir ink level maintenance is disabled in this state. The Status lamp will blink at the fast rate. When the controller sends a request to exit the Aborted state, the printhead will clear all of its faults without notifying the controller of their cleared state. The controller must also clear all of the faults so the two modules are in sync. Manual Mode The Manual mode allows the operator to directly control all of the printhead devices. This includes pumps, solenoids, lamps, heat zones, strobe voltage. The Manual mode will also provide a means to manually trigger printhead sequences that occur in Automatic mode.

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Section 2.0 Printer Description - Theory Primary Reservoir fill The system will not allow the primary reservoir to be filled beyond the normal IN INK state. Manual Purge No low vacuum faults will be thrown when this is performed. This allows the Manual mode Manual Purge to empty the primary reservoir without generating nuisance faults. No limits on how much ink may be purged after the primary reservoir reaches an Ink Out state is enforced in Manual mode. The primary reservoir may be purged until it becomes empty. The Primary Reservoir and Jetting Assembly must be at their respective set points before this command is allowed (it is ignored otherwise). Auto Purge No low vacuum faults will be thrown when this is performed. This allows the Manual mode Auto Purge to empty the primary reservoir without generating nuisance faults. No limits on how much ink may be purged after the primary reservoir reaches an Ink Out state is enforced in Manual mode. The primary reservoir may be purged until it becomes empty. The Primary Reservoir and Jetting Assembly must be at their respective set points before this command is allowed (it is ignored otherwise).

The Controller will issue a MANUAL mode command to transition the printhead to the Manual mode. This occurs when the operator enters the UI’s Menu\Diagnostics\Manual Control menu. Exiting the UI Menu\Diagnostics\Manual Control menu will cause the Controller to issue an AUTOMATIC command to the printhead. The printhead will enter the STOPPED state on transition from the MANUAL mode to AUTOMATIC mode. Purging and Jet Testing is allowed in this mode regardless of the readiness of the system to perform these functions. On entering this mode, the Status lamp will blink at the fast rate. Automatic Supply Reservoir ink level checking is disabled in this mode. All heaters and vacuums that were actively being maintained prior to entering the Manual mode will continue to be maintained in the Manual mode unless the operator disables that particular feature. This allows troubleshooting of the system in any state.

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Section 2.0 Printer Description - Theory Image The minimum length of an image is one encoder line or 0.17 mm (0.0067 inches). The maximum length of an image is 1000 mm (39.37 inches). The height of an image is fixed at 65.02 mm (2.56 inches). The system will only support image rotations of 0 and 180 degrees The system will not support image mirroring Field Types: The Printhead will print all fields types defined in the Image Data Model specification. Printing Encoder The printhead supports connection to one external quadrature encoder that generates a pulse stream of 5.9 lines per millimeter (150 lines per inch). There are no provisions for detecting negative travel. There is an internally generated encoder signal that may be selected for applications where the product speed is constant. The Internal Encoder option should not be chosen for applications where the product speed is variable. This is especially true when printing bar codes due to the critical nature of bar spacing. Density A density feature will allow a given vertical line’s worth of dots to be repeatedly printed an integral number of times between actual encoder lines. The range of the density will be 1 – 8, where a value of 1 would print a different line’s worth of image data on every encoder line. A value of 2 would print a given line data two times before advancing to the next line’s worth of image data and so on. A density value of 1 would give the lightest printed image and the image would get progressively darker as the density value increased. For density values greater than 1, the strobe pulses would be uniformly spaced between the encoder pulses. The divisor shown below is inversely proportional to the density value (divisor = 1 equates to a density value of 8).

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Section 2.0 Printer Description - Theory Variable Encoder The variable encoder feature allows the external encoder to be applied to a surface whose speed is not equal to but is proportional to the speed of the product. This is accomplished by multiplying the raw encoder frequency by a fractional number in the range of 0.02 – 5.00. The output of the variable encoder module is a 150 DPI encoder pulse stream as shown in the figure below. Strobe Rate Limits There is a strobe rate setting that will set a warning when the strobe pulse train rate (see below) exceeds the entered value. This warning will inform the operator that the system has exceeded the strobe rate to which the jetting assembly was designed and if it were allowed to continue, the jetting assembly could fail. This feature will post a warning if the density value is automatically reduced in order to reduce the strobe rate; however, no fault will be thrown which will allow the system to continue uninterrupted printing. If the operator determines that the reduced density is not acceptable, they can then modify their conveying system. The variable encoder feature will allow the external encoder to be applied to a surface whose speed is not equal to but is proportional to the speed of the product. This is accomplished by multiplying the raw encoder frequency by a fractional number in the range of 0.02 – 5.00. The output of the variable encoder module is a 150 DPI encoder pulse stream as shown in the figure below. The physical application of the variable encoder is shown in: Strobe Rate Limits There will be a strobe rate setting that will set a warning when the strobe pulse train rate (see below) exceeds the entered value. This warning will inform the operator that the system has exceeded the strobe rate to which the jetting assembly was designed. There will be a strobe rate setting that will set a fault when the strobe pulse train rate exceeds the entered value and the system cannot reduce the density to a level that brings the strobe rate back into compliance. This fault informs the operator that the system has exceeded the maximum strobe rate for the jetting assembly and if it were allowed to continue, the jetting assembly could fail. This feature will post a warning if the density value is automatically reduced in order to reduce the strobe rate however no fault will be thrown which will allow the system to continue uninterrupted printing. If the operator determines that the reduced density is not acceptable, they can then modify their conveying system. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2.0 Printer Description / Theory

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Section 2.0 Printer Description / Theory Print Triggers Product Sensor (Local, Remote) One product sensor may be connected to the printhead. The product sensor must be an Open Collector or Open Emitter device. There is no support for a device that both sources and sinks when switching between its two output states. The product sensor may be set to trigger a print on the positive or negative edge of the signal. The product sensor has an associated debounce value menu value that causes the trigger to only go active when the signal has been active for the full debounce distance. The trigger is only acted upon when the system is in the PRODUCING state. A Registration setting will provide a distance offset between the activation of the Print Trigger and the start of actual printing. If the printhead is in the registration phase and it receives another trigger, a fault will be raised because this indicates the product is spaced too close together. The system does not support multiple products between the print trigger and the start of printing. A printhead may enter the registration phase while actively printing as long as the printing completes on that printhead before that printheads’ registration counts down to zero. Fixed Spacing The Fixed Spacing mode causes the printhead to be automatically triggered after a fixed distance has passed. Fixed spacing mode does not use an external product sensor. The Spacing setting determines the distance between print triggers. The Spacing setting must be greater than the image width to avoid causing a Product Spacing fault. Entry to the Producing state will cause an immediate print to occur. Succeeding prints will occur on integral Spacing setting value multiples. The Registration setting is used to offset the start of the print. Comms The NGPCL supports the triggering of a print. When Comms triggering is selected, all other trigger types are ignored. The effect of a Comms triggered print is identical to a Product Sensor triggered print (see Product Sensor above).

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Section 2.0 Printer Description / Theory Job Management The printhead provides no direct support for job management. All controlled through the controller. Barcode Scanning The printhead provides no direct support for barcode scanning. All controlled through the controller. File Management Language Files • • • • • •

• •

Language files are stored in the printhead file database. The printhead will support English as the default language. English will be hard-coded and does not occupy any space in the database. The printhead will support two additional languages to be stored in the database. Additional languages will be downloaded from the Controller. If the Controller downloads a language file with the name “English”, it will be placed in the language file database as one of the two supplemental languages (it does not overwrite the hard-coded English language file). The English language file in the database is the file that the printhead will upload if the Controller later requests the English language. The Controller may request a listing of all language files The Controller may upload any language file in the printhead database.

Logging The printhead provides no logging feature. Controller Event Log The Controller provides an Event Log which the printhead may write entries to using the MCPAP Log Maintenance Event message. Log entries contain a time-stamped (year, month, day, hour, minute, second and printhead ID). This log has a finite size. If an entry will exceed the size, the Controller will overwrite the oldest entry with the new data. This log is non-volatile (retained between power cycles) The printhead will log the following in the Event Log: Manual purge event Auto purge event Supplies addition to the Supply Reservoir

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Section 2.0 Printer Description / Theory Strobe Voltage The strobe voltage that Dimatix specifies for the jetting assembly is saved in the statistics module when the printhead is built or when the jetting assembly is changed in ARC. The system needs a method of setting and retrieving the serial numbers. The value is not over-writeable via the system menu. Printhead Settings All numeric values will be in metric units when received from the Controller or sent to the Controller.

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Section 2.0 Printer Description / Theory Category

Setting

Description

Default

Range Fixed Spacing, Local, Remote, Comms Local, Remote, Internal 0 - 3048

Print Initiation

Product Sensor

Fixed Spacing

Encoders

Encoder

Internal

Internal Enc. Speed

Print Position

Registration

When Internal encoder selected – max determined by 18000 max strobe rate at Density 1 Distance between external products going active and the start of the printing.

40

0

010000

Units (as saved)

Job File Settable

Restorable

Producing Settable

Enum

Security Access Level 3

No

Yes

No

Enum

3

No

Yes

No

mm/sec

3

No

Yes

Yes

Tenths of mm

1

Yes

Yes

Yes

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Section 2.0 Printer Description / Theory Category

Setting Fixed Spacing Length

Ink

* *

Supply Reservoir Temperature Primary Reservoir Temperature Jetting Assembly Temperature Primary Reservoir Temperature Jetting Assembly Temperature Low Vacuum

Description

Default

Range

Units (as saved)

Security Access Level 3

Job File Settable

Restorable

Producing Settable

Distance between internal print triggers when Fixed Spacing is selected as the Product Sensor Hotmelt

3000

020000

Tenths of mm

Yes

Yes

Yes

110

100 – 125C

Whole C degrees

3

No

Yes

No

Hotmelt

125

100 – 125C

Whole C degrees

3

No

Yes

No

Hotmelt

125

100 – 125C

Whole C degrees

3

No

Yes

No

Liquid

50

40 – 60C

Whole C degrees

3

No

Yes

No

Liquid

50

40 – 60C

Whole C degrees

3

No

Yes

No

43

0 – 105

mm of H2O

3

No

Yes

No

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Section 2.0 Printer Description / Theory Category

Setting Low Vacuum Filter Plugged Duty Cycle Primary Res. Leak DC Ink Present Set Point (Hotmelt)

*

Ink Present Set Point (Liquid)

Description

Voltage at which ink is sensed measured at the thermistor Voltage at which ink is sensed measured at the thermistor. Needs to be a function of the primary reservoir temperature.

Default

Range

Units (as saved)

12

0 - 100

%

Security Access Level 3

35

0 – 100

%

3

No

Yes

No

40 @ 125C

0 – 119

Tenths of Volts

3

No

Yes

No

90 @ 50C

0 – 119

Tenths of Volts

3

No

Yes

No

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Job File Settable

Restorable

Producing Settable

No

Yes

No

Section 2.0 Printer Description / Theory Category

Purging

Setting Supply Reservoir Calibration Start Volume Supply Reservoir Calibration Final Volume Supply Reservoir Volume Factor Supply Reservoir Volume Offset Manual Purge Duration Auto Purge Duration Auto Purge Count

Description

Default

New cal. procedure

0

0 - 400

New Cal. procedure

0

Conversion factor for millisecs to mL Conversion factor for millisecs to mL

Number of products printed between purges – 0 disables

Range

Units (as saved)

Job File Settable

Restorable

Producing Settable

mL

Security Access Level 3

No

No

No

0 - 400

mL

3

No

No

No

65

1 - 300

NA

3

No

No

No

815

0 - 1000

NA

3

No

No

No

250

50 1000

Milliseconds

3

No

Yes

No

0

0 - 1000

Milliseconds

3

No

Yes

No

0

010000

NA

3

No

Yes

No

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Section 2.0 Printer Description / Theory Category

Setting Auto Purge Timeout

Drip Tray Full Count Print Quality

*

*

Strobe Voltage

Strobe 1 Width Strobe Voltage

Strobe 1 Width Strobe 2 Delay Strobe 2 Width

Description Time between purges in nonproducing mode - 0 disables Purge volume tray can hold – 0 = Disabled Hotmelt Defined by Dimatix for each jetting assembly Hotmelt

0

0 - 480

Minutes

Security Access Level 3

??????

0 - 100

mL

3

No

Yes

No

150

90 - 175

Volts

3

No

No

No

14

0 - 50

Microseconds

3

No

Yes

No

Liquid Defined by Dimatix for each jetting assembly Liquid

90

60 - 120

Volts

3

No

Yes

No

8

0 - 50

Microseconds

3

No

Yes

No

0

0 - 50

Microseconds

3

No

Yes

No

0

0 - 50

Microseconds

3

No

Yes

No

Ignored if Strobe 2 delay is 0

Default

Range

Units (as saved)

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Job File Settable

Restorable

Producing Settable

No

Yes

No

Section 2.0 Printer Description / Theory Category

Setting Strobe Warning Freq.

Strobe Fault Freq.

Density

Description

Default

Range

Warning boundary for degraded print quality. Must be less than Strobe Fault Freq. setting Fault boundary for destructive strobe rate. Must be greater than Strobe Warning Freq. setting 1 = Lightest

12

1 - 17

18

3

Units (as saved)

Job File Settable

Restorable

Producing Settable

kHz

Security Access Level 3

No

Yes

No

2 – 18

kHz

3

No

Yes

No

1-8

NA

1

Yes

Yes

Yes

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Section 2 - Printer Description / Theory Diagnostics Definition Diagnostic information reports the current state of the machine and its inputs and outputs. It would typically be used by a service person to identify the cause of faults within the machine or to monitor the warm-up or shutdown process. Digital signals Digital signals (either inputs or outputs) are displayed as one of three states: ACTIVE, CHANGING or INACTIVE. Since the display will be updated periodically, the value reported will be CHANGING if the diagnostic item changes one or more times during the display update. A stable state will be displayed if the digital channel monitored has the same state for two consecutive display updates All numeric values will be sent in metric units Lists

Grouping Configuration

Heat

Item Printhead FUU Version Printhead Software Version Supply Reservoir Temperature Supply Reservoir Thermal State Primary Reservoir Temperature Primary Reservoir Thermal State Jetting Assembly Temperature Jetting Assembly Thermal State Printhead Internal Temp

Printhead Diagnostics States / Value

Not truly a diagnostic as it shows up in the About menu. Current integer Cº

Responsibility Printhead – Version Screen Printhead – Version Screen Printhead

Off, Warming, Cooling, Ok, Fault

Printhead

Current integer Cº

Printhead

Off, Warming, Cooling, Ok, Fault

Printhead

Current integer Cº

Printhead

Off, Warming, Cooling, Ok, Fault

Printhead

Current integer Cº as measured by a sensor on the printhead control board

Printhead

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Section 2 - Printer Description / Theory Grouping Vacuums

Ink

Valves

Item High Vacuum Sensor (Liquid) High Vacuum State (Liquid) High Pump State Low Vacuum Sensor Low Vacuum Pump State Low Vacuum Pump Duty Cycle Supply Reservoir Pressure Primary Reservoir Ink Sensor Primary Reservoir Ink Level Status Door Status (Hotmelt) Ink Container Switch (Liquid) Ink Container Volume (Liquid) Supply Reservoir Volume Supply Res. Calibration Time Supply Res. Calibration Factor Supply Res. Calibration Offset Ink Usage Rate Door Lock Solenoid State (Hotmelt) Solenoid 1 State (Liquid) Solenoid 2 State Solenoid 3 State Solenoid 4 State Solenoid 5 State

States / Value Current Vacuum (mm of Hg)

Responsibility Printhead

On / Off On / Off Current Vacuum (mm of H2O) On / Off

Printhead Printhead Printhead

Percent

Printhead

Current Pressure (millibars)

Printhead

Voltage in tenths

Printhead

Ink Sensed / Ink not Sensed

Printhead

Open / Closed Present/Absent

Printhead

mL mL

Printhead

mSec

Printhead Printhead Printhead

mL / Hour On / Off

Printhead Printhead

On / Off On / Off On / Off On / Off

Printhead Printhead Printhead Printhead

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Section 2 - Printer Description / Theory Grouping

Interface

Printhead States

Miscellaneous

Item Solenoid 6 State (Liquid) Jet Test Switch Purge Switch Status Lamp State FUU Lamp State Primary Reservoir Fill State Ink Recovery State (Liquid) Supply Res. Fill State (Liquid) Purge State PackML State Cabinet Temperature Strobe Voltage

On / Off

States / Value

Responsibility Printhead

Pressed / Released Pressed / Released On / Off / Changing On / Off / Changing Active/Inactive

Printhead Printhead Printhead Printhead Printhead

Active/Inactive Active/Inactive Active/Inactive Stopped, Starting, Ready, Producing, Holding, Held, Stopping, Aborting, Aborted Temperature measured on the control board Volts - Measurement is +/- 6V

Printhead Printhead Printhead

Statistics: Definition Statistical values represent a record of how the machine has performed over a period of time. Lifetime vs. Current There are two sets of statistics maintained by the printhead which exist in non-volatile memory that is affixed to the primary reservoir – current statistics and lifetime statistics. The statistics memory is attached to the primary reservoir to allow it to travel with the primary reservoir / jetting assembly when it is returned for service independent of the data on the control board. This data is used by Quality and Engineering for print engine performance. Current statistics will be reset when the unit is sent back to be refurbished. Therefore they represent the status of the system since the last time it was manufactured/refurbished. The Current statistics are what is displayed on the UI when the Controller asks for the printheads’ statistics. Lifetime statistics will never be reset.

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Section 2 - Printer Description / Theory Lifetime statistics are only viewable at a repair center using special software/hardware. Both sets of statistics consist of the same items as shown in the table below. Statistics Grouping Jetting Assembly

Statistic Name Jet Assembly Power-up Count

Details PackML Off to Ready state transition count

Responsibility Printhead

Jet Assembly Hours Jet Assembly Printing Hours Jet Assembly Ink Supplies Used Count Jet Assembly Prim. Res. Fill Count Jet Assembly Purge Count Jet Assembly Supply Res. Fill Count (Liquid) Jet Assembly Print Count Jet Assembly Waste Ink Recovery Count (Liquid)

Time with power applied Hours in the PRODUCING state Ink block count for Hot Melt, containers used for Liquid Completed fill cycles

Printhead Printhead Printhead

Completed purge cycles Number of time filling the supply reservoir from the ink container Number of images printed by this head. Number of times sucking the waste ink back into the ink container

Printhead Printhead

Printhead

Printhead Printhead

Manual Control: Definition The MANUAL mode allows manipulation of the outputs to aid installation and to diagnose faults (see PackML description above). Manual Mode Behavior All manual controls will cause the system to be placed in PackML MANUAL mode. It is not possible to use Manual mode controls while the machine is in AUTOMATIC mode because the manual functions may affect the print function. Switching into MANUAL mode will automatically remove the system from the PRODUCING state. Faults in Manual Mode The only fault conditions monitored in Manual mode are the heater Over-Temp faults. If any of these faults are activated, the system will automatically attempt to set the devices to a safe state. The system will remain in the Manual mode – no transition to the Auto mode Aborted state. It should not be possible to flood the printhead through the changing of any combination of device states in the manual mode.

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Section 2 - Printer Description / Theory Grouping Heaters

Pneumatics

Misc

Commands

Manual Controls Control Supply Reservoir (Hotmelt) Primary Reservoir Jetting Assembly High Pump Low Vacuum Solenoid 1 (Liquid) Solenoid 2 Solenoid 3 Solenoid 4 Solenoid 5 Solenoid 6 (Liquid) Printhead Status Lamp FUU Lamp Door Solenoid (Hotmelt) High Voltage Control Manual Purge

Auto Purge

Measure Supply Volume Primary Reservoir Fill

Retrieve Factory Strobe Voltage

Description Off / Regulate Off / Regulate Off / Regulate Off / On Off / Regulate Off / On Off / On Off / On Off / On Off / On Off / On Off / On Off / On Off / On Off / On (use voltage set point) Command – Off / Purge (use Manual purge time). This will do a purge as it would be initiated if the operator pressed the Purge switch on the Printhead. Command – Off / Purge (use Auto purge time). This will do a purge as it would be initiated if the conditions for an Auto Purge were true. Command – This will cause the Supply Reservoir volume to be tested. Command – Enable/Disable This will automatically perform the necessary steps to attempt to fill the Primary Reservoir. The printhead will not allow the Primary Reservoir to be filled beyond the In Ink sensed level. Command – Causes the strobe voltage setting in the statistics module to replace the current strobe voltage setting.

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Section 2 - Printer Description / Theory Grouping

Control Supply Res Calibration Step 1 Supply Res Calibration Step 2 Purge Supply Reservoir Start Purge Supply Reservoir Stop Supply Fill (Liquid) Recover Ink (Liquid)

Description Command – Do the first step to calibrate the supply reservoir – no ink Command – Do the last step to calibrate the supply reservoir – ink full Command – Push ink from the supply reservoir out the jetting assembly Command – Stop pushing ink from the supply reservoir out the jetting assembly Command – Empty the ink container into the supply reservoir Command – Recover the liquid ink from the ink tray

Printhead Firmware Upgrade: Upgrade from USB The user must copy the required NGE file to a USB memory stick There may only be one NGE file on the stick. The memory stick must be inserted into the USB slot in the Controller and then the user has to select the ‘Upgrade from USB’ option on the UI. The controller will then carry out the following sequence of events: Automatically back-up settings and files to the USB stick prior to performing the upgrade. In a case where there is not enough space available for backup on the USB stick, the user will be notified, told how much additional space is required, and provided the option to continue anyway or cancel. Reboot into FUU mode and upgrade the main application firmware using the file on the memory stick. Reboot into the main application code which will check the NVRAM section to see that the firmware has been upgraded from the USB stick. Connect to each of the print heads in turn and update the firmware in each. Continue with the standard boot up process of the system. Backed-up settings and files are automatically restored as part of the boot-up process with no user interaction required. If the USB key is not present during the reboot following firmware upgrade or has no configuration files to copy, the controller will continue to boot-up, but will notify the user that default settings and files will be used.

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Section 2 - Printer Description / Theory If the controller is a virgin board with no application code programmed in it the user can insert the USB stick and when the board is powered on it will automatically run in FUU mode and will load the new firmware. There can only be one NGE file on the memory stick during an upgrade process. Upgrade Using DCP Using CoLOS Tools, the user will select to upgrade the firmware and then select the required NGE file when prompted. The following set of actions will happen between CoLOS and the controller: Prompt the user to save the settings. Firmware Upgrade message sent from CoLOS to the controller. The controller then reboots into the FUU application. CoLOS reconnects to the controller and upgrades the controller application using the FUU protocol. When the upgrade is complete the controller reboots with main controller application. CoLOS reconnects to the controller and sends the UpdatePrinterFirmware message with the printhead firmware file included in the message. The controller puts each connected printhead into FUU mode. The controller downloads the new firmware into each connected printhead using the printhead FUU protocol. The controller reboots itself so that it gets all the new files from the printhead when it restarts. If the controller is a virgin board CoLOS will detect this and update the controller firmware using the FUU and then run through the rest of the update sequence as described above. Security The printhead provides no direct support for security beyond defining what settings may be changed at each security level. See the Settings section for this information. Host Communications The printhead provides no direct support for Host communications. Localization The printhead provides no direct support for Localization. 5600/5800 Service Manual Rev. 02 November 2009

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Section 2 - Printer Description / Theory Local User Interface The printhead provides no direct support for Local User Interface. Web-Based User Interface The printhead provides no direct support for the Web-based User Interface. System Debug Serial Debug The printhead has an internal serial debug port that supports the outputting of printhead diagnostics for versions of the program that are built to support this special feature (not production intent). Power Management Line Voltage The system will support 100, 110, 120, 200, 220, 240 VAC +/- 10% at 50 or 60 Hz Conversion effort from one voltage to another will be minimal and will not require a special version of the machine. This means that any conversion must be able to be done in the field without requiring a modification kit or special tools. Line voltage will be input to the Controller only. System Power Distribution The printheads receive all power from the Controller. The printheads will receive 24VAC for use on all heaters. The printheads will receive 24VDC for use as an input to internal DC-to-DC converters. These converters will produce the various voltages required for the printhead control board and any I/O. The Optional Expansion Unit (OEU) will receive 24VDC for use to power the externally attached FlexIO devices from the Controller. 5V logic levels will be used for implementation of the SPI communications interface. Jetting Assembly High Voltage The high voltage required to strobe the Jetting Assembly will be derived from the 24VDC in the printhead.

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Section 2 - Printer Description / Theory Environment Temperature The system will operate over the range of 0°C to 40°C A warning will be posted if the system detects an ambient temperature below 0ºC on boot up. The temperature range is specified for a “still air” wind velocity. Operation under extreme wind velocities, especially at ambient temperatures below 20°C will need to be evaluated on a case by case basis. Wind velocities may extend the warm-up times or in extreme cases require shielding of the printhead to allow it to warm-up. Humidity The system will operate over the humidity range of 0 – 90% non-condensing. The system will continue to operate normally when exposed to incidental water (splash from washdown of other nearby equipment, etc.) Airborne Contaminants The system must be able to operate normally in environments where airborne particles such as fiberboard box dust, sugar dust, flour dust, and oils are present. IP Rating The controller will carry an IP rating of 42. The printhead will have no claimed IP rating. Altitude The system must function at altitudes up to 2300 meters. This was chosen to include high altitude cities such as Mexico City (2250 meters) and Denver (1610 meters). A printhead may enter the registration phase while actively printing as long as the printing completes on that printhead before that printhead’s registration counts down to zero.

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Section 2 - Printer Description / Theory Fixed Spacing The Fixed Spacing mode causes the printhead to be automatically triggered after a fixed distance has passed. • Fixed spacing mode does not use an external product sensor. • The Spacing setting determines the distance between print triggers. • The Spacing setting must be greater than the image width to avoid causing a Product Spacing fault. • Entry to the Producing state will cause an immediate print to occur. Succeeding prints will occur on integral Spacing setting value multiples. • The Registration setting is used to offset the start of the print. Comms The NGPCL supports the triggering of a print. When Comms triggering is selected, all other trigger types are ignored. The effect of a Comms triggered print is identical to a Product Sensor triggered print (see Product Sensor above). Job Management The printhead provides no direct support for job management. Barcode Scanning The printhead provides no direct support for barcode scanning. File Management

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Section 2 - Printer Description / Theory Language Files • • • • • •

• •

Language files are stored in the printhead file database. The printhead will support English as the default language. English will be hard-coded and does not occupy any space in the database. The printhead will support two additional languages to be stored in the database. Additional languages will be downloaded from the Controller. If the Controller downloads a language file with the name “English”, it will be placed in the language file database as one of the two supplemental languages (it does not overwrite the hard-coded English language file). The English language file in the database is the file that the printhead will upload if the Controller later requests the English language. The Controller may request a listing of all language files The Controller may upload any language file in the printhead database.

Logging The printhead provides no logging feature. Controller Event Log The Controller provides an Event Log which the printhead may write entries to using the MCPAP Log Maintenance Event message. Log entries contain a time-stamped (year, month, day, hour, minute, second and printhead ID). This log has a finite size. If an entry will exceed the size, the Controller will overwrite the oldest entry with the new data. This log is non-volatile (retained between power cycles) The printhead will log the following in the Event Log: Manual purge event Auto purge event Supplies addition to the Supply Reservoir Settings Lists A list of the Hotmelt Printhead settings can be found in the settings.xml project file. A list of the liquid Printhead settings can be found in the lqd_settings.xml project file.

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Section 2 - Printer Description / Theory Serial Numbers While not technically a setting, these numbers will be entered by the manufacturing department when the assembly is built. Therefore the system needs a method of setting and retrieving the serial numbers. Strobe Voltage The strobe voltage that Dimatix specifies for the jetting assembly will be saved in the statistics module when the printhead is built or when the jetting assembly is changed in ARC. The system needs a method of setting and retrieving the serial numbers. The value will not be over-writeable via the system menu. Printhead Settings All numeric values will be in metric units when received from the Controller or sent to the Controller

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Section 2 - Printer Description / Theory Category

Setting

Description

Default

Print Initiation

Product Sensor

Fixed Spacing

Encoders

Encoder

Internal

Internal Enc. Speed

Print Position

Registration

When Internal encoder selected – max determined by 18000 max strobe rate at Density 1 Distance between external products going active and the start of the printing.

Range

40

Fixed Spacing, Local, Remote, Comms Local, Remote, Internal 0 - 3048

0

0 - 10000

Units (as saved)

Security Access Level

Restorable

Producing Settable

Enum

3

No

Yes

No

Enum

3

No

Yes

No

mm/sec

3

No

Yes

Yes

Tenths of mm

1

Yes

Yes

Yes

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Job File Settable

Section 2 - Printer Description / Theory Category

Setting

Description

Default

Range

Distance between internal print triggers when Fixed Spacing is selected as the Product Sensor Hotmelt

3000

020000

110

100 – 125C

Primary Reservoir Temperature

Hotmelt

125

100 – 125C

Jetting Ass’y Temperature

Hotmelt

125

100 – 125C

*

Primary Reservoir Temperature

Liquid

50

40 – 60C

*

Jetting Assembly Temperature

Liquid

50

40 – 60C

Fixed Spacing Length

Ink

Supply Reservoir Temperature

Units (as saved) Tenths of mm

Whole C degrees Whole C degrees Whole C degrees Whole C degrees Whole C degrees

Security Access Level

Restorable

Producing Settable

3

Yes

Yes

Yes

3

No

Yes

No

3

No

Yes

No

3

No

Yes

No

3

No

Yes

No

3

No

Yes

No

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Job File Settable

Section 2 - Printer Description / Theory Category

*

Setting

Description

Default

Range

Job File Settable

Restorable

Producing Settable

3

No

Yes

No

0 - 100

3

No

Yes

No

35

0 – 100

%

3

No

Yes

No

Voltage at which ink is sensed measured at the thermistor Voltage at which ink is sensed measured at the thermistor. Needs to be a function of the primary reservoir temperature. Conversion factor for millisecs to mL

40 @ 125C

0 – 119

Tenths of Volts

3

No

Yes

No

90 @ 50C

0 – 119

Tenths of Volts

3

No

Yes

No

65

1 - 300

NA

3

No

No

No

Conversion factor for millisecs to mL

815

01000

NA

3

No

No

No

43

0 – 105

Low Vac Filter Plugged Duty Cycle Primary Res. Leak DC Ink Present Set Point (Hotmelt)

12

Supply Reservoir Volume Factor Supply Reservoir Volume Offset

Security Access Level

mm of H2O %

Low Vacuum

Ink Present Set Point (Liquid)

Units (as saved)

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Section 2 - Printer Description / Theory Category Purging

Setting Manual Purge Duration Auto Purge Duration Auto Purge Count Auto Purge Timeout Drip Tray Full Count

Print Quality

Strobe Voltage

*

Strobe 1 Width Strobe Voltage

*

Strobe 1 Width Strobe 2 Delay Strobe 2 Width Strobe Warning

Description

Default

Range

250

50 1000 01000 010000

Job File Settable

Restorable

Producing Settable

Milliseconds

Security Access Level 3

No

Yes

No

Milliseconds

3

No

Yes

No

NA

3

No

Yes

No

0

0 - 480

Minutes

3

No

Yes

No

??????

0 - 100

mL

3

No

Yes

No

150

90 175

Volts

3

No

No

No

14 90

0 - 50 60 120

Microseconds Volts

3 3

No No

Yes Yes

No No

8

0 - 50

Microseconds

3

No

Yes

No

0 0

0 - 50 0 - 50

Microseconds Microseconds

3 3

No No

Yes Yes

No No

12

1 - 17

kHz

3

No

Yes

No

0 Number of products printed between purges – 0 disables Time between purges in nonproducing mode - 0 disables Purge volume tray can hold – 0 = Disabled Hotmelt Defined by Dimatix for each jetting assembly Hotmelt Liquid - Defined by Dimatix for each jetting assembly Liquid Ignored if Strobe 2 delay is 0 Warning

0

Units (as saved)

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Section 2 - Printer Description / Theory Category

Setting Freq.

Strobe Fault Freq.

Density

Fault boundary for destructive strobe rate. Must be greater than Strobe Warning Freq. setting 1 = Lightest

Description

Default

Range

boundary for degraded print quality. Must be less than Strobe Fault Freq. setting 18

2 – 18

kHz

3

1-8

NA

Units (as saved)

Security Access Level

Job File Settable

Restorable

3

No

Yes

No

1

Yes

Yes

Yes

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Producing Settable

Section 2 - Printer Description / Theory Diagnostics Definition Diagnostic information reports the current state of the machine and its inputs and outputs. It would typically be used by a service person to identify the cause of faults within the machine or to monitor the warm-up or shutdown process. Digital signals Digital signals (either inputs or outputs) will be displayed as one of three states: ACTIVE, CHANGING or INACTIVE. Since the display will be updated periodically, the value reported will be CHANGING if the diagnostic item changes one or more times during the display update. A stable state will be displayed if the digital channel monitored has the same state for two consecutive display updates. All numeric values will be sent in metric units Lists A list of the LCIJ Hot Melt Printhead diagnostics can be found in the printerdiagnostics.xml file. A list of the LCIJ Liquid Printhead diagnostics can be found in the lqd_printerdiagnostics.xml file.

Grouping Configuration

Heat

Item Printhead FUU Version ( ????) Printhead Software Version Supply Reservoir Temperature Supply Reservoir Thermal State Primary Reservoir Temperature Primary Reservoir Thermal State Jetting Assembly Temperature Jetting Assembly Thermal State Printhead Internal Temp

Printhead Diagnostics States / Value

Not truly a diagnostic as it shows up in the About menu. Current integer Cº

Responsibility Printhead – Version Screen Printhead – Version Screen Printhead

Off, Warming, Cooling, Ok, Fault

Printhead

Current integer Cº

Printhead

Off, Warming, Cooling, Ok, Fault

Printhead

Current integer Cº

Printhead

Off, Warming, Cooling, Ok, Fault

Printhead

Current integer Cº as measured by a sensor on the printhead control board

Printhead

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Section 2 - Printer Description / Theory Grouping Vacuums / Pressures

Ink

Valves

Interface

Printhead States

Item High Vacuum Sensor (Liquid) High Vacuum State High Pump State Low Vacuum Sensor Low Vacuum Pump State Low Vacuum Pump Duty Cycle Supply Reservoir Pressure Primary Reservoir Ink Sensor Primary Reservoir Ink Level Status Supply Reservoir Volume Supply Res. Vol. Check Time Ink Usage Rate Door Lock Solenoid State Solenoid 1 State (Liquid) Solenoid 2 State Solenoid 3 State Solenoid 4 State Solenoid 5 State Solenoid 6 State (Liquid) Jet Test Switch Purge Switch Status Lamp State Comms Fault Lamp State Ink Container Status (Liquid) Door Status (Hotmelt) Printhead State PackML State

Miscellaneous

Cabinet Temperature Strobe Voltage

States / Value Current Vacuum (mm of Hg)

Responsibility Printhead

On / Off On / Off Current Vacuum (mm of H2O) On / Off

Printhead Printhead Printhead

Percent

Printhead

Current Pressure (millibar)

Printhead

Voltage in tenths

Printhead

Ink Sensed / Ink not Sensed

Printhead

mL

Printhead

mSec

Printhead

mL / Hour On / Off

Printhead Printhead

On / Off On / Off On / Off On / Off On / Off

Printhead Printhead Printhead Printhead Printhead

Pressed / Released Pressed / Released On / Off / Changing On / Off / Changing

Printhead Printhead Printhead Printhead

Present / Absent

Printhead

Open / Closed Purging, Filling Primary Reservoir, Measuring Supply Volume, Idle Stopped, Starting, Ready, Producing, Holding, Held, Stopping, Aborting, Aborted Temperature measured on the control board Volts - Measurement is +/- 6V

Printhead Printhead Printhead Printhead Printhead

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Section 2 - Printer Description / Theory Statistics Definition Statistical values represent a record of how the machine has performed over a period of time Lifetime vs. Current There will be two sets of statistics maintained by the printhead which exist in non-volatile memory that is affixed to the primary reservoir – current statistics and lifetime statistics. The statistics memory is attached to the primary reservoir to allow it to travel with the primary reservoir / jetting assembly when it is returned for service independent of the data on the control board. This will support warrantee issues. Current statistics will be reset when the unit is sent back to be refurbished. Therefore they represent the status of the system since the last time it was manufactured/refurbished. The Current statistics are what is displayed on the UI when the Controller asks for the printheads’ statistics. Lifetime statistics will never be reset. Lifetime statistics are only viewable at a repair center using special software/hardware. Both sets of statistics consist of the same items as shown in the table below. List A list of the LCIJ Hot Melt Printhead statistics can be found in the printerstatistics.xml file. A list of the LCIJ Liquid Printhead statistics can be found in the lqd_printerstatistics.xml file. Statistics Grouping Jetting Assembly

Statistic Name Jet Assy Power-up Count Jet Assy Hours Jet Assy Printing Hours Jet Assy Ink Supplies Used Count Jet Assy Prim. Res. Fill Count Jet Assy Purge Count Jet Assy Supply Res. Fill Count (Liquid) Jet Assy Print Count Jet Assy Waste Ink Recovery Count (Liquid)

Details PackML Off to Ready state transition count Time with power applied Hours in the PRODUCING state Ink block count for Hot Melt, containers used for Liquid Completed fill cycles Completed purge cycles Number of time filling the supply reservoir from the ink container Number of images printed by this head. Number of times sucking the waste ink back into the ink container

Responsibility Printhead Printhead Printhead Printhead Printhead Printhead Printhead Printhead Printhead

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Section 2 - Printer Description / Theory Manual Control Definition The MANUAL mode allows manipulation of the outputs to aid installation and to diagnose faults (see PackML description above). Manual Mode Behavior All manual controls will cause the system to be placed in PackML MANUAL mode. It will not be possible to use manual mode controls while the machine is in AUTOMATIC mode because the manual functions may affect the print function. Switching into MANUAL mode will automatically remove the system from the PRODUCING state. Faults in Manual Mode The only fault conditions monitored in Manual mode are the heater Over-Temp faults and the Ink In Vacuum Line faults. If any of these faults are activated, the system will automatically attempt to set the devices to a safe state. The system will remain in the Manual mode – no transition to the Auto mode Aborted state. It should not be possible to flood the printhead through the changing of any combination of device states in the manual mode. List A list of the LCIJ Hot Melt Printhead Manual Controls can be found in the manualcontrol.xml file.

A list of the LCIJ Liquid Printhead Manual Controls can be found in the lqd_man_ctrl.xml file. Grouping Heaters

Pneumatics

Misc

Manual Controls Control Supply Reservoir (Hotmelt) Primary Reservoir Jetting Assembly High Pump Low Vacuum Solenoid 1 (Liquid) Solenoid 2 Solenoid 3 Solenoid 4 Solenoid 5 Solenoid 6 (Liquid) Printhead Status Lamp FUU Lamp

Description Off / Regulate Off / Regulate Off / Regulate Off / On Off / Regulate Off / On Off / On Off / On Off / On Off / On Off / On Off / On Off / On

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Section 2 - Printer Description / Theory Grouping

Commands

Manual Controls Control Description Door Solenoid (Hotmelt) Off / On High Voltage Control Off / On (use voltage set point) Manual Purge Command – Off / Purge (use Manual purge time). This will do a purge as it would be initiated if the operator pressed the Purge switch on the Printhead. Auto Purge Command – Off / Purge (use Auto purge time). This will do a purge as it would be initiated if the conditions for an Auto Purge were true. Measure Supply Volume Command – This will cause the Supply Reservoir volume to be tested. Primary Reservoir Fill Command – Enable/Disable This will automatically perform the necessary steps to attempt to fill the Primary Reservoir. The printhead will not allow the Primary Reservoir to be filled beyond the In Ink sensed level. Retrieve Factory Strobe Command – Causes the strobe Voltage voltage setting in the statistics module to replace the current strobe voltage setting. Supply Fill (Liquid) Command – Empty the ink container into the supply reservoir Recover Ink (Liquid) Command – Recover the liquid ink from the ink tray

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Section 2 - Printer Description / Theory 2.4 Specifications and Dimensions 5600 Layout Drawing Part Number 10051661 Rev.AAsh01

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Section 2 - Printer Description / Theory 5800 Layout Drawing Part Number 10039771 Rev. AAsh01

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Section 2 - Printer Description / Theory Controller Layout Drawing Part Number 10039771 Rev. AAsh02

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Section 2 - Printer Description / Theory Layout Drawing Part Number 10039771 Rev.AAsh03

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Section 2 - Printer Description / Theory Layout Drawing Part Number 10039771 Rev. AA sh04

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Section 2 - Printer Description / Theory 5800 Layout Drawing Part Number 10039771 Rev. AAsh05

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Section 2 - Printer Description / Theory 5800 Layout Drawing Part Number 10039771 Rev. AAsh06

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Section 2 - Printer Description / Theory 5800 Layout Drawing Part Number 10039771 Rev. AAsh07

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Section 2 - Printer Description / Theory Notes :

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Section 3 Pre Installation

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Section 3 - Pre Installation 3.1 Installation Policy Installation 56/5800 4 Identified Installation Groups: • • • •

Markem - Imaje Service Installs Distributor Installs OEM Installs Customer Installs

For Markem-Imaje Service performed installations, the following applies: • Purchase 56/5800 machine with CoLOS Professional • You would have 2 installation orders one for 56/5800 and one for CoLOS • S22420 - Installation 56/5800 Package • S25420 - Installation CoLOS Customers do not need to purchase CoLOS Create freeware and requires no training. Installation Package includes: • Physical assembling and mounting of the equipment • Creation of simple first image and download to the machine • Instruct on how to prep the system for operation • Instruct on how to select images to print • Instruct on how to make registration adjustments • Instruct on how to ensure quality print • Instruct on daily cleaning and purging of the Printheads • Review instructions and options for Printhead / engine replacement • Review after sales support options for warranty, training and service contracts CoLOS installation includes: • Working with customers IT group to load software • Train on software package tool and usage • Train on image creation • Train on image database management Distributor Installs: They perform their own installs and contact their support team for help OEM Installs: Are recommended to have the end user contact Markem-Imaje and purchase startup assistance (installation or advanced operator training). We need packets for OEM with this type of instruction.

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Section 3 - Pre Installation Customer Installs: Customer uses supplied manual to become educated about the equipment and perform the installation them selves. (Note, if put into place we could charge for phone support to assist in the self installation)

3.2 Pre-Installation form for 5600/5800 General Information

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Section 3 - Pre Installation Date:

Signature/Name: ⇑Markem-Imaje person completing this form ⇑

1. Customer company data Customer name: Address: City: Country:

Market segment:

Market HS code:

1.1 Sales contact

1.2 Technical contact

Name:

Name:

Function:

Function:

Direct phone no.:

Direct phone no.:

E-mail:

E-mail:

1.3 Does this company belong to a group? (If no group skip section 1.4 - 1.5) Group name: Address: City: Country: 1.4 Sales contact

1.5 Technical contact

Name:

Name:

Function:

Function:

Direct phone no.:

Direct phone no.:

E-mail:

E-mail:

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Section 3 - Pre Installation 1.6 Equipment Number of (Product) Systems to be installed: Type of (Product) system(s) 5800 - 1 Head ˆ

5800 - 2 Head ˆ

1 Stand

ˆ

5600 - 1 Head ˆ

5600 - 2 Head ˆ

2 Stands

ˆ

Undecided ˆ

Comments:

2. Installation environment 2.1 Installation area Packaging

ˆ

Warehouse ˆ

Manufacturing

ˆ

Other ˆ

2.2 Environment: Temperature range

From:

Humidity

° C / °F

To:

°C / °F

%

Condensing ˆ

Non-condensing ˆ

Clean ˆ

Dusty ˆ

Sticky ˆ

Particulates ˆ 2.3 Operating time

Static Electricity ˆ

Washdown ˆ

Air quality

Hours

From:

To:

Days

From:

2.4 Main power supply 240 VAC

ˆ

110 VAC

ˆ

50Hz

ˆ

60Hz

ˆ

Other:

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To:

Section 3 - Pre Installation 2.5 Conveyor Customer’s name for line Manufacturer Conveyor type

(5X00 Series requires a powered belt )

Powered Roller ˆ

Standard Belt ˆ

Flat Inter Locking Top - Plastic ˆ

Mesh Top - Plastic ˆ

ˆ

Other

mm ˆ

Height of conveyor (from floor to top of conveyor belt/rollers) New

Installation

ˆ

Existing

in ˆ

ˆ

2.6 Speed of Conveyor Continuous motion packaging line Speed Fixed Throughput Speed

ˆ

Variable

Min.

ˆ cpm Max.

f/pm ˆ in/m ˆ m/m ˆ mm/m ˆ

cpm Min.

Max.

2.7 Package Information Package spacing on conveyor, from front of one pack to front of next: mm ˆ

Gap between packages How is spacing accomplished Cartoner

ˆ

Conveyor Speed Deferential ˆ

2.8 Print Trigger Photo Sensor ˆ ˆ PLC 2.9 Signal Interface ˆ Ready ˆ Error/Fault 2.10 Encoder ˆ Standard ˆ Other

Break Beam Other

ˆ ˆ

Warning Other(s)

ˆ ˆ

Fixed Speed Internal

PLC & Pneumatic Spacing device ˆ Other ˆ

ˆ

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in ˆ

in ˆ

ˆ

Fixed Taper

mm ˆ

Section 3 - Pre Installation 2.11 Peripheral Devices Fault Tower

ˆ

Product Look up Scanner ˆ

Verification Scanner/s ˆ

1 ˆ

2 ˆ

Code Symbology

Data Verification ˆ

ˆ Code Readability ˆ

2.12 Mounting Layout Floor Stand Set-up

ˆ

Number of heads per side of conveyor Conveyor Stand Set-up

One ˆ

Two

ˆ

One ˆ

Two

ˆ

ˆ

Number of heads per side of conveyor Encoder riding on conveyor

ˆ

Encoder riding on shaft

ˆ

Comments (include drawing if required):

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Section 3 - Pre Installation 3. Product Marking 3.1 Material Cardboard

ˆ

White Cardboard

ˆ

Film

ˆ

Bag Material

ˆ

Wood

ˆ

Chipboard/Particle Board

ˆ

Other(s)

ˆ

3.2 Print details Pack Length

Min.

mm

Max.

mm

Pack Height

Min.

mm

Max.

mm

Print Length

Min.

mm

Max.

mm

3.3 Location Location of label(s) on product (circle): Top Sides ( ) Front Adjacent Sides *5X00 prints sides or top in the web direction; front or adjacent sides will require a bump and turn. • Exact location of label(s) on product with reference to edges. On sketch below, show distance from bottom of product to bottom edge of label and from corner edge of product to side edge of label. Be precise. Show measurements in inches or millimeters:

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Section 3 - Pre Installation 4.0 Consumables 4.1 Ink type Ink type 5601

ˆ

5803

ˆ

Other(s):

ˆ

5805

ˆ

Color(s) Black

5. Image & Platform Application 5.1 Requested media layout(s) (Give as descriptive an example as possible - if multiple images please indicate and supply additional attachments)

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Section 3 - Pre Installation 5.2 Image Fields In the above image please indicate and acknowledge the following: Controller Variable Text (V) ˆ

Fixed Text (F) ˆ

Barcode Symbology

Operator Manipulated Text (O) ˆ Date Offsets (BBE) ˆ Image Width mm

Image Height mm

Printed Date Language Character Height mm

5.3 Label design CoLOS Create Pro

CoLOS Create Freeware

ˆ

ˆ

Other

ˆ

5.4 Application platform Stand-alone

ˆ

Networked

ˆ

Host PC ˆ

Menu language(s):

Wired / Wireless

5.5 Package & Contents Handling Before and After Printing Before Printing ˆ After Printing Product is Heated - (What Temp) Product is Frozen - (What Temp)

Before Printing

ˆ

After Printing

ˆ ˆ

Product is not effected by heat, cold or moisture during the packaging process Other -

ˆ

ˆ

5.6 Other optional equipment required

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Section 3 - Pre Installation 5.7 Other information (including integration details)

6. Product training 6.1 Basic training Number of shifts

Number of people per shift

Suitable dates for training 6.2 Advanced training Number of shifts

Number of people per shift

Suitable dates for training 6.3 Engineer training Number of people Suitable dates for training

3.3 Dry Start-Up

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Section 3 - Pre Installation Serial Number Controller Serial Number of Printhead #1 Serial Number of Printhead #2

Startup Questionnaire Number of "Purges" before seeing clean jet test?

Did you ever see a good clean test pattern?

How long did it take to assemble the unit (in minutes)?

Yes

□

No

□

How long before you were able to perform your first "Printhead Test" image print (in minutes)?

List all "Faults and Warnings" in order that you see them during startup

Additional Comments:

Print Quality Questionnaire Character and or Bar Code Edge Quality Uniform across image Print Quality Comments: Print Darkness

□

Smooth

Start of Print to Light

□

End of Print to Light

□ □

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□

Saw Tooth Top of Print to Light

□

Jagged Bottom of Print to Light

□ □

Section 3 - Pre Installation Notes:

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Section 4 Advanced Installation

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Section 4 - Advanced Installation 4.1 Scanners CLV Utility The SICK CLV utility is a carry over from the 52/5400. The following information regarding the CLV utility is included to act as a placeholder and to provide some idea of what functionality will be available in regard to CLV scanner setup and the 5600/5800. Some of the information in this section will be revised and edited to reflect the changes made for the implementation of this utility for the 5600/5800. Future revisions of this manual will include these changes. This is under construction along with the new Cognex scanner for 2D codes. SICK CLV Programming Utility The SICK 430-1010-S03 scanner is shipped from Markem-Imaje with the following parameters preprogrammed. •

Scanner is set up as a verification reader (the Scanner Returned Data String Format determines the operating mode).

•

Scanner is set up for "Low contrast" scanning (good for corrugate cardboard).

•

Scanner is set up for "External scanner trigger" (needs start signal from external sensor).

•

Data String packet is set for SICK mode (verification scanner string). Changes must be performed on the data string packet if scanner is to be used in the Product ID mode. Refer to the "Product ID Data String Header."

At times it is necessary to adjust scanner default settings for your application. If the scanner is to be used for such applications as a Product ID reader or set to free running versus remote sensor triggering, re-programming will be necessary to support these changes. Scanners may be re-programmed through the Controller’s Scanner Ports 1 and/or 2 using the SICK CLV programming utility, which is shipped with the bar-code reader. The SICK CLV programming utility must be installed on the PC that will be used to program the barcode reader. 1. Plug the serial cable into the correct PC serial port. The serial port is selectable within the programming utility, typically Com1 at 9600 baud. 2. Plug the other end of the serial cable into the DB9 RS232 port (X6) on the back of the Controller. 3. Power on the Model 5600/5800. 4. Navigate to “Machine Settings” and select the “Serial Ports” tab. Set up the Host Port for “Program SICK on port 1 (or 2)”.

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Section 4 - Advanced Installation 5. Run the CLV program by selecting the CLVSetup.exe. On the Welcome screen for CLV Setup, click on the OK button. The specific bar-code reader may now be programmed using the programming utility. For detailed information on using the programming utility, refer to the CLV Installation Manual and the CLV Setup Software Guide, included with the SICK CLV programming utility. Basic Parameters Once the program is open, select "Device" CLV 43X. The programming utility will attempt to connect to the scanner through the default communications protocol which is RS-232 Com1 9600 no parity 8 data bits and 1 stop bit. If you are not set up at this configuration an automatic baud rate interrogator will attempt to match your baud rate. Edit Reading Trigger From the "Device Config" tab, click on "Edit Reading Trigger." The mode should be set to "Sensor Input (active high)" if the bar-code reader will be using the external trigger. If the bar-code reader will not be using the external trigger, change this setting to "Free Running with time out." Free Running with Time Out The free running time out value usually needs to be adjusted to fit the application. However you can try the default setting before adjusting any values. The value of this parameter will need to change with the line speed that is being printed. If large variations are in the line speed, it would be better to use the external trigger. Faster lines will require smaller timer values. If the timer value is set too low, multiple readings of the same bar code will result in errors. If the timer value is set too high, bar codes may go by without being read. Data String Header Standard SICK Verification Scanner The proper data string packet for verification scanner operation using the programming utility is: [CC + ID CL data string] [ ] = open and closed square brackets command the start and stop of the data packet CC = number of bar codes per label ID = code symbology (Interleaved 2 of 5, EAN 128, etc.) CL = code length (number of characters in the bar code) Data string = the actual bar code data (This is the default pre-programmed data string header on all MARKEM purchased scanners.) Header [CC Separator + ID CL Terminator ] Format Mark 00 PRODUCT ID Scanner Data String Header To change the scanner mode from Verification to Product ID, the data string header must be modified. Set the Product ID scanner for Generic or Raw through the Machine Settings menu on the Model 5600/5800. This will be listed as Scanner Port 3 under “Verification” If the Model 5600/5800 will be using Generic for Product ID (Lookup) Mode, the header character of the bar-code reader must be set to be the same character as the Product ID Start Char parameter.

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Section 4 - Advanced Installation The default value for the Product ID Start Char is 91 (91 decimal is the "[" character). To use the default, the bar-code reader header character needs to be "[" (without the quotation marks). If the Model 5600/5800 will be using Raw for Product ID (Lookup) Mode, the header character needs to be blank. NOTE: CC, or the number of bar codes read, is not needed for the Product ID scanner and will create problems if present. •

Data String Separator: This should be blank. NOTE: + ID CL is not needed for the Product ID scanner and will create problems if present.

•

Data String Terminator: If the Model 5600/5800 will be using Generic for Product ID (Lookup) Mode, the terminator character of the bar-code reader must be set to be the same character as the Product ID End Char parameter. The default value for the Product ID End Char is 93. (93 decimal is the "]" character.) To use the default, the bar-code reader terminator character needs to be "]" (without the quotation marks). If the Model 5600/5800 will be using Raw for Product ID (Lookup) Mode, the header character needs to be "\n" for the return character.

•

EAN 128 FCI Values: When using a bar-code reader for Product ID (Lookup), the bar-code reader must return nothing for FC1 characters. Set the FC1 fields to None.

•

Reprogram the Data String Header using the "Data Strings" tab and enter the correct header, separator, and terminator character for Generic or Raw Product ID scanner use as discussed above.

•

When programming is complete, unplug the serial cable.

NOTE: The following error message may appear: "Communication Message. Inappropriate Scanner Response…" This message, which results from using the scanner port, may be ignored. All setup information will be programmed.

SICK CLV Programming Utility General Programming Tips •

Eliminate unused code symbology and be more specific about number of code elements to help decipher scanned data rapidly. Use the "Code Config" tab and deselect code symbology that the end user has no need for. Use the "Edit Codes" tab to set code length from "free" to "set value" and enter typical number of characters seen in customer bar codes.

•

Set the scanner for "Low Contrast" scanning when scanning brown corrugate cartons. To do this select the "Reading Config" tab and then "Codelabel Quality" and set to "Low Contrast". This should be the programmed setting of the scanner as received from Markem-Imaje.

•

At times slower scanning frequencies provide better scanning results, the default is 700Hz. If you have bar codes that return low scanning percentage values when operated in CLV diagnostic. Changing the scanning frequency may help.

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Section 4 - Advanced Installation •

The CLV Diagnostic Utility: To optimize the ability to scan a print, use the Terminal Emulator found in the "View" pull down menu. In the "Device Mode" menu, select "Percent Evaluation". When this utility is open, changes to the physical setup of the scanner can be altered and the scan performance observed.

•

Scanners should be slightly angled to the product they are scanning; this reduces specular reflection, which blinds the scanner. Skew angles of 10 to 15 degrees are good practice.

•

Adjust the distance of the scanner to the product based off the reading range (depth of field) of the scanner and the minimum bar width of the bar code to be scanned. Refer to the scanner documentation for preferred settings. A bar code using a narrow bar width will need the scanner moved closer to a bar code. Typical starting settings are 8 to 9 inches for a 0.010 bar, and 9 to 12 inches for a 0.012 bar.

•

Avoid setting the bar-code reader up in areas with bright overhead light. If this cannot be avoided, shield the scanner from this light to increase the scanner performance.

•

Set scanner to output "Immediate" on a good read versus end of reading trigger. This should be the programmed default setting. Select the "Device Config" tab and click "Edit reading trigger" then set for "Output on good read" immediate.

Errors and Warnings •

20101 - Print Head 1 Verification Failure: The maximum number of consecutive verification failures for Print Head 1 has been reached. - Verify that system parameters and physical setup related to printing and barcode verification are correct.

•

20301 - Print Head 2 Verification Failure: The maximum number of consecutive verification failures for Print Head 2 has been reached. - Verify that system parameters and physical setup related to printing and barcode verification are correct.

•

20401 - Verification Failure: The maximum number of consecutive verification failures for both print heads has been reached. - Verify that system parameters and physical setup related to printing and barcode verification are correct.

Cognex Dataman 100 setup The Dataman 100 will come with a Markem-Imaje bracket that can be mounted directly on the 5800 head. If this bracket will not work with your mounting configuration you will need to mount the Dataman 100 in a suitable location to achieve the proper focal distances listed below. (Note: The size of the image in relation to the focal distance.)

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Section 4 - Advanced Installation Mount

Fig1 Focal distances shown in mm.

Fig 2 *This diagram shows one possible mounting position. Here you can see you can adjust to the proper focal distance for a package traveling from right to left.

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Section 4 - Advanced Installation Setup To Set Focal distance: Remove 4 screws to remove lens cover.

1. Set focus position. (40,65,105)

2. Replace lens cover and screws.

After finding a suitable mounting location you will need to complete the setup for the Dataman100.

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Section 4 - Advanced Installation Teach You will now teach the Dataman for the image you are printing: (the teach button is located on the Dataman 100, refer to the following picture) 1. Print your 2d image 2. Stop the image in front of the Dataman 100 3. Press the teach button for 3seconds

Printed 2D Image

Teach Button

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Section 4 - Advanced Installation Verification Scanner Machine Parameter Setup 1. From the “Home” screen select “Menu”.

2. Select “Settings”

3. Select “Machine Settings”

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Section 4 - Advanced Installation 4. Using the blue arrow, scroll across and look for “Serial Ports”. Highlight “Scanner Port 1 Mode” and select the Notepad

5. Highlight “PH1 Verification Scanner” and accept.

Note: This setup is just one example. Either printhead can be assigned to any one of the scanner ports.

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Section 4 - Advanced Installation 6. Select “Home” to return to the Home screen.

7. Select “Menu”

8. Select “Settings”

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Section 4 - Advanced Installation 9. Select “Machine Settings”.

10. Use the blue arrow to scroll across until you find “Verification” which has now become active since enabling the scanner port. Highlight the desired parameter and touch the notepad to alter the Verification settings per the application requirements and accept.

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Section 4 - Advanced Installation

In the machine settings menu you will need to configure the following: • • • • • • • • • •

Consecutive failures- This is the number of bad reads until the 5800 goes into a fault state Verification mode- this setting will either be set for readability (the device read a barcode) or verification (where the 5800 confirms what was printed was scanned) Scanner baud rate- Cognex(Dataman) default will be 115200 Scanner type- in this case Cognex Scanner trigger- start of print (the scanner will be triggered of the same signal as the printhead) Scanner delay- This is the delay from when the start signal is triggered until you want the scanner to turn on. Maximum bar codes- the number of barcodes to be read in one print cycle Reject Relay Delay- The delay that you wait until the reject relay is activated. Reject Relay On Time- The amount of time the Reject Relay is active Reject Relay Encoder- The encoder that is reference for the Reject Relay Delay.

The Scanner Port(s) should now be set up for use. Return to the Home screen to resume operation.

11. In the diagnostic mode the scanner data should be shown. To access Diagnostics: Press Menu, Diagnostics, and in the Input/Output tab read scanner data for the appropriate scanner.

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Section 4 - Advanced Installation

Operation ***The Cognex is a small camera system and can be affected by light and in some applications you will need to adjust the scanner to work in the applications light conditions. Depending on substrates and lighting conditions different angles to the product can be used.

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Section 4 - Advanced Installation

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Section 4 - Advanced Installation Notes:

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Section 5 After Sales Support

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Section 5 - After Sales Support

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Section 5 - After Sales Support 5.1 Installation/Start-Up Markem-Imaje Service Performed Installations For “Standard Applications” Purchase 5800 machine with CoLOS Professional You would have 2 installation orders one for 5800 and one for CoLOS • S24420 - Installation 5800 Startup Service • S24420 - Installation 5600 Startup Service • S25420 - Installation CoLOS For a "Complex Applications" purchase use the following Service Codes You would have 2 installation orders one for 5800 and one for CoLOS • S24421 - Installation 5800 Complex • S24421 - Installation 5600 Complex • S25420 - Installation CoLOS Complex Customers who elect CoLOS Create (freeware) have no additional training beyond installation package. Startup Service / Installation Package includes: 3.5hr installation + 3.0hr instruction (max 4 people) • Physical assembling and mounting of the equipment • Creation of simple first image and download to the machine Instruction includes: • Safety rules (operators) • How to prep the system for operation (operators) • How to select images to print (operators) • How to make registration adjustments (operators) • How to ensure quality print (operators) • Daily cleaning and purging of the Printheads (operators) • Front head replacement (operators and maintenance engineers) • Review instructions and options for Printhead / engine replacement • Review after sales support options for warranty, training and service contracts CoLOS installation includes: 8h instruction (max 4 people) Working with customers IT group to load software • Train on software package tool and usage • Train on image creation • Train on image data base management

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Section 5 - After Sales Support Complex Installations: 11 hours of on site labor plus an additional 3 hour travel. (Typically 2 days) Distributor Installations Distributors perform their own installations and contact their designated Markem-Imaje support team for help. OEM Installs OEM’s are recommended to have the end-user contact Markem-Imaje to purchase startup assistance (installation or advanced operator training). We need packets for OEM with this type of instruction. Product Install Base The "Product Install Base" represents end-user locations for our equipment; which is captured in SAP. Technical Managers Technical managers have the responsibility to ensure the integrity of the SAP Install Base information. It is recommended that all new equipment purchases be followed up to ensure that the correct end-user location is properly linked to the newly purchased equipment. This is especially important when dealing with OEMs who send their equipment all over the world.

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Section 5 –After Sales Support 5.2 Warranty “Refer to Markem - Imaje Document A1 OTS 001 Interco Warranty Conditions for Additional Information” Machine Defect in Materials & Workmanship New Machine Warranty (defect in materials, and/or workmanship) period begins the date of shipment from the platform. This Warranty period is validated by serial number in SAP. The main Markem- Imaje manufacturing warranty conditions are the following: Operations warranty conditions: • M-I manufacturer warranty covers only repairable parts defined as REN • Non repairable part are not covered by manufacturer warranty • The standard equipment warranty period defined is 12 months from the invoice date except specific cases Distributors warranty conditions: • M-I manufacturer warranty covers repairable parts defined as REN • Non repairable parts: Agreement should be given to the distributors by the M-I distributor’s help desk before return under warranty • The standard equipment warranty period defined is: 15 months from the invoice date except specific cases New Machine Items

Material Number

Warranty Period of Assembly

5800/5600 Control Box Assembly

10029432 / ENM10029432

12 Months

Printhead Ink Control Module 5800 Hot Melt

10029435 / ENM10029435

12 Months

Printhead Ink Control Module 5600 Liquid Ink

10029437 / ENM10029437

12 Months

Print Engine 5800 Hot Melt

10042234 / ENM10042234

12 Months

Print Engine 5600 Liquid Ink

10042237 / ENM100042237

12 Months

New Spare Parts

Material Number

Warranty Period of Assembly

5600 / 5800 Models

All (except for items listed above)

3 Month

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Section 5 –After Sales Support If using Advanced Exchange Service or the Return Repair process during the warranty period, the faulty assembly must be sent back as a complete unit. All warranty non-ENR replacement parts should be maintain and processed at the division level. Warranty – Rejection Refer to Markem-Imaje “Manufacturer Warranty Conditions” which outlines “conditions to return” and “reasons for warranty rejection”.

5.3 Servicing Options After Sales Repair Service Options Break Fix (repair on request): •

On site labor, parts & travel - Basic circuit board replacement. - Sub-assembly replacement. - Component replacement of heaters, thermistor, ink level sensor.

•

Advance Exchange Service (ARC, ERC) Limited Offerings - Refurbished machine or part sent to customer. - Customer returns bad unit to repair center in same box if not returned with in 3 weeks customer is charged the difference of new and refurbished. - Customer will not receive back the same serial number they sent. - Install base record is updated.

•

Repair & Return (ARC, ERC) - Customer sends their machine or modules into the repair center for repairs - Repair center evaluates and quotes cost of repair to customer for repair approval. - With customer approval, repair is performed and the unit is sent back to the customer. - Customer maintains their original serial numbered unit.

Details Advanced Exchanged Items: All exchanges require an ENR material and are handled through the Advanced Exchanged process. These items will not be a car/technician or locally stocked item.

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Section 5 –After Sales Support Advanced Exchange Item

Material Number

Warranty Period of Exchange

Print Engine 5800 Hot Melt

ENR10042234

3 Month

Printhead Assembly 5800 Hot Melt

ENR10029435

3 Month

Print Engine 5600 Liquid Ink

ENR10042237

3 Month

Printhead Assembly 5600 Liquid Ink

ENR10029437

3 Months

Return Repair Items Items that are customer return repairable do not require and ENR material number. They can be either ENM or ENR. These are Customer Owned goods; they will receive back their original equipment repaired. Return Repair Item

Material Number

Warranty Period of Repair

5800/5600 Control Box

10029432

3 Month

Print Engine 5800 Hot Melt

10042234 / ENR10042234

3 Month

Printhead Assembly 5800 Hot Melt

10029435 / ENR10029435

3 Month

Print Engine 5600 Liquid Ink

10042237 / ENR10042237

3 Month

Printhead Assembly 5600 Liquid Ink

10029437 / ENR10029437

3 Months

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Section 5 –After Sales Support 5.4 PM Contracts PM Service Preventive Maintenance: • These are regularly scheduled visits to inspect equipment for normal operation, replace common wear maintenance items such as filters, rollers and certain types of pumps. • This type of contract is designed to maintain quality operation of the equipment. Proactive Maintenance: • Preventative contract plus: • Predictive (anticipated) part failure replacement. • This type of contract is designed to replace components before there calculated or known predictive failure, combined with preventive maintenance visits to maintain, maximum uptime and quality of operation. Full Maintenance: • Proactive contract plus break fix (labor & parts) which could be : • On site and/or Advanced Exchange • This type of contract is designed to provide maximum uptime, quality of operation and the highest priority repair response. Contract Types:

Access Type Contract: Not available for this product. Standard/Premium Type Contract: Include scheduled (Preventative) and Predictive Maintenance Kits. Kits contain all needed parts plus instructions for installing the parts.

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Section 5 –After Sales Support

Schedule service interval. Visits to perform preventive and predictive maintenance.

1 to 2 Shifts Operation. (8 to 16 hours a day, 7 days a week)

3 Shift Operation (24 hour a day, 7 days a week) 9

6 Month Interval

5800 Replacement Kit part number for visit

5600 Replacement Kit part number for visit

Quantity of Kits PerPrinthead

10042231

10051809

1

10042231

10051809

1

Yearly Interval

9

Every 5 Years

9

9

10051807

10051808

1

SAP Task List Code

S00P2B03

S00P3B04

-

-

-

“Standard” Umbrella Code

S22515

S22515

-

-

-

“Premium” Umbrella Code

S22511

S22511

-

-

-

5.5 Access Checklist

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Section 5 –After Sales Support

Global Distribution Support Version: 01 Date: 14-JUL-2009 Page:192/339

PM Contract Check List 5800 Date :

Service Order :

Field Service Engineer :

Company Name :

Printer Model :

Software & Version :

Contact Name : Address / Location :

Serial # :

1|

Number of Heads: City/State/Zip :

# of Shifts Running:

Phone (optional) :

Is this Unit a: (circle one)

Options & Configurations:

Production unit

General Appearance Printer Installed Correctly. Ensure head(s) are level and stands (Controller and Printhead) are securely mounted. Encoder free from obstructions. Controller / Cabinet in Good Condition Printing System / Applicator in Good Condition. Overall appearance of equipment free of damage, clean and complete

2|

Line # Backup Unit

Yes 9

No 9

If no, provide detail in comment section of report

Yes 9

No 9

|

|

Physical Connections should be secure and fitted in a manner so that a tool is required to undo them.

|

|

|

|

|

|

Printer Currently in Use

|

|

Environment: | Dry | Damp | Wet | Hot | Cold | Dirty | Dusty

/

Packages per minute: ________

(check all that apply)

Pre & Post PM Checks

Pre PM

Post PM

Pre & Post PM Checks

Print a Test Image – Attach to back of report (internally generated test image)

Print Trigger / Sensors Firmly Mounted, Connected and/or Adjusted

Review Print Quality with customer

Printer Alignment for Straight Prints

Printer Securely Mounted

Unit Functioning Correctly

Encoder or Substrate Speed, measuring device functionality

Overall Cleanliness of System

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Pre PM

Post PM

Section 5 –After Sales Support

Attach Print Sample/ Example of Good Test Image Machine generated test image showing all 256 jets

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Section 5 –After Sales Support Install PM Parts, Perform Checks and Clean: Preventative Maintenance Kit # 10042231

Photo of Kit

Required Tools

Part number: 10042231 - 5800 PM Kit Replacement Schedule 6 Mo

Interval

#2 Phillips Screwdriver, Small Flat Blade Screwdriver, 2mm Allen Wrench (for pushing out Hinge Pin), 3mm Allen Wrench, Wire Cutter / Stripper, Knife / Hose cutter,

12 Mo

X

1 & 2 Shift Operation

X

3 Shift Operation

Quantity: 1 Items in Kit by Part # and Quantity Part number: 0694001 Description - Tubing Low Vac Quantity: 3

Part number: 0694656 Description - Filter Inline 1/8 barb 10 Micron Quantity: 2

Part number: 10000053 Description - SCR - PHH Cap M4 X 10 SST

Instruction

Required Tools

| Yes

Appendix A (5800) Instruction

Required Tools

Required Tools

Appendix A (5800)

Description - SCR - PHH Pan M3 X 20 SST

Instruction

Required Tools

Appendix A (5800)

Description - SCR - PHH Pan M4 X 10 SST Quantity: 3

Part number: 10029749 Description - O-Ring Hollow, Door Quantity: 1

Part number: 10030278 Description - Screen Supply Basket

Instruction

Required Tools

Required Tools

Required Tools

Appendix A (5800)

Description - O-Ring, Reservoir

Instruction

Required Tools

Appendix A (5800)

Quantity: 1

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Part Replaced

| Yes

Quantity: 1

Part number: 10032228

Part Replaced

| Yes

Appendix A (5800) Instruction

Part Replaced

| Yes

Appendix A (5800) Instruction

Part Replaced

| Yes

Quantity: 2

Part number: 10000248

Part Replaced

| Yes

Quantity: 2

Part number: 10000232

Part Replaced

| Yes

Appendix A (5800) Instruction

Part Replaced

Part Replaced

| Yes

Section 5 –After Sales Support Part number: 10036041

Instruction

Description - Tubing Silicone - Low Vac

Required Tools

Part Replaced

| Yes

Appendix A (5800)

Quantity: 4

Instruction

Description - Coupling Reducer

Required Tools

Part Replaced

| Yes

Appendix A (5800)

Quantity: 2

Part number: 10050011

| Yes

Instruction

Description - SCR-PHH Pan w/ O-Ring Part number: 10051490

Part Replaced

Appendix A (5800)

Quantity: 1500mm

Part number: 10048391

Required Tools

Instruction

Description - Low Vac Pump 24Vdc

Required Tools

Part Replaced

| Yes

Appendix A (5800)

Quantity: 1

Cleaning and Checks: Material #

Task Performed

Replacement Recommended

-

| Yes

| Yes

Clean display, check viewing of the display and touch screen functionality. Calibrate the display if touch points are not aligned. If display is unreadable or damaged - recommend replacing.

10042242

| Yes

| Yes

Remove all ink from mating surfaces of Ink Load Door and Reservoir - If damaged recommend door replacement.

10042243

| Yes

| Yes

Required Tasks Clean Printhead: • Purge Head - look for a good flow of ink from head • Use approved printhead wipes to wipe away any debris from face plate.

Required Checks

Material #

Checked

Encoder - Ensure that the encoder is tensioned and making good clean contact with the conveyor or conveyor shaft.

-

| Yes

| Yes

| No

Ensure that stand adjustments for head and controller are free of debris and slide/adjust properly.

-

| Yes

| Yes

| No

Check for proper gap between printhead and printing surface. This distance should be no more than 1/4in (5mm).

-

| Yes

| Yes

| No

Latest mandatory upgrades/improvements installed per TB: Yes |

No |

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Adjustment Needed

Section 5 –After Sales Support Operational Test after PM Verified 9

Description

Comments

Printer Start-up correctly with no errors or faults. Ink, verify the ink that is being used is still with in its lot shelf life. Old ink can cause poor print quality. Print Registration - After reassembling printer run test prints on customers packaging and verify print is being applied to the correct location and you are able to adjust print position and still maintain print quality for operation. Select different images - Select different customer’s images and verify that they select and print correctly. Status Beacon & LED System Check - Verify that all power, fault and warning indicators properly illuminate. Print Quality Acceptable to Customer - Is the final print image acceptable for customers production.

Comments & Recommendations: __________________________________________________________________________________________________ __________________________________________________________________________________________________

Markem-Imaje Recommendations for Maximum Uptime: Training

|

Safety

|

Replace Unit

Installation Improvement |

|

Upgrade System

Care & Maintenance of Equipment

|

|

Actions to support the above selection( include contact information for recommendation): Action to be taken by Markem-Imaje by ___ / ___ / ___¤

Action to be taken by customer by ___ / ___ / ___

Service Engineer

Customer

Name:

Name:

Signature:

Signature:

Previous Recommendations Implemented Yes ‰

No ‰

N/A ‰

Detail: _____________________________________________________________________________

Signature of Customer Contact: Signature of Field Service Engineer:

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Section 5 –After Sales Support Global Distribution Support Version: 01 Date: 14-JUL-2009 Page:1/6

PM Contract Check List 5600 Date :

Service Order :

Field Service Engineer :

Company Name :

Printer Model :

Software & Version :

Contact Name : Address / Location :

Serial # :

1|

Number of Heads: City/State/Zip :

# of Shifts Running:

Phone (optional) :

Is this Unit a: (circle one)

Options & Configurations:

Production unit

General Appearance Printer Installed Correctly. Ensure head(s) are level and stands (Controller and Printhead) are securely mounted. Encoder free from obstructions. Controller / Cabinet in Good Condition Printing System / Applicator in Good Condition. Overall appearance of equipment free of damage, clean and complete

2|

Line # Backup Unit

Yes 9

No 9

If no, provide detail in comment section of report

Yes 9

No 9

|

|

Physical Connections should be secure and fitted in a manner so that a tool is required to undo them.

|

|

|

|

|

|

Printer Currently in Use

|

|

Environment: | Dry | Damp | Wet | Hot | Cold | Dirty | Dusty

/

Packages per minute: ________

(check all that apply)

Pre & Post PM Checks

Pre PM

Post PM

Pre & Post PM Checks

Print a Test Image – Attach to back of report (internally generated test image)

Print Trigger / Sensors Firmly Mounted, Connected and/or Adjusted

Review Print Quality with customer

Printer Alignment for Straight Prints

Printer Securely Mounted

Unit Functioning Correctly

Encoder or Substrate Speed, measuring device functionality

Overall Cleanliness of System

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Pre PM

Post PM

Section 5 –After Sales Support Install PM Parts, Perform Checks and Clean : Preventative Maintenance Kit # 10051809

Photo of Kit

Required Tools

Part number: 10051809 - 5600 PM Kit Replacement Schedule 6 Mo

Interval

12 Mo #2 Phillips Screwdriver, Small Flat Blade Screwdriver, 3mm Allen Wrench, Wire Cutter / Stripper, Knife / Hose cutter

X

1 & 2 Shift Operation

X

3 Shift Operation

Quantity: 1 Items in Kit by Part # and Quantity Part 1

Instruction

Description - Retainer Quantity: 2

Part 2 Quantity: 1

Part 3 Description – Filter Inline 10 micron

Required Tools

Required Tools

Appendix A (5600) Instruction

Description – SCR – SKT Cap M4 x 10 SST

Required Tools

Appendix A (5600) Instruction

Description - SCR - PHH Pan M3 x 20 SST Quantity: 2

Part 6 Description – SCR – PHH Pan M4 x 10 SST Quantity: 9

Part 7

Required Tools

Required Tools

Appendix A (5600) Instruction

Description – Tubing Silicone 3/32” ID

Part Replaced

| Yes Required Tools

Appendix A (5600)

Quantity: 2310mm

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Part Replaced

| Yes

Quantity: 1

Part 8

Part Replaced

| Yes

Appendix A (5600) Instruction

Description – SCR – PHH Flat M3 x 6 SST

Required Tools

Appendix A (5600) Instruction

Part Replaced

| Yes

Quantity: 2

Part 5

Part Replaced

| Yes

Quantity: 3

Part 4

Part Replaced

| Yes

Appendix A (5600) Instruction

Part Replaced

| Yes

Appendix A (5600) Instruction

Description – Tubing Silicone 1/16” ID

Required Tools

Part Replaced

| Yes

Section 5 –After Sales Support Part 9

Instruction

Description – O-Ring 4.129 Peroxide EPDM Quantity: 1

Part 10

Required Tools

Description - SCR-PH XRecess Cheese Head M2.5 x 8 ZC

| Yes

Appendix A (5600) Instruction

Part Replaced

Required Tools

Part Replaced

| Yes

Appendix A (5600)

Quantity: 2

Part 11

Instruction

Description – Pump Diaphragm 24VAC Quantity: 1

Part 12

Required Tools

Description – Terminal Strip 2Pos Screw 20A 300V (Not Shown)

| Yes

Appendix A (5600) Instruction

Part Replaced

Required Tools

Part Replaced

| Yes

Appendix A (5600)

Quantity: 1

Part 13

Instruction

Description – Coupling Reduce Barb Quantity: 2

Part 14

Required Tools

Description – Jack Socket Screw Quantity: 2

| Yes

Appendix A (5600) Instruction

Part Replaced

Required Tools

Part Replaced

| Yes

Appendix A (5600)

Cleaning and Checks: Wear protective gloves for all cleanings Material #

Task Performed

Replacement Recommended

8000186 – (5601 Face Cleaner)

| Yes

| Yes

Clean display, check viewing of the display and touch screen functionality. Calibrate the display if touch points are not aligned. If display is unreadable or damaged - recommend replacing.

10042242

| Yes

| Yes

Inspect for broken or missing clips on Male matting connector for ink cartridge.

10051846

| Yes

| Yes

Inspect Ink recovery tray filter for signs of contamination and recommend replace

10049951

| Yes

| Yes

Required Tasks Clean Printhead: • Purge Head - look for a good flow of ink from head • Use approved printhead wipes to wipe away any debris from face plate. • Clean the face of the printhead using 5601 Printhead Cleaner.

Ensure that the Photo Eye is clean and free of debris (if damaged beyond Need Part | Yes cleaning replace) Number 5600/5800 Service Manual Rev. 02 November 2009

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| Yes

Section 5 –After Sales Support

Required Checks

Material #

Checked

Encoder - Ensure that the encoder is tensioned and making good clean contact with the conveyor or conveyor shaft..

-

| Yes

| Yes

| No

Ensure that stand adjustments for head and controller are free of debris and slide/adjust properly.

-

| Yes

| Yes

| No

Check for proper gap between printhead and printing surface. This distance should be no more than 1/4in (5mm).

-

| Yes

| Yes

| No

Review current revision of operating firmware and upgrade to latest revision.

-

| Yes

| Yes

| No

Latest mandatory upgrades/improvements installed per TB: Yes |

Adjustment Needed

No |

*There are no mandatory 5800 bulletins to implement at this time.

Operational Test After PM: Description

Verified 9

Comments

Printer Start-up correctly with no errors or faults. Verify the ink that is being used is still with in its lot shelf life. Old ink can cause poor print quality. Print Registration - After reassembling printer run test prints on customers packaging and verify print is being applied to the correct location and you are able to adjust print position and still maintain print quality for operation. Select different images - Select different customers’ images and verify that they select and print correctly. Status Beacon & LED System Check - Verify that all power, fault and warning indicators properly illuminate. Print Quality Acceptable to Customer - Is the final print image acceptable for customers production. Comments & Recommendations: __________________________________________________________________________________________________ __________________________________________________________________________________________________

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Section 5 –After Sales Support Markem-Imaje Recommendations for Maximum Uptime: Training

|

Safety

|

Replace Unit

Installation Improvement |

|

Upgrade System

Care & Maintenance of Equipment

|

|

Actions to support the above selection( include contact information for recommendation): Action to be taken by Markem-Imaje by ___ / ___ / ___¤

Action to be taken by customer by ___ / ___ / ___

Service Engineer

Customer

Name:

Name:

Signature:

Signature:

Previous Recommendations Implemented Yes ‰

No ‰

N/A ‰

Detail: _____________________________________________________________________________

Signature of Customer Contact: Signature of Field Service Engineer:

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Section 5 –After Sales Support Notes:

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Section 6 Remove and Replace Procedures

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Section 6 –Remove and Replace Procedures 6.1 New Head Replacement New Dry Hot Melt Printhead Startup Process 1. 2. 3. 4. 5.

Make all connections and power on the system System will report a “PH# supply reservoir Ink Out Fault” Add one block of ink to the system Clear the fault Enter Diagnostics/Manual Control (this must be done before a fault reoccurred) -

Select “PH# Supply Reservoir Regulate On” Select “PH# Primary Reservoir Regulate On” Select “PH# Jetting Assembly Regulate On” Using the diagnostics monitor the PH# Supply Reservoir Temperature “OK” Allow the ink in the supply to melt fully, this could take 20 minutes or more Select “PH# Low Vacuum Regulate On” Select “PH# Enable Primary Reservoir Filling” Using Diagnostics monitor the PH# Primary Reservoir Ink State “Present”

6. Select the home icon 7. Perform a purge and jet test to see all the jets are functional. This may require multiple purges New Dry Liquid Printhead Startup Process 1. Make all connections and power on the system 2. Install an ink container- system will report a “PH# supply container missing” warning if this is not done 3. Once the supply reservoir is satisfied the system will fill the primary reservoir and go into the ready state 4. Perform a purge and jet test to see all the jets are functional. This may require multiple purges.

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Section 6 –Remove and Replace Procedures

6.2 5800 Print Engine Replacement Procedure Replacement of the 5600/5800 Print Engine Assembly requires a clean, dry working environment. Contaminates introduced to the internal workings of the print system during service may significantly decrease performance or cause irreversible damage to the Printhead and/or Print Engine assembly. As with any electrical components, ESD precautions must be taken during servicing of the Printhead. •

Prior to removing the Print Engine from the Model 5600, you will need to purge any remaining ink from the Printhead. If this step is not completed, the remaining ink will drain from the printhead onto the work surface.

•

This step is not required with the 5800 as the ink will be in a solid state once it has cooled.

To purge the ink from the Model 5600 printhead: Once a 5600 printhead has been installed and used, it cannot be moved without draining it. These instructions describe how to drain the printhead and prepare it for storage or shipping. The 5600 Printhead Store / Ship Prep Kit is required.

1) Obtain 5600 Printhead Store / Ship Preparation Kit 1 - Printhead flush fluid cartridge

2

1

2 - Pink anti-static zipper bag 3 - Tubing clamp 4 - Rubber caps

3

5 - Non-vented double-ended caps 6 - Push button fitting plugs

4

5 6

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Section 6 –Remove and Replace Procedures 2) To prepare the printhead for emptying: •

Remove the ink cartridge.

•

Carefully remove the ink recovery tray, taking care not to tilt it.

•

Obtain a receptacle suitable for collecting large volumes of purged ink and place it below the jetting assembly.

3) To empty the supply reservoir: •

Display the Home screen.

•

Select

•

Select

repeatedly until

Sequence is displayed. •

Select PH# Purge Supply Reservoir On

•

Select The screen does not change. The ink will begin draining from the jetting assembly. When the ink stops draining, wait five seconds.

• Select

and then

PH# Purge Supply Reservoir Off The draining should stop.

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Section 6 –Remove and Replace Procedures 4) To prepare the supply reservoir for flushing: • Ensure that the receptacle placed below the jetting assembly has room to collect the flush fluid. • Obtain a shield such as a piece of cardboard that will be used to prevent being sprayed by the jetting assembly. • Install the flush fluid cartridge the same way an ink cartridge would be installed. Note: The Kapton tape on the edge of the flush fluid cartridge will be used later in this procedure to protect the jetting assembly. • Select from the Manual Control / Sequence screen. The Home screen will appear and the supply reservoir will automatically begin to fill with flush fluid. • Wait for the Ready state to appear on the title pane of the Home screen. This may take a couple of minutes. • Hold the shield in front of the jetting assembly. • Perform five purges.

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Section 6 –Remove and Replace Procedures 5) To flush the supply reservoir: • To initiate flushing, continue holding the shield and use the same method that was used to empty the supply reservoir in step 3:

Select

Sequence PH# Purge Supply Reservoir On • Select

The screen does not change. Flushing will take 2 to 3 minutes. • Wait for the flush fluid to stop draining. • Select and then PH# Purge Supply Reservoir Off The purging should stop. • Remove the flush fluid cartridge.

6) To remove the printhead: • Use the Shutdown feature and wait for “Stopped” to appear on the title pane. Power off the print system. • Disconnect all cables from the rear of the printhead. • Insert one of the red push-button fitting plugs into the waste recovery tube. • Place an absorbent pad on your workbench. • Remove the printhead from its mounting and place it on the absorbent pad, oriented as shown, with the supply interface facing up.

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Section 6 –Remove and Replace Procedures 7) To remove the print engine cover: • Remove the two M3 Phillips screws retaining the print engine cover. • Remove the print engine cover.

8) To remove ink from the printhead exterior: • Obtain lint-free printhead wipes. • Use a clean dry printhead wipe to clean ink from: ƒ the outside of the print engine cover. ƒ the inside of the print engine cover. ƒ the outside of the printhead enclosure.

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Section 6 –Remove and Replace Procedures 9) To clean the face plate, use a

clean dry printhead wipe: • Make a wiping motion from the center, away from the jets. • Do not scrub the face plate. • Do not drag contaminants across the jetting assembly.

X 10) To protect the face plate: • Remove the Kapton tape from the edge of the flush fluid cartridge. • Apply the Kapton tape over the face plate.

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Section 6 –Remove and Replace Procedures 11) To clamp the supply pressure line: • Make a loop in the supply pressure line. • Push the loop into clamp. • Ensure the tube is in the clamp as shown. • Close the clamp to pinch the tube. • Tuck the supply pressure line and the closed clamp out of the way so the print engine cover can later be reinstalled.

12) To plug the vacuum line: • Remove the vacuum line from the fitting. • Insert the second red push-button fitting plug into the vacuum line. • Install one of the black rubber caps on the fitting.

13) To tuck the vacuum line in the printhead: • Tuck the vacuum line under the wires so it will be out of the way when the print engine cover is later re-installed.

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Section 6 –Remove and Replace Procedures

14) To plug the supply interface: • Install the second black rubber cap on the center ink supply fitting. • Install the two red non-vented doubleended caps on the luer fittings as shown. • To reinstall the print engine cover, place the cover over the print engine and install the two M3 Phillips screws.

15) To protect the printhead from electrostatic discharge (ESD): • Carefully place the printhead in the pink anti-static bag as shown. • Zip the bag to close it.

16) To store or ship the printhead: • If storing the printhead, package it (if desired) and keep it in its upright position. • If shipping the printhead, package it in protective packaging. • If shipping the printhead to MarkemImaje, call your Markem-Imaje representative for further instructions.

------------------------------

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Section 6 –Remove and Replace Procedures 1. Remove the (2) M3 Phillips head screws retaining the Print Engine cover.

M3

2. Remove the M4 cap screw holding the ground strap to the printhead.

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Section 6 –Remove and Replace Procedures 3. Remove the Low Vacuum line from the tap on the Primary reservoir.

4. Disconnect the 5 way flat and 6 pin connections of the Print Engine Heater / Thermistor harness.

5. Disconnect the (4) Jet array harnesses.

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Section 6 –Remove and Replace Procedures 6. Disconnect the blue Statistics Module harness.

7. Using a ball end 4mm Hex wrench of appropriate length, remove the (2) M5 cap screws holding the Print Engine to the Printhead. 1. 2.

~Note: Take care while removing and installing the Print Engine fasteners that you do not cause damage to the Jetting Array / Statistics module harnesses.

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Section 6 –Remove and Replace Procedures 8. Gently pull the Print Engine away from the printhead body enough to access the 4 way connector for the Ink Level Sensor harness. Disconnect this harness and remove the Print engine

9. Clean off the Supply Interface port and replace the O-Ring.

10. Remove the tape covering the Supply Interface port on the Print Engine. (Subject to change – updated in Rev. 01)

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Section 6 –Remove and Replace Procedures 11. Position the Print Engine near the front of the Printhead such that the Ink Level Sensor harness may reach and be connected to X15 on the Printhead PCA.

12. Carefully line up the recessed Supply Interface port on the Print Engine to the Supply Interface tube. Seat the tube (which should contain a new o-ring as mentioned in step 9) in the Print Engine port and hold the Engine firmly against the Printhead.

13. Insert the (2) M5 Cap screws with spacers into the bores on either side of the Print Engine. Tighten the screws evenly until the Print Engine is fastened securely to the Printhead.

Take care not to damage the Jetting array or Statistics Module Harnesses while tightening the fasteners.

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Section 6 –Remove and Replace Procedures 14. Connect the blue Statistics Module harness connector to X3 on the Printhead PCA

15. Connect the (4) Jetting Array harnesses to the Printhead PCA .

16. Connect the Heater and Thermistor connections from the Print Engine Harness

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Section 6 –Remove and Replace Procedures 17. Remove the protective cover on the Low Vacuum port and install the Low Vacuum silicone tube.

18. Secure the ground strap to the Printhead using the supplied M4 cap screw.

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Section 6 –Remove and Replace Procedures 19. Remove the strip of protective tape covering the Jetting Array. 20. Install the Print Engine cover using (2) M3 Phillips head screws.

6.3 Upgrading Firmware from the F.U.U. This process requires access to the interior of the 5600/5800 Controller while AC power is applied. Electrical hazards are present in the Controller during this operation. Personal injury or equipment damage could occur if care is not taken to avoid contact with live electrical components. Only trained Markem-Imaje personnel are approved to perform this procedure.

1. Copy the desired firmware file to the USB device. The file should look similar to the following: lcij_hm_v0_3_7.nge.

- Be sure the firmware file you wish to load is the only .nge file resident on the USB device. 2. Shut off power to the machine.

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Section 6 –Remove and Replace Procedures 3. Remove the 9 screws securing the Controller front cover in place and rotate the cover forward to expose the controller’s interior.

4. Place jumper X16 in the #1 position.

X16

Position 1

5. Insert USB device containing firmware file into the USB A port.

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Section 6 –Remove and Replace Procedures 6. *Attention* - The next step will enable exposed electrical components in the controller’s interior. -

Switch on the controller

7. Monitor LED V33 on the Controller PCA. Once the LED begins to blink, place jumper X16 back to its original position 2 (move the jumper with power remaining on).

2 1

8. The firmware upgrade will now proceed. LED V33 will blink at a faster rate as the upgrade progresses. The upgrade may take up to 15 to 20 minutes. Do not disturb the machine during the upgrade. 9. Once complete, the system will reboot (A). During reboot, the UI touch screen calibration will appear (B). This process will require the user to touch each target as it repositions itself. A. B.

.

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Section 6 –Remove and Replace Procedures 6.4 Upgrading Firmware with USB 1. Copy the desired firmware file to the USB device. The file should look similar to the following: lcij_hm_v0_3_7.nge. Be sure the firmware file you wish to load is the only .nge file resident on the USB device. 2. Power on the 5600/5800 and wait for the system to boot. 3. Install the USB device into the USB Type A port on the back of the controller.

4. From the User Interface, Select “Menu”. 5. Security will need to be enabled to access the “Service” option. To do this, select “Enable Security”. This will prompt the User for a password entry. At this point enter the 8 digit “Password of the Day”. Once the password is entered, the “Service” option will become available. 1. Select Enable Security

2. Enter 8 digit password and accept

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Section 6 –Remove and Replace Procedures

o

3. Agree to continue

6. Select “Service”.

7. Select “Upgrade from USB”.

8. Do not disturb the machine during the upgrade process. Once the upgrade is finished the machine will reboot. Once the system reboots, normal machine activity may resume. Note: Job and Settings files will be backed up on the USB device prior to the upgrade. These will be downloaded back to the machine once the upgrade is complete. These files will not be removed from the USB device as part of the process. Care should be taken to monitor what is on the USB before each upgrade to avoid unwanted files being downloaded from machine to machine.

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Section 6 –Remove and Replace Procedures 6.5 Printhead Calibration Printhead Supply Volume Calibration Process All systems must start the calibration with the supply reservoir empty. To Empty the System: 1. Remove the drip tray and place a 500 ml or larger container that can handle hot liquid under the Jetting Assembly (for liquid 5600 systems also remove the supply container) 2. Power on the system 3. Enter Diagnostics/Manual Control - /Heater - (during this process do not leave manual control) - Select “PH# Jetting Assembly Regulate On” - Select “PH# Primary Reservoir Regulate On” - Select “PH# Supply Reservoir Regulate On” - Using the diagnostic in manual control monitor the supply reservoir temperature to be “OK” - /Sequence - Select “PH# Purge Supply Reservoir On” - Monitor the ink coming out of the Jetting Assembly to stop flowing - Select “PH# Purge Supply Reservoir Off” 4. Select the home icon Printhead Calibration COLD 1. Power on the system 2. System will report a “PH# supply reservoir Ink Out Fault” 3. Clear the fault 4. Enter Setting/Machine Setting (this must be done before a fault reoccurred) - /Ink - Change the “PH# Supply Calibration Temperature Factor” to 13 - Change the “PH# Supply Calibration Finale Volume” to 260 5. Enter Diagnostics/Manual Control (this must be done before a fault reoccurred) - /Heater– (during this process do not leave manual control) - Select “PH# Jetting Assembly Off” - Select “PH# Primary Reservoir Off” - Select “PH# Supply Reservoir Off” - /Sequence - Select “PH# Supply Calibration Step 1” o Repeat 5 times

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Section 6 –Remove and Replace Procedures 6. Add two blocks of ink to the system 7. Select “PH# Supply Calibration Step 2” - Repeat 5 times 8. Select “PH# Check Supply Reservoir Volume” 9. Select the diagnostic button and verify the “PH# Supply Volume” is 260 +/-10 10. Select the home icon Printhead Calibration HOT 1. Power on the system 2. System will report a “PH# supply reservoir Ink Out Fault” 3. Clear the fault 4. Enter Setting/Machine Setting (this must be done before a fault reoccurred) - /Ink - Change the “PH# Supply Calibration Temperature Factor” to 13 - Change the “PH# Supply Calibration Finale Volume” to 298 5. Enter Diagnostics/Manual Control (this must be done before a fault reoccurred) - /Heater - (during this process do not leave manual control) - Select “PH# Jetting Assembly Regulate On” - Select “PH# Primary Reservoir Regulate On” - Select “PH# Supply Reservoir Regulate On” - Using the diagnostic in manual control monitor the supply reservoir temperature to be “OK” - /Sequence - Select “PH# Supply Calibration Step 1” o Repeat 5 times - Add two blocks of ink to the system - Wait 90 minutes for the two blocks of ink to melt completely - Select “PH# Supply Calibration Step 2” o Repeat 5 times - Select “PH# Check Supply Reservoir Volume” - Select the diagnostic button and verify the “PH# Supply Volume” is 298 +/-10 6. Select the home icon

6.6 Kits, Etc.

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Section 6 –Remove and Replace Procedures Kit #10051375 - 5800 Heater and Thermal Sensor Harness Kit for Print Engine

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Section 6 –Remove and Replace Procedures Kit #1005376 - 5800 Ink Level Sensor Harness Kit

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Section 6 –Remove and Replace Procedures Kit #10051377 5800 Heater and Thermal Sensor Harness Replacement Kit for Supply Reservoir:

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Section 6 –Remove and Replace Procedures Notes:

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Section 7 Troubleshooting

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Section 7 - Troubleshooting 7.1 Basic Troubleshooting

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Section 7 - Troubleshooting Basic Troubleshooting Symptom Not Printing

Possible Cause Printhead not enabled

Action Enable the printhead from Settings menus

MenuÆ

SettingsÆ

Machine

Job not selected Coder not online (If warming up, wait.) Incorrect print registration

from the Controller Panel. Select a job by pressing Observe the GREEN STATUS LED on the Status Beacon. Adjust the registration by Panel.

pressing from the Controller Front

Print Adjust

Adjust registration parameters from the

Product sensor not functioning

Æ Registration menus. Select product sensor from the

MenuÆ

Light print

Missing prints

Possible printhead failure Density setting too low

Throw distance too far Incorrect print registration

SettingsÆ Machine SettingsÆ Printing Menu Request further diagnostics, printhead might need to be replaced contact Markem-Imaje Service. Print Adjust

Increase density from the

Æ DarknessÆ menus. Mount the printhead so the jet array is no further than 4,7mm (0.188") from the product being printed.

Adjust the registration by pressing

from the Controller Front Panel.

Adjust registration parameters from the

Gap between cartons too small Product sensor sensitivity Slipping Encoder

Print Adjust Æ

Registration menus. Check for small gaps; adjust the product sensor for sensitivity (Gain control). Adjust product sensor Gain control. Adjust encoder mounting for better contact.

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Section 7 - Troubleshooting

Symptom

Possible Cause

Smudged, blurred print

Product contacting printhead Product contacting guide rail Airflow near printhead

Action Adjust printhead mounting, allowing more space. Install Printhead Slide Assembly 10051443 for Model 5800. Avoid guide rail rubbing on printed image and ink build-up. Make sure air is not blowing on the jet array, redirecting the ink droplets, blurring the printed image.

Problems and Recommended Solutions Symptom

Possible Cause

Stretched, condensed Wavy prints

Encoder line speed mismatch Vertical movement of the carton or printhead Contamination Poor purge pressure

Poor print quality Ink weeping, dripping

Low vacuum line connection Incorrect low vacuum setting Electrical static Vibration or mechanical Printing too soon after Auto Purge Low Vacuum system failure Printhead soak: ink in the low vacuum line Low Vacuum system failure Low vacuum line connection Auto Purge is enabled

Action Ensure that the encoder speed and packaging line speed match. Improve product handling or printhead mounting to eliminate vertical motion. Follow procedures for daily cleaning of the printhead. The VPC is not able to generate enough purge pressure to clear the air and debris from the jets. Recommend replacing the low vacuum pump diaphragm. Ink is in the low vacuum line, limiting the purge pressure to the printhead. Clear or replace the low vacuum line. Ensure that low vacuum lines are properly connected to both the Primary Reservoir and Low Vacuum Pump contact Markem-Imaje Service. Ensure that the correct PH Position is selected: Machine Setup menu / Printhead Settings / PH Position. If Custom PH Position is selected, verify the Custom Vacuum setting. Identify the source of the static and make necessary corrections. Printhead must be securely fastened to the mounting bar. Avoid mechanical shock and interference from packaging line Adjust Auto Purge Settings from SettingsÆ

MenuÆ

SettingsÆ Machine Purging Menu

contact Markem-Imaje Service. Refer to diagnostics Follow Printhead Soak Kit instructions to recover from a printhead soak (Ref# 10042238) contact Markem-Imaje Service. Refer to diagnostics Ensure that low vacuum lines are properly connected to both the Primary Reservoir and Low Vacuum Pump contact Markem-Imaje Service. Adjust Auto Purge Settings from SettingsÆ

MenuÆ SettingsÆ Purging Menu

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Machine

Section 7 - Troubleshooting 7.2 Fault and Warning Types To be published in revision 03

7.3 Fault and Warning List Warnings A Warning is raised when a condition is detected that will prevent the system from printing at some future time if the operator does not intervene or to indicate that there is a condition that the operator should be aware of but will not immediately affect the printing. Warnings will not cause a change in the system PackML state. The operator will have the option to hide active warnings once they have been acknowledged. Faults have higher precedence than warnings. If both a fault and a warning are active, the fault has display priority. The beacon will indicate a fault, not a warning, is active. The Warning output will be active whenever a warning condition is active. Warning indicating digital outputs, including relays, must be designed to indicate a warning is active by being driven to report ‘no warning’. Thus when power is removed from system, the output will appear to report a ‘warning’ (not driven). In the Manual mode, it is possible to toggle outputs while a warning is active. A list of the Controller and Printer warnings can be found in the faultwarningdeffile.xml file. When a warning occurs, the warning description will be published to the local user interface. When a warning is active, the banner on the CUI will be yellow to indicate the presence of the warning. When a warning is selected from the list in the Status menu it can be viewed and each message contains a tick icon to enable the operator to either clear the message for warnings that can be cleared without operator intervention, or to hide the message screen for warnings that need operator intervention to be addressed. When a warning occurs, the warning description will be published to the web-based user interface. When a warning occurs, the warning description will be published via DCP. All warnings are cleared when the system shutdown is initiated via the CUI.

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Section 7 - Troubleshooting * Warning ID Codes are listed in numerical order. Warning ID 10400

Warning Name Variable Data Logging Has Stopped

10500

Variable Data log Nearly Full

10800

Suppression File Parse Error Variable Data Log Cleared

10900

11100 11200

11300 11500 12410

13910 14010

File Management Nearly Full Missed Print

Synopsis (Annotation) The Variable Data Log is full and the Data Log Full Action Setting is set to Stop Logging so logging has stopped. The variable data log file is nearly full.

Problem parsing the fault and warning suppression file. The Variable Data Log is full and the Data Log Full Action Setting is set to Delete Old Data so the log has been cleared. File system is 90% full. A product has passed the Print Head(s) without being printed on.

Troubleshooting Actions No action necessary, this is simply a notification.

If variable data logging is setup to stop logging and fault when full, either upload the variable data log (clearing it in the process) or change the Data Log Full Action Setting so that the machine will not fault when the log is full. Verify that the format and content of the user supplied fault and warning suppression file. No action necessary, this is simply a notification.

Remove old files as desired to make additional space in the file system. This occurs when a print trigger fires either during registration or when allocation is complete and the previous job is not finished printing. Check your product spacing. Verify that the image is designed correctly.

Image Cropped Calendar File Nearly Exhausted Low Vacuum flooded

Image had to be cropped to fit the printable area. The calendar file is nearly exhausted.

(5800) Supply Reservoir Ink Low Drip Tray full

Low ink volume in the Supply reservoir

Remove the Print Engine cover and inspect the low vacuum line to the Primary Reservoir for signs of ink ingestion. If ink is present, replace the tubing using 5800:10042238 Printhead Tubing Kit 5600: 10051387 Solenoid Valve kit Add no more than 2 ink blocks soon to avoid an ink supply fault.

The Drip Tray may be full

Empty the drip tray and clear the warning

Ink may have entered the Low Vacuum air path. If so, this will cause jet outages and may cause the jetting assembly to weep ink

Update calendar file appropriately.

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Section 7 - Troubleshooting Warning ID 14110

Warning Name Low Vacuum leak

14210

Low Vac. filter

14310

Door open

14410

Manual control function conflict Over temperature

15410

16100

Allocation Warning

16410

High Strobe Rate

16700

Print Head 1 Warning Strobe Rate

16900

Print Head 2 Warning Strobe Rate

17310

Ink Container Absent

17400

Flex IO Scanner Trigger Missed Image Warning Default Configuration Applied

17600 19300

Synopsis (Annotation)

Troubleshooting Actions

There may be a leak in the Low Vacuum air path

Check to see if the Low Vacuum air path has been compromised.

Low Vacuum Filter F4 may need to be replaced Ink door may be open or leaking

Replace F4 filter

Sequence aborted

The User selected another Manual Control before the prior Manual Control sequence completed

The Printhead enclosure temperature is very high which may cause erratic behavior. Allocation has completed and no job is available to print.

Be sure the printer is in an environment which meets the environmental specification guidelines.

The combination of the Density and the Printing Speed has caused the printhead to exceed the qualified Strobe Rate. The combination of density and print speed of Print Head 1 has exceeded the warning strobe rate. The combination of density and print speed of Print Head 2 has exceeded the warning strobe rate. There is no Ink Cartridge installed

Ensure the door gasket surfaces are clean and close the door

Make sure a job with allocation is available to print. If you are not using job queuing, fix your product spacing to avoid this condition. Reduce the Density or Printing Speed to continue to ensure quality prints.

Either decrease print density or print speed to avoid this warning condition. Either decrease print density or print speed to avoid this warning condition. Install a new Ink Cartridge

A Flex IO Scanner Trigger has been missed.

Make sure your scanner port mode and scanner trigger settings are configured correctly.

Imaging engine returned a warning error code There were no files to restore following the firmware upgrade. Default settings and files were applied.

Verify that the image file is properly formatted. If the desire is to clone and restore files during a firmware upgrade, configuration files must be present when rebooting following a firmware upgrade.

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Section 7 - Troubleshooting Warning ID 19400 19500 19700 21410

Warning Name Print Head 1 Image Not Ready Print Head 2 Image Not Ready Controller Upgrade Failed Low Ambient Temperature

21700

Print Overlap Print Head 1

21800

Print Overlap Print Head 2

22910

Supply container empty

23010

Inaccurate Supply Volume

23300

No Print Heads ONLINE

23410

Automatic Density Reduction

23510

Settings Definition Change

Synopsis (Annotation)

Troubleshooting Actions

Controller image processing not completed in time to start printing on Print Head 1. Controller image processing not completed in time to start printing on Print Head 2. Upgrade process was terminated early and upgrade was not completed. The ambient temperature is below the acceptable range, which may affect performance. System setup is causing the next print to be started before the previous print was completed. System setup is causing the next print to be started before the previous print was completed. The Ink Cartridge has run out of ink.

Verify that print speeds fall within system specifications.

The Supply Reservoir ink volumes will be inaccurate until the ink has fully melted (90 minutes after applying power). There are no print heads online and an attempt has been made to transition to the PRODUCING State. The Density setting has been automatically reduced to to allow the printhead to continue printing within its strobe rate limit The new firmware has modified the definition of the printhead settings.

This is for notification only

Verify that print speeds fall within system specifications. Re-attempt to upgrade the system. Adjust the application so there is a higher ambient temperature. Verify product spacing. If this fault was preceded by an Image Not Ready Warning, verify speed and image length are within system capabilities. Verify product spacing. If this fault was preceded by an Image Not Ready Warning, verify speed and image length are within system capabilities. Install a new Ink Cartridge

Please check your settings and ensure that there are at least one print head ONLINE before attempting to go to PRODUCING. . If this is unacceptable, the system printing speed must be reduced and the Density setting restored

Read the Firmware Release Notes to determine how these changes could affect the operation of the printhead.

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Section 7 - Troubleshooting Warning ID 24000

Warning Name Print/Verify Sequence Interrupted

24110

Supply Reservoir leak (5800) Supply Reservoir leak (5600) Select Job Flexible Input Error

24210 24500

24900 25300

25400

USB Hardware Failure Remote Encoder Setup Warning Remote Product Sensor Setup Warning

Synopsis (Annotation)

Troubleshooting Actions

Items on the conveyor have not conveyor have not completed the print and verify cycle. Leak detected at the Supply Reservoir

Remove all products between the first and last devices connected to the system before restarting printing.

A leak has been detected at the Supply Reservoir

Ensure that the air path to the Supply Reservoir is not compromised. This will affect volume measurements and calibration. This indicates that the previously selected job was not printed before selecting the new job.

A SELECT JOB flexible input was activated while the OK TO SELECT NEXT JOB flexible output was deactivated. USB port failed to initialize and is not currently functional. Both print heads are setup to use a Remote Encoder.

Inspect and clean the Door Gasket. This will affect volume measurements and calibration.

Both print heads are setup to use a Remote Product Sensor.

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Section 7 - Troubleshooting Faults A fault is an occurrence that prevents the system from printing. The discovery of a fault during an automated sequence will halt the sequence with the system coming to a safe state. All faults will cause the system to enter the PackML ABORTED state. Once a fault has been generated, it must be cleared before the system can be returned to the PRODUCING state. Faults have higher precedence than warnings. In the Manual mode, it is possible to toggle outputs while a fault condition is active. The Fault output (beacon & relay) will indicate a ‘fault’ whenever a fault condition is active. Fault indicating digital outputs, including relays, must be designed to indicate a fault is active by being actively driven to report ‘no fault’. Thus when power is removed from system, the output will appear to report a ‘fault’ (not driven). A list of the Controller and Printer faults can be found in the faultwarningdeffile.xml file. When a fault occurs, the fault description will be published to the local user interface. When more than one fault is activated at the same time, one fault will be displayed in focus and additional fault screens will be brought to the front when the first fault screen is hidden. When a fault is active, the banner on the CUI will be red to indicate the presence of the fault. Each fault message contains a tick icon enabling the operator to hide the message screen. This leaves the fault active on the system but closes the message screen, allowing the operator to navigate around the CUI. When a fault occurs, the fault description will be published to the web-based user interface. When a fault occurs, the fault description will be published via DCP. All faults are cleared when the system shutdown is initiated via the CUI.

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Section 7 - Troubleshooting * Fault ID Codes are listed in numerical order. Fault ID 10302 10602 10703 11001 11601

Fault Name Calendar File Exhausted Logging stopped Definition File Parse Error File Management Full Failed To Restore Job

Synopsis The calendar file is completely exhausted. The Variable Data Log is full and the Data Log Full Action setting is set to Stop Printing. Problem parsing the fault/warnings definition xml file. File system is 99% full. Failed to restore previous job following a power cycle.

11712

Supply Reservoir Thermal sensor

The system has detected an open or shorted supply reservoir temperature sensor

11812

Primary Reservoir Thermal Sensor

The system has detected an open or shorted primary reservoir temperature sensor

11912

Jet Assembly Thermal Sensor

The system has detected an open or shorted jetting assembly temperature sensor.

Troubleshooting Actions Update calendar file appropriately. Please retrieve the Variable Data Log or change the setting in order to continue printing. Call Markem-Imaje. Delete files from the file system if more space is required for new files. Make sure that all necessary files associated with the job are present in the file system. *Measure the resistance of the sensor when it is disconnected from the PCA. -Reference the Resistance Table in the Electronics section to determine if its resistance is reasonable. *Measure the resistance of the sensor when it is disconnected from the PCA. -Reference the Resistance Table in the Electronics section to determine if its resistance is reasonable. *Measure the resistance of the sensor when it is disconnected from the PCA. -Reference the Resistance Table in the Electronics section to determine if its resistance is reasonable.

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Section 7 - Troubleshooting Fault ID 12012

Fault Name Supply Reservoir Temperature

Synopsis

Troubleshooting Actions

*This could mean that the system could not detect an increase in reservoir temperature when it was supposed to be heating *The system detected a rise in temperature when the reservoir was supposed to be cooling *The reservoir could not reach the set point temperature in the allotted time *The reservoir temperature could not be maintained within a valid band of temperatures

*The ambient temperature is outside the specified limits. -The system is rated to function properly in environments greater than 0Cº and less than 40Cº *The 24VAC to the print head is absent. -Measure the 24VAC at X1 on the print head PCA. If it is missing, suspect a blown fuse in the Controller. Note that the AC voltage reading at the print head end of the print head power cable could measure up to 10 VAC even though the fuse is blown. This is due to a capacitive effect of the cable *The temperature setting was just changed to a much lower temperature. -Sometimes when lowering the temperature setting significantly, especially in a hot environment, the system cannot cool down fast enough. This should be a one-time fault so simply clear it and wait for the system to reach the lower temperature *The electronic driver for the heater has failed to a shorted state causing the heater to be on continuously. Check for AC voltage at X1 on the print head PCA. If the diagnostic value for this heater states it should be off yet there is 24VAC applied to the heater, replace the PCA *The electronic driver for the heater has failed to an open state causing the heater to be off continuously. Check for AC voltage at X1 on the print head PCA. If the diagnostic value for this heater states it should be on yet there is no 24VAC applied to the heater, replace the PCA * The temperature sensor is defective or not mounted properly. -Measure the resistance of the sensor when it is disconnected from the PCA. Reference the resistance table in the Electronics section to determine if its resistance is reasonable. Ensure the sensor is properly mounted

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Section 7 - Troubleshooting Fault ID 12112

Fault Name Primary Reservoir Temperature

Synopsis

Troubleshooting Actions

*This could mean that the system could not detect an increase in reservoir temperature when it was supposed to be heating * The system detected a rise in temperature when the reservoir was supposed to be cooling * The reservoir could not reach the set point temperature in the allotted time * The reservoir temperature could not be maintained within a valid band of temperatures

* The ambient temperature is outside the specified limits. -The system is rated to function properly in environments greater than 0Cº and less than 40Cº *The 24VAC to the printhead is absent. -Measure the 24VAC at X1 of the printhead PCA. If it is missing, suspect a blown fuse on the Power Distribution PCA. Note that the AC voltage reading at the printhead end of the printhead power cable could measure up to 10 VAC even though the fuse is blown. This is due to a capacitive effect of the cable *The temperature setting was just changed to a much lower temperature. -Sometimes when lowering the temperature setting significantly, especially in a hot environment, the system cannot cool down fast enough. This should be a one-time fault so simply clear it and wait for the system to reach the lower temperature *The electronic driver for the heater has failed to a shorted state causing the heater to be on continuously. Check for AC voltage at X1 on the print head PCA. If the diagnostic for this heater states it should be off yet there is 24VAC applied to the heater, replace the PCA *The electronic driver for the heater has failed to an open state causing the heater to be off continuously. Check for AC voltage at X1 on the print head PCA. If the diagnostic for this heater states it should be on yet there is no 24VAC applied to the heater, replace the PCA *The temperature sensor is defective or not mounted properly. -Measure the resistance of the sensor when it is disconnected from the PCA. Reference the resistance table in the Electronics section to determine if its resistance is reasonable. Ensure the sensor is properly mounted

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Section 7 - Troubleshooting Fault ID 12212

Fault Name Jetting Assembly Temperature

Synopsis

Troubleshooting Actions

* This could mean that the system could not detect an increase in reservoir temperature when it was supposed to be heating * The system detected a rise in temperature when the reservoir was supposed to be cooling * The reservoir could not reach the set point temperature in the allotted time * The reservoir temperature could not be maintained within a valid band of temperatures

*The ambient temperature is outside the specified limits. -The system is rated to function properly in environments greater than 0Cº and less than 40Cº * The 24VAC to the printhead is absent. -Measure the 24VAC at X1 on the printhead PCA. If it is missing, suspect a blown fuse on the Power Distribution PCA. Note that the AC voltage reading at the printhead end of the printhead power cable could measure up to 10 VAC even though the fuse is blown. This is due to a capacitive effect of the cable. *The temperature setting was just changed to a much lower temperature. -Sometimes when lowering the temperature setting significantly, especially in a hot environment, the system cannot cool down fast enough. This should be a one-time fault so simply clear it and wait for the system to reach the lower temperature *The electronic driver for the heater has failed to a shorted state causing the heater to be on continuously. Check for AC voltage at X1 on the print head PCA. If the diagnostic for this heater states it should be off yet there is 24VAC applied to the heater, replace the PCA *The electronic driver for the heater has failed to an open state causing the heater to be off continuously. Check for AC voltage at X1 on the print head PCA. If the diagnostic for this heater states it should be on yet there is no 24VAC applied to the heater, replace the PCA *The temperature sensor is defective or not mounted properly. -Measure the resistance of the sensor when it is disconnected from the PCA. Reference the resistance table in the Electronics section to determine if its resistance is reasonable. Ensure the sensor is properly mounted

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

Troubleshooting Actions * The ambient temperature is outside the specified limits. -The system is rated to function properly in environments greater than 0Cº and less than 40Cº *The 24VAC to the printhead is absent. -Measure the 24VAC at X1 on the printhead PCA. If it is missing, suspect a blown fuse in the Controller. Note that the AC voltage reading at the printhead end of the printhead power cable could measure up to 10 VAC even though the fuse is blown. This is due to a capacitive effect of the cable *The temperature setting was just changed to a much lower temperature. -Sometimes when lowering the temperature setting significantly, especially in a hot environment, the system cannot cool down fast enough. This should be a one-time fault so simply clear it and wait for the system to reach the lower temperature *The PCA driver for the heater has failed to a shorted state causing the heater to be on continuously. Check for AC voltage at X1 on the print head PCA. If the diagnostic for this heater states it should be off yet there is 24VAC applied to the heater, replace the PCA *The PCA driver for the heater has failed to an open state causing the heater to be off continuously. Check for AC voltage at X1 on the print head PCA. If the diagnostic for this heater states it should be on yet there is no 24VAC applied to the heater, replace the PCA *The temperature sensor is defective or not mounted properly. -Measure the resistance of the sensor when it is disconnected from the PCA. Reference the resistance table on in the Electronics section to determine if its resistance is reasonable. Ensure the sensor is properly mounted *No ink in the supply reservoir. This will usually cause air to be blown out the jetting orifices (hissing) during the fill cycle. It usually will cause a Low Vacuum fault since the primary reservoir will become pressurized with air: Add ink to the supply reservoir and wait for it to melt

12312

Primary Reservoir Ink Level Sensor

*This could mean that the system could not detect an increase in reservoir temperature when it was supposed to be heating * The system detected a rise in temperature when the reservoir was supposed to be cooling * The reservoir could not reach the set point temperature in the allotted time * The reservoir temperature could not be maintained within a valid band of temperatures

12512

Ink Fill Timeout (5800)

The primary reservoir took too long to complete a fill cycle. Once the system detects the level sensor in an Ink Out state, a fill cycle is started. When the high pump is enabled, a timer is started. The pressure in the supply reservoir must be raised above the cracking pressure of check valve

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis CV2 in order to make ink flow from the supply reservoir to the primary reservoir. If it takes too long to fill the primary reservoir, this fault is activated

Troubleshooting Actions *Supply reservoir ink is not fully melted. This will cause air to be blown out the jetting orifices (hissing) during the fill cycle. It usually will cause a Low Vacuum fault since the primary reservoir will become pressurized with air. A. Ink blocks were newly installed so although the reservoir is at temperature, not enough ink has melted yet. This could happen after recovering from an Ink Out fault. B. Set the Supply Reservoir Idle Temperature to a higher value to reduce the time to melt ink, especially in a cold environment C. Supply reservoir thermistor is defective causing the supply reservoir to be colder than the temperature reading on the UI. Measure the thermistor resistance and compare it to the resistance table * Defective Primary Reservoir Ink Level Sensor. The primary reservoir has actually been filled (probably overfilled) but the level sensor is not registering the new level - Remove the Print Engine Cover then the Low Vacuum hose from the primary reservoir; insert a dipstick to measure the ink volume. If more than 10 mm of ink is present, the ink level sensor is not functioning correctly. Ensure a flood condition does not exist (low vacuum hose is filled with ink). If a flood has occurred, repair using the Printhead tubing kit or the printhead will need to be returned to Markem-Image for service. * Check Valve CV2 is stuck closed -If the Supply Reservoir Pressure rises to at least 345 millibars (5psi) during a fill cycle and there is sufficient melted ink in the supply reservoir, CV2 could be stuck. In this case, the printhead will need to be shipped back to Markem-Imaje for service. * The coarse filter in the bottom of the supply reservoir is plugged - Clean or replace the filter * Solenoid S3 is malfunctioning - Ensure the light on Solenoid 3 changes state when the manual control for solenoid 3 is turned on and off * Restrictor R5 is blocked

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

Troubleshooting Actions - If R5 is blocked the system will not measure any ink or will measure an abnormally low volume of ink compared to the actual level of ink. If blockage cannot be cleared, the printhead will need to be returned for service. * High Pump failure - Enable the high pump using a manual control with its output hose removed. Ensure it outputs a stream of air * Filter F1 is blocked - If this is blocked, the system will not do a purge either. Replace the filter. * Filter F3 is blocked - If the Supply Reservoir Pressure rises to at least 345 millibars (5psi) during a fill cycle and there is sufficient melted ink in the supply reservoir, F3 could be plugged. * Restrictor R6 is blocked - If the Supply Reservoir Pressure rises to at least 345 millibars (5psi) during a fill cycle and there is sufficient melted ink in the supply reservoir, R6 could be plugged.

12611

Supply Reservoir out of ink

The measured volume of ink in the supply reservoir is below the minimum value. The reservoir should not be empty due to a need to keep a minimum amount of ink in the reservoir

12812

Low Vacuum Fault

The system maintains the low vacuum in the primary reservoir to counteract the tendency for the ink to flow out the jetting assembly due to gravity. If the system cannot maintain this vacuum within fairly tight limits, this fault is activated

*Supply reservoir volume measurement not calibrated - Calibrate the supply reservoir * Pressure leak - Check that the ink door gasket and the surface it contacts is clear of ink and debris - Check that the ink door gasket is not damaged - Check that the supply cover gasket between the supply cover and the supply reservoir is not damaged - Check that there is no leak in the hose leading to the supply reservoir - Check that there is no leak in the hose leading to the pressure sensor on the PCA * Filling the primary reservoir when the supply reservoir is empty -If air is forced into the primary reservoir during a primary reservoir ink fill cycle due to the supply reservoir being empty, the pressure created in the primary reservoir will be too great for the low vacuum system to overcome when restoring the vacuum. Add more ink to the supply reservoir and ensure it is melted. Low vacuum faults may continue until the primary reservoir is filled since a “leak” may exist through the jetting

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

Troubleshooting Actions assembly if air was blown out of it during the failed fill cycle. This can be prevented by doing a Manual Control Primary Reservoir Filling sequence. * Jetting assembly has not been wetted or has had air blown through it during a primary reservoir fill cycle and the primary reservoir is completely empty - See “Filling the primary reservoir when the supply reservoir is empty” above * Low vacuum sensor is not plumbed properly - The Low Pump Duty Cycle will be 50% if this is wrong. The sense hose should be attached to the U5 sensor port closest to the jet test and purge switches. The other end of the sense hose should be connected to the manifold between Solenoid 4 and Solenoid 5. * Plumbing problem - Check that the sense hose on U5 vacuum sensor is on tightly. Ensure no hose is kinked * Restrictor R2 is plugged - This is indicated by a very high (50%) Low Pump Duty Cycle on the Diagnostics menu. Remove the hose from the output of the low pump (white port) to test if the problem is fixed. If R2 is blocked, carefully clear the orifice. * Restrictor R3 is plugged - This is indicated by a very high (50%) Low Pump Duty Cycle on the Diagnostics menu. If R3 is blocked, carefully clear the orifice * Filter F4 is plugged -This is indicated by a very low (0%) Low Pump Duty Cycle on the Diagnostics menu. Remove the hose from the input of the low pump (blue port) to test if the problem is fixed but be careful not to introduce contaminants into the hose. If F4 is determined to be plugged, replace the filter. * Restrictor R4 is plugged - This is indicated by a very low (0%) Low Pump Duty Cycle on the Diagnostics menu. If R4 is blocked, carefully clear the restrictor

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

12912

Supply Reservoir pressure leak

It took too long to reach the 83 millibars pressure point in the supply reservoir when doing a supply reservoir volume measurement

13011

Ink Door Open

The Supply Reservoir door has been open too long. This door must be kept closed to prevent contaminants from entering the reservoir

Troubleshooting Actions *Ink door gasket is leaking - The ink door is not fully latched. Ensure the door latch is functioning properly - Ink contamination on the door gasket or the surface the door gasket mates with. Clean each of these - The ink door gasket is defective. Check for cracks and nicks * Plumbing problem - Ensure the pressure sense hose is well attached to U6 on the PCA and not kinked - Ensure the hose on the output of the high pump is well attached - Ensure the hose from the manifold to the supply reservoir is well attached * Solenoid 3 (S3) is not functioning properly -Ensure the S3 lamp is lit during a volume measurement cycle. R5 and S3 can be tested by bypassing them using a T connector to the sense hose on U6 and connecting to the output of the high pump. Do a Manual Control Check Supply Reservoir Volume to see if the problem is fixed. * Restrictor R5 is blocked -R5 and S3 can be tested by bypassing them using a T connector to the sense hose on U6 and connecting to the output of the high pump. Do a Manual Control Check Supply Reservoir Volume to see if the problem is fixed. If R5 is blocked, carefully clear the restrictor * Ink cover gasket is leaking - Remove the ink cover assembly and inspect the gasket * Operator failed to fully close the door - Close and fully latch the door * Defective door switch - Replace the switch. Do not over-tighten the switch mounting screws * Incorrect or defective wiring from the printhead PCA to the switch - Ensure the wires go to the correct terminals of the switch

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

13312

Corrupt settings

The settings checksum does not match the calculated settings checksum. This indicates a change has taken place with the settings

13412

Corrupt Database

13711

High Strobe rate

The Printhead detected a corruption of the language file database and has deleted all language files. The strobe rate for the jetting assembly is too high. The system has reduced the density to try to correct the problem but it is still too fast. The pulse stream from the encoder combined with the density setting and variable encoder setting determine this value. Reference the Speed/Density/Strobe Rate chart in the manual

Troubleshooting Actions *A new version of code has just been loaded on the system. -This version has changed the number of settings, the default value of the settings or the valid range of the settings values. The system will restore the settings to factory default values. The operator will need to restore any custom settings including the supply reservoir calibration settings *The system was powered down just as the operator was changing a printhead setting. -This could cause the setting to not be fully written to the memory device. The checksum would not be valid because of this * The non-volatile memory device on the printhead PCA has failed -In this instance, the Printhead PCA will need to be replaced The user must restore all required language files to the printhead * A setting was changed when using the internal encoder that caused the strobe rate to be exceeded * Density setting too high for the current conveyor speed. The system will automatically reduce the density setting in an effort to allow printing to continue. If this happens, a warning will be posted. The fault is activated when the density has been reduced to 1 and the strobe rate is still too high. At this point the only solution is to reduce the conveyor speed. Possible causes are: * Incorrect encoder scaling setting * Incorrect encoder wheel * Incorrectly placed encoder * Defective encoder

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

Troubleshooting Actions * Filter F1 is blocked - If this filter is blocked the path to atmosphere is restricted. * Restrictor R5 is partially blocked - This will cause any initial pressure to bleed down much slower. Carefully clear the restrictor * Solenoid S3 is not functioning properly - If S3 does not de-activate properly the bleed path to atmosphere is blocked. Ensure the S3 lamp is off prior to the supply measurement sequence. * Solenoid S2 is not functioning properly - If S2 does not de-activate properly the bleed path to atmosphere is blocked. Ensure the S2 lamp is off prior to the supply measurement sequence. * The supply pressure sensor is defective - Replace the printhead PCA * Hoses are kinked - Ensure the hoses leading from the supply reservoir and Filter 1 is not restricted. Check cables and reboot the system.

13812

Supply Reservoir Zero pressure

To begin to measure the supply reservoir volume, the supply reservoir must have no measurable pressure initially. The system will wait for up to a minute for any initial pressure to dissipate before starting the supply volume measurement sequence. This initial pressure may be caused by closing the ink door (gasket compression) or left over from a prior supply reservoir measurement

14502

Print Head Communications Error Failed to Select Job in Queue Load Job Failed

Error communicating with Print Head 1.

14601 14701

14803 14903

Controller Initialization Failed Print Head 1 Initialization Failed

There is no job in the job queue at the specified or next position. The job failed to load properly for any number of reasons. This error will be generated when a job is in the job queue but fails to properly load for printing. Initialization of the controller failed. Initialization of Print Head 1 Failed. Print Head 1 was detected at startup but failed to complete the system initialization sequence correctly with the controller. No print heads are attached to the controller.

15001

No Print Head Connected

15101

Print Overlap Print Head 1

Print Overlap PH1

15203

Print Head 1 Image Transfer Error

Error transferring image data to Print Head 1.

Make sure your job queue is set up correctly. Make sure that all necessary files associated with the job are present in the file system. Call Markem-Imaje. Call Markem-Imaje.

This is not a valid system configuration. A Print Head must be attached during normal operation. Verify product spacing, fixed spacing, and registration settings are configured such that the system will not attempt to begin a second print before the first is completed on PH1. Also, verify line speed and pack rate are within system capabilities. Verify that line speed falls within system specifications. Call Markem-Imaje if problem persists.

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

15303

Print Head 2 Image Transfer Error

Error transferring image data to Print Head 2.

15513

Software fault

15612

Low Supply Voltage

This is a generic fault that covers a myriad of problems that should never occur in production. They tend to be issues such as message values out of range, message ID’s that do not exist, states that do not have a handler function or invalid file types. These issues should only occur in development The supervisory circuit on the printhead PCA has detected a low DC power supply level. This fault occurs when the 24VDC drops to less than 18VDC. The system needs to be power cycled after this fault occurs because the printhead suspends any write operations to memory when this is active

15712

Jetting Voltage fault

The Strobe Voltage is not within an acceptable range. Due to the inaccuracies of measuring this voltage, the system can only detect gross variances of +/- 20VDC from the Strobe Voltage set point

15812

Supply Reservoir orifice blocked

If the measured supply volume is greater than 500 mL (an unreasonably high value) the system assumes the air path from the supply reservoir is blocked. A blockage in this hose/port would cause the system to pressurize just the hose prior to the blockage rather than the supply reservoir itself. This would take much less time than pressurizing the supply reservoir and would indicate an abnormal amount of ink Initialization of Print Head 1 Failed. Print Head 1 was detected at startup but failed to complete the system initialization sequence correctly with the controller.

15903

Print Head 2 Initialization Failed

Troubleshooting Actions Verify that line speed falls within system specifications. Call Markem-Imaje if problem persists. Development Fault Only

*The controller was powered down by the operator - This is normal and, due to the speed at which the power dissipates, the operator never sees this fault * Noise spikes on the 24VDC from the controller - If the spikes are longer than 15 microseconds they could cause this fault to activate * Failure of the jetting assembly electronics -Check the Strobe Voltage status in Diagnostics. If the status is Present, check the Strobe Voltage on TP11 of the Printhead PCA. If it is not within 5 volts+/- the jetting assembly is suspect. If the status is Absent, the Printhead PCA is suspect. * Printhead PCA failure - Replace the PCA * The printhead was moved when the ink was melted in the supply reservoir - This ink has frozen and blocked the pressurizing circuit. * The hose leading to the supply reservoir is restricted - Ensure the hose leading from the supply reservoir to the manifold is not kinked or plugged Call Markem-Imaje.

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

16012

Statistical Data fault

16201

Allocation Complete

16301

Print Queue Full

16501

Print Overlap Print Head 2

Print Overlap PH2

16601

Print Head 1 Max Strobe Rate

16801

Print Head 2 Max Strobe Rate

The combination of density and print speed has caused Print Head 1 to exceed the fault strobe rate. The combination of density and print speed has caused Print Head 2 to exceed the fault strobe rate.

17002

Print Head Communications Error Print Head 1 Upgrade Error

17101 17201

Print Head 2 Upgrade Error

17501

Image Not Ready

17701

Image Fault

17801

Scanner Port Mode Setting Conflict Print Head 1 Verification Failure Software Fault

18901

19003

A problem was detected with the statistical data (either Lifetime or Current) when it was read from the memory device The allocation for the current job is complete. Either job queuing is not enabled or there are no more jobs in the job queue. More than 8 items have been added to the print queue.

Troubleshooting Actions Development use only * Source of fault is defined by the Error Code accompanying the fault Make sure a new job with allocation is available to print. If this fault followed a missed print warning, fix your product spacing to avoid this condition. Make sure system is setup so that there will never be more than 8 items in the print queue. Also, verify that the second Print Head in the line is setup and printing correctly. Verify product spacing, fixed spacing, and registration settings are configured such that the system will not attempt to begin a second print before the first is completed on PH2. Also, verify line speed and pack rate are within system capabilities. Either decrease print density or print speed. Either decrease print density or print speed.

Error communicating with Print Head 2.

Check cables and reboot the system.

There was a problem during the upgrade of the print head. The print head will not contain valid firmware. There was a problem during the upgrade of the print head. The print head will not contain valid firmware Imaging engine was not able to deliver a new image in time for the required print. Imaging engine returned a fault error code.

Repeat the upgrade process.

Two scanner ports have been set up to perform the same operation.

This is an invalid configuration so the last scanner port configured has been automatically disabled by the system. Verify that system parameters and physical setup related to printing and barcode verification are correct. System must be restarted to clear this error. Call Markem-Imaje.

The maximum number of consecutive verification failures for Print Head 1 has been reached. The system has encountered an irrecoverable software error.

Repeat the upgrade process. Alter system setup parameters to decrease pack rate to within maximum system specifications. Verify that the image file is properly formatted.

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

Troubleshooting Actions

19101

Print Head 2 Verification Failure

19201

Verification Failure

21302

Invalid Job Settings File Print Head 1 MCPAP Version Mismatch

The maximum number of consecutive verification failures for Print Head 2 has been reached. The maximum number of consecutive verification failures for both print heads has been reached. Job settings file could not be applied.

Verify that system parameters and physical setup related to printing and barcode verification are correct. Verify that system parameters and physical setup related to printing and barcode verification are correct. Possible reasons may include syntax errors, invalid setting IDs, or invalid setting values. Upgrading the print head and/or controller with compatible software is required to continue

21502

21602

Print Head 2 MCPAP Version Mismatch

21901

Print Trigger Sequence Fault Clearable Software Fault Incompatible Software fault

22503 22613

22711 22812

Supply Reservoir Ink Out Supply Reservoir pressure leak

23101

PH1 Verification Spacing Fault

23201

PH2 Verification Spacing Fault

23612

Ink fill timeout (5600)

The print head firmware and the controller firmware are incompatible due to a mismatch in the MCPAP versions. The print head firmware and the controller firmware are incompatible due to a mismatch in the MCPAP versions. Print Go signals have been received out of sequence. The controller has received a minor software fault. The software that is loaded is not appropriate for the printhead hardware

Upgrading the print head and/or controller with compatible software is required to continue Check trigger sensitivity and system setup. Please clear the fault to continue operation.

The Ink container is empty.

*The printhead hardware is specified by a code programmed into the statistics module PCA. This fault indicates that the ink type of the software does not match the ink type of the jetting assembly. Alternately it can mean that the orientation of the jetting assembly does not match the orientation supported by the software. On new printheads this can also mean that the statistics module has not been programmed with the hardware configuration key. The printhead will need to be returned to Markem-Imaje for service. Insert a full container to resume printing

The Supply Reservoir has a pressure leak.

5800 - Check the door seal for debris or residual ink that may cause a leak.

Another scanner trigger has occurred before the on-distance for the previous scan completed. Another scanner trigger has occurred before the on-distance for the previous scan completed. The Primary reservoir could not be filled from the Supply Reservoir in the allotted time.

-Check the Supply Reservoir plumbing for loose connections or leaking hoses Adjust package spacing. Adjust package spacing. *No ink in the supply reservoir. This will usually cause air to be blown out the jetting orifices (hissing) during the fill cycle. It usually will cause a Low Vacuum fault since the primary reservoir will become

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Section 7 - Troubleshooting Fault ID

Fault Name

Synopsis

Troubleshooting Actions pressurized with air: 5600 – Install a new ink cartridge * Defective Primary Reservoir Ink Level Sensor. The primary reservoir has actually been filled (probably overfilled) but the level sensor is not registering the new level - Remove the Print Engine Cover then the Low Vacuum hose from the primary reservoir; insert a dipstick to measure the ink volume. If more than 10 mm of ink is present, the ink level sensor is not functioning correctly. Ensure a flood condition does not exist (low vacuum hose is filled with ink). If a flood has occurred, repair using the Printhead tubing kit or the printhead will need to be returned to Markem-Image for service. * Solenoid S3 is malfunctioning - Ensure the light on Solenoid 3 changes state when the manual control for solenoid 3 is turned on and off * Restrictor R5 is blocked - If R5 is blocked the system will not measure any ink or will measure an abnormally low volume of ink compared to the actual level of ink. If blockage cannot be cleared, the printhead will need to be returned for service. * High Pump failure - Enable the high pump using a manual control with its output hose removed. Ensure it outputs a stream of air * Filter F1 is blocked - If this is blocked, the system will not do a purge either. Replace the filter. * Filter F3 is blocked - If the Supply Reservoir Pressure rises to at least 345 millibars (5psi) during a fill cycle and there is sufficient ink in the supply reservoir, F3 could be plugged. * Restrictor R6 is blocked - If the Supply Reservoir Pressure rises to at least 345 millibars (5psi) during a fill cycle and there is sufficient ink in the supply reservoir, R6 could be plugged

23701 23801 23901

Too many files in file system Image Not Loaded TU Look Up Scan Failed

Too many files in file system performance suffers. No image loaded when tried to print. TU look up scan failed.

Delete unused files to make more file space available Check TU look up setup. Check scanner setup and position.

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Section 7 - Troubleshooting Fault ID

Fault Name

24301

Job Queue Full

24401

Select Job Flexible Input Error

24601

PackML Flexible Input Error

24701

TU Lookup Spacing Fault

24801

Flexible I/O Mapping File Parse Error

25001

Fixed Spacing Setup Fault

25101

Remote Encoder Setup Fault

25201

Remote Product Sensor Setup Fault

Synopsis The job queue is already full; no more jobs can be added. A SELECT JOB flexible input was activated while the OK TO SELECT NEXT JOB flexible output was deactivated. The correct PackML state transition could not be determined due to the controller receiving multiple PackML flexible inputs at the same time. Another scanner trigger has occurred before the on-distance for the previous scan completed. Problem parsing the flexible I/O mapping XML file. One print head is setup to use fixedspacing and the other is setup to use an external product sensor. The print head has been setup to use a remote encoder. Since there is only once print head attached, this is not a valid configuration. The print head has been setup to use a remote product sensor. Since there is only once print head attached, this is not a valid configuration.

Troubleshooting Actions Reduce the number of jobs in the queue. This indicates that the previously selected job was not printed before selecting the new job. PackML flexible inputs need to be asserted individually in order to execute the correct state transition. Check your print spacing, scanner delay distance, and on-distance settings. Please check the content of your Flexible I/O Mapping File and make sure it is formatted correctly. This may result in print sequencing errors if care is not taken to ensure triggers remain consistent throughout the print process. Please setup the print head to use its Local Encoder or Internal Encoder. Please setup the print head to use its Local Product Sensor or Fixed Spacing.

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Section 7 - Troubleshooting Thermistor Resistance Application

Supply, Primary, Array Thermistor

Ink Level Sensor Thermistor

Nom R +/-25°C

100,000 Ω

5,000 Ω

Temperature °C 0 10 20

Resistance Ω 351,000 207,800 126,700

25 30 40 50 60 70 80 90

100,000 79,430 51,060 33,598 22,593 15,502 10,837 7,710

100 105 110 115 120 125 130 135 140 145 150 160 170

5,574 4,767 4,092 3,525 3,047 2,642 2,299 2,006 1,756 1,542 1,358

Temperature °C 180 190 200

Resistance Ω

Resistance Ω 15,000 9,760 6,517 (+/5%) 5,369 4,448 3,099 2,202 1,593 1,171 875 662 (+/8%)

508 447 395 350 310 276 247 221 198 178 160 135 113

Resistance Ω 94 80 68

Heater Resistance Jetting Array - 50Watt

10.3Ω - 12.07Ω

Primary Reservoir - 100Watt

5.18Ω - 6.05Ω

Supply Reservoir - 100 Watt

5.18Ω - 6.05Ω

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Section 8 Electronics

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Section 8 - Electronics Definitions Static Electricity • •

Is an electrical charge caused by an imbalance of electrons on the surface of a material Damage occurs only when it is discharged (ESD)

ESD • •

ESD = Electro Static Discharge It is the transfer of a static charge between bodies at different electrical potentials

• •

Ground = A place for electrons to go Types of Ground o Earth ground o ESD ground o Common ground o Electrical system ground o Water pipe o Building ground o Chassis ground

Ground

8.1 Electrical Layouts

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Section 8 - Electronics

X8

X9

X1

X2

X3

X4 X10

X5

X6

X7

X11

TP1 V29

V18 BATTERY TP3

V34 V35 X17 V36 TP7

TP2

X14

TP5 TP6

X20

X18 TP15 TP18

TP4

X13

J12 X19

RESET V27 SWITCH V28 V30 V32 V31 V33

MICRO- X16 PROCESSOR

TP19

TP14 TP17

V42 V46 V47

Figure 1 - 5600/5800 Controller PCA Connectors, LED's and Test points

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Section 8 - Electronics User accessible (external) controller PCB connectors: Number Type Function X1 20 pin mini-D Printhead 1 communications link (LVDS) X2 20 pin mini-D Printhead 2 communications link (LVDS) X3 15 socket high density D- Scanner 1 sub X4 15 socket high density D- Scanner 2 sub X5 15 socket standard OEU power and communications density D-sub X6 9 socket standard density RS-232 Host port communications D-sub X7 15 pin standard density D- Fault, Warning and Reject relays sub X8 USB Type A USB upstream port for FLASH memory devices (USB sticks) X9 USB Type B USB downstream port for connection to CoLOS. X11 8 pin RJ45 connector Ethernet 10/100 Base – T Local Area Network Controller Connectors used for internal wiring Number Type Function X10 8 pin header 24VDC Power and RS-232 configuration port to wireless LAN. X14 4 pin Molex Signal tower harness connector X17 8 pin RJ45 connector Ethernet 10/100 Base – T Wireless LAN connector. X18 6 pin header 24V DC power in from switching power supply J12 50 pin FFC (Flexible LCD signals, touch screen SPI port, 24V power, 3.3V Flat Cable) power, backlight driver controls.

Number Type X13 3 pin jumper X16 3 pin jumper

Controller PCB configuration jumpers Function Settings Backup battery enable 1-2 Enable battery (default) jumper Factory programming 2-3 FUU upgrade disable (Default) jumper

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Section 8 - Electronics Number X19 X20

Connectors used for manufacturing and engineering debug Type Function 10 pin header JTAG programming port for programmable logic. 14 pin header Power PC BDM port Test Points Number Function TP1 0V TP2 0V TP4 +1.2V TP5 +3.3V TP6 +24V TP7 0V TP14 0V TP15 +5V TP17 +1.8V TP18 0V TP19 +3.3V

Number Function V18 USB-B Good Link V27 V28 V29 V30 V31 V32 V33 V34 V35 V36

+3.3V Power On FPGA-LED3 External Ethernet port speed FPGA-LED2 FPGA-LED1 RESET Firmware Upgrade LED WiFi Ethernet port Speed WiFi Ethernet port link WiFi Ethernet port Receive

On Board LEDs Interpretation Blinks when a USB host is first connected to X9 and then is steady on when the connection is complete. On steady when the +3.3V power is on Spare Off = 10 Base – T On = 100 Base – T Spare FPGA Heartbeat (blinks every two seconds) On when system is in reset Blinks when the firmware is being upgraded, otherwise normally on. Off = 10 Base – T On = 100 Base – T On when an Ethernet link is present Blinks when Ethernet communications occur.

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Section 8 - Electronics Number V42 V46 V47

Function Power PC LED1 Power PC LED3 Power PC LED2

On Board LEDs Interpretation Spare Spare Spare

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Section 8 - Electronics

Figure 2 - 5600/5800 LCD-IO PCA Connectors, LED’s and Test Point

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Section 8 - Electronics Number Type X1 4 pin FFC (Flexible Flat Cable) X2 4 pin FFC (Flexible Flat Cable) X3 33 pin FFC (Flexible Flat Cable) X4 50 pin FFC (Flexible Flat Cable) X5 5 pin header

PCB connectors: Function LED Backlight Touch Screen interface Power and control signals to LCD LCD signals, touch screen SPI port, 24V power, 3.3V power, backlight driver controls from main controller PCA Keypad connector Test Points

Number TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11

Function LED Backlight anode drive voltage (common anode) LED String #3 cathode return current LED String #2 cathode return current LED String #1 cathode return current LCD brightness control PWM (+3.3V = 100% brightness) +5V (generated by U1 for internal operation) +3.3V Ground LCD Enable LCD Clock Vee (16V-19V)

Reference PCA # 10032984 Schematic # 10032986

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Section 8 - Electronics

Figure 3 - 5600/5800 Print Head PCB Components and Test Points Top Side

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Section 8 - Electronics

Figure 2 - 5600/5800 Print Head PCB Components and Test Points Bottom Side

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Section 8 - Electronics User accessible PCB connectors: Number Type Function X13 9 Pin D-Shell Product Encoder X19 22 pin HD LVDS comms connection to controller S1 Push button Jet Test S2 Push button Ink Purge Connectors used for internal wiring: Number Type Function X1 2 pin header +24VDC supply from controller X2 4 pin header 24V AC to Supply Reservoir heater X3 5 pin header Statistics EEPROM connection X4 5 pin header Jetting and primary reservoir Thermistors X5 2 pin header Supply reservoir Thermistor X6 2 pin header 24V AC supply from controller X7 6 pin header 24V AC supply to primary reservoir and jetting assembly heaters. 24 AC return. X8 8 pin header Jetting assembly connection; Clock, Data, Strobe (high voltage) X9 8 pin header Jetting assembly connection; Clock, Data, Strobe (high voltage) X10 8 pin header Jetting assembly connection; Clock, Data, Strobe (high voltage) X11 8 pin header Jetting assembly connection; Clock, Data, Strobe (high voltage) X15 4 pin header ILS sensor and Ink Flood sensor connection X16 4 pin header Product Sensor (terminates to panel mount M12) X20 4 pin terminal block HI and LOW pump connection X21 14 pin terminal block Solenoid and ink door switch connection U5 Vacuum sensor Low vacuum sensor U6 Vacuum sensor Supply reservoir pressure sensor (ink level) Print Head Programming and Debug connectors: Manufacturing/Engineering only Number Type Function X12 10 pin header CPLD JTAG connection X14 4 pin header Processor debug port X17 10 pin header Processor JTAG connection X18 4 pin header Processor programming port

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Section 8 - Electronics LEDs: Number Type Function V4 Green SMT Processor status LED V8 Red SMT Processor fault LED V11 Green SMT Product trigger LED V10 Green SMT Encoder channel 1 LED V14 Green SMT Encoder channel 2 LED Service accessible test points, top side: Number Type Function TP1 Probe hook +5V DC TP2 Probe hook Digital ground TP3 Probe hook +200V DC (high voltage for strobe drive) TP4 Probe hook Digital ground TP5 Probe hook Digital ground Service accessible test points, bottom side: Number Type Function TP6 PCB pad High voltage current draw TP7 PCB pad +24V DC TP8 PCB pad Print head data2 TP9 PCB pad Print head data 1 TP10 PCB pad +12V DC TP11 PCB pad High voltage strobe TP12 PCB pad Print head clock TP13 PCB pad +3.3V DC TP17 PCB pad Product trigger channel B TP18 PCB pad Product encoder channel 2 TP19 PCB pad Product encoder channel 1 TP20 PCB pad Product trigger channel A TP21 PCB pad Manual reset

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Section 8 - Electronics F1

X1

F2

F3

X2

F4

X3

X4

X6 X7 X5

X10

X8

X9

Figure 4 - 5600/5800 Power Distribution Board PCA Connectors and Fuses

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Section 8 - Electronics

Number X1 X2 X3 X4 X5 X6 X7 X8 X9 X10

Number F1 F2 F3 F4

Type 2 pin 3 pin 2 pin 6 pin 3 pin 3 pin 6 pin 6 pin 3 pin 5 pin

PCB connectors Function 24V DC out to printhead 1 24V AC in from transformer 24V DC out to printhead 2 24V DC in from power supply 24V AC out to printhead 1 24V AC out to printhead 2 115/230 tap AC Mains out to transformer 100/200 tap AC Mains out to transformer AC Mains out to power supply AC Mains input

Fuses Type 4A 250V time delay fuse 4A 250V time delay fuse 12.5A 250V time delay fuse 12.5A 250V time delay fuse

Function 24VDC to Printhead 2 24VDC to Printhead 1 24VAC to Printhead 1 24VAC to Printhead 2

Reference PCA # 10034976 Schematic # 10034975

8.2 Schematics

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Section 8 – Electronics 8.3 Flow Block Diagrams

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Thermistor Resistance

Application

Supply, Primary, Array Thermistor

Ink Level Sensor Thermistor

Nom R +/25°C

100,000 Ω

5,000 Ω

Temperature °C 0 10 20 25 30 40 50 60 70 80 90 100 105 110 115 120 125 130 135 140 145 150 160 170 180 190 200

Resistance Ω 351,000 207,800 126,700 100,000 79,430 51,060 33,598 22,593 15,502 10,837 7,710 5,574 4,767 4,092 3,525 3,047 2,642 2,299 2,006 1,756 1,542 1,358

Resistance Ω 15,000 9,760 6,517 (+/-5%) 5,369 4,448 3,099 2,202 1,593 1,171 875 662 (+/-8%) 508 447 395 350 310 276 247 221 198 178 160 135 113 94 80 68

Heater Resistance Jetting Array - 50Watt

10.3Ω - 12.07Ω

Primary Reservoir - 100Watt

5.18Ω - 6.05Ω

Supply Reservoir - 100 Watt

5.18Ω - 6.05Ω

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Section 9 Hydraulics

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Section 9 – Hydraulics 9.1 Hydraulic / Pneumatic Layout Print Density Options Density Selection 1 2 3 4 5 6 7 8

(DPI) Dots/Inch 150 300 450 600 750 900 1050 1200

Max. Speed mm/sec 2032 1016 677 508 406 339 290 254

Max. Speed Meters/Min 121.9 61.0 40.6 30.5 24.4 20.3 17.4 15.2

Max. Speed in/min 4800 2400 1600 1200 960 800 686 600

Max. Speed Feet/Min 400.0 200.0 133.3 100.0 80.0 66.7 57.1 50.0

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Section 9 – Hydraulics 5600 Liquid Fluid Diagram Part Number 10028105 Rev. AF

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Section 9 – Hydraulics 5800 Hot Melt Fluid Diagram Part Number 10026316 Rev. AH

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Section 9 – Hydraulics Notes:

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Section 10 Software & Connectivity

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Section 10 – Software & Connectivity 10.1 CoLOS Downloading CoLOS images with CoLOS Create / Create Pro 1. From “File” menu select “Download”.

2. Select “Next” at the Download Wizard Welcome page.

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Section 10 – Software & Connectivity 3. If no device (Printer) has been added to the system, proceed with the Add Device Wizard by selecting “Next”. If a device has already been set up then proceed to step 9.

4. Choose the device you wish to add to the program, first by choosing the machine series, then by selecting the specific device. Select “Next” to proceed.

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Section 10 – Software & Connectivity 5. The description will automatically populate with the default device name. This can be changed to any name the user wishes to identify this device or it can be left as the default. Select “Next” to proceed.

6. Select “Associate new connection with device” to set connection properties. Select “Next”

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Section 10 – Software & Connectivity 7. On the left side of the screen, select Ethernet as the connection type. Then apply the appropriate IP Address and Port number. The port for the 5x00 is 3836.

Connection Method IP Address

Port

8. Complete the “Add Device Wizard” by selecting Finish.

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Section 10 – Software & Connectivity 9. Once the “Add Device Wizard” is complete, the Download Image Wizard will run. Select “Next” to proceed.

10. Highlight the icon for the desired device and select “Next”.

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Section 10 – Software & Connectivity 11. Select “Download”. Select “Next” to proceed.

12. Highlight the desired job in the left hand column. If applicable, a settings file may be attached to this file by browsing to the appropriate file using the browser. The browser is enabled by clicking once on the “Settings File” line then clicking the ellipsis.

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Section 10 – Software & Connectivity 13. Review the job to be downloaded. If the job is acceptable, select “Next” to proceed. If the job is not satisfactory, select “Back” to change.

14. To Complete the Image Download, select “Finish.

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Section 10 – Software & Connectivity 15. The System Activity will appear on the bottom of the screen. This will allow you to monitor the progress of the download. The “Status” will state the percentage of download completed then will respond with “Successful” of “Failed”. If the reply is “Failed” verify the correct device connection properties.

Status

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Section 10 – Software & Connectivity 10.2 Downloading CoLOS Create files to USB Device 1. Insert the USB storage device in the desired PC port. Select “Print to File” from the File menu.

2. If the device has already been added to the system, proceed to step 8. If the device is not present, select “Add” to set up the device

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3. At the “Add Device Wizard” screen, select “Next”.

4. Select 5000 series from the column on the left then select 5600 or 5800 from the column on the right. After selecting the printer, select “Next”.

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2 1

3

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Section 10 – Software & Connectivity 5. Enter a description of the 5600/5800 – This can be any name or description of which the operator chooses to identify the device. Select “Next”.

6. Select “Do not associate a connection at this time”; then select “Next”

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Section 10 – Software & Connectivity 7. Select “Finish” closing out the Add Device Wizard

8. The 56/5800 machine icon should now appear in the “Printers” window. Highlight the icon (A), check the “All Jobs” box (B), the select “Send” (C).

B

C

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Section 10 – Software & Connectivity 9. Use the browser to locate the USB storage device. Select the device and select “OK”.

The CoLOS files will now be sent to the USB device. They are now ready to be downloaded to the 56/5800. 10. Insert the USB device in the USB A port of the 56/5800.

11. From the Home screen select “Menu”.

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Section 10 – Software & Connectivity 12. Select “File Management”

13. Select “Copy Files”

14. Select “Copy Jobs from USB”

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Section 10 – Software & Connectivity 15. A confirmation screen will appear to verify that files will be copied to the device. Select the blue check to proceed or the blue “X” to cancel.

Selecting the blue check will send the files to the 56/5800. The jobs may now be accessed through the “Select Jobs” options on the User Interface;

Job Select soft key on the front panel or

Select Job key

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Section 10 – Software & Connectivity 10.3 Web User Interface Connecting to the 5600/5800 Web UI The 5600/5800 has in integrated Web based User Interface which can be utilized through an Ethernet connection. If the 5600/5800 is already on a network, the user will only need to enter the IP address of the printer into the web browser of a networked PC. If the PC is not on the network, the following procedure will allow the user to make a point to point connection to use the Web UI feature: This process requires the IP address assigned to the 5600/5800 controller. If this address is not yet known, it can be found using the following path: 1. 2. 3. 4. 5.

From the “Home” screen, select “Menu”. Next select “Settings” Now select “Machine Settings” Using the Blue arrows, toggle to the tab labeled “Comms”. Within the “Comms” menu you will find the IP address and Subnet.

To connect to the Web UI with point to point connection: 1.

From the Start menu on your PC, select “Network Connections”.

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Section 10 – Software & Connectivity 2. Select the appropriate Local Area Connection.

3. Select the “Properties” tab.

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Section 10 – Software & Connectivity 4. Scroll trough the list and highlight the option for “Internet Protocol” and select the “Properties” button.

5. Select the option for “Use the following IP Address”. ~Next input an IP address that’s in the same range as the 56/5800 but is still unique to avoid and IP conflict. For example: if the printer has an IP Address of 10.0.0.15, set the IP Address of the PC to 10.0.0.20 6. ~Input a subnet mask to match that used in the printer. Next select “OK” You may now close all of the “Network Connection” windows.

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7. Type the IP address assigned to the 56/5800 into the browser on your PC.

8. If connected properly the following screen will appear and the WEB UI interface is ready for use.

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Section 10 – Software & Connectivity 10.4 Scanner Interface Utilities Verification Scanner Setup 1. From the “Home” screen select “Menu”.

2. Select “Settings”

3. Select “Machine Settings”

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Section 10 – Software & Connectivity 4. Using the blue arrow, scroll across and look for “Serial Ports”. Highlight “Scanner Port 1 Mode” and select the Notepad.

5. Highlight “PH1 Verification Scanner” and accept.

Note: This setup is just one example. Either printhead can be assigned to any one of the scanner ports.

6. Select “Home” to return to the Home screen.

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Section 10 – Software & Connectivity 7. Select “Menu”

8. Select “Settings”

9. Select “Machine Settings”.

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Section 10 – Software & Connectivity 10. Use the blue arrow to scroll across until you find “Verification” which has now become active since enabling the scanner port. Highlight the desired parameter and touch the notepad to alter the Verification settings per the application requirements and accept.

The Scanner Port(s) should now be set up for use. Return to the Home screen to resume operation.

10.5 Connectivity Parameters Introduction This document describes power supplies and the input and output ports on the LCIJ 5600/5800 series of printers: -

Control Box Input/Output Ports Signal Tower Network (Ethernet) interface Relay Outputs RS-232 Host communications OEU Interface Scanner connectors (2) Print Head 1 & 2 communications interface USB Device Interface USB Host Interface Print Heat 1 & 2 Power supplies AC Mains input Power Board Voltage Conversion for 100/200V operation. Printhead Input/Output ports Encoder Interface Product Sensor Interface Communications interface Power connection Control Box Input/Output Ports

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Section 10 – Software & Connectivity Signal Tower The Status Beacon/Signal tower interface provides three 24V, active high outputs intended to drive a signal tower. The ex-Imaje LED signal tower is the standard equipment for the LCIJ control box. The signal tower connector on the outside of the control box is part of harness number 10038870 and uses a circular DIN connector with the following pinout: Table 1 - Signal Tower External Connection Pin Number 1 2 3 4 5

Description 0V (signal return) Light #1 No Connection Light #2 Light #3

The signal tower harness connects to the control board via right angle header X14 with the following pinout: Table 2 - Signal Tower Internal board Connection Pin Number 1 2 3 4

Description 0V (signal return) Light #1 Light #2 Light #3

Each output produces +24V when the output is on and 0V when the output is off. The signal tower driver is based on the Infineon BTS716G driver chip and is fault protected for direct shorts to 0V. Each signal tower output is rated for 5W at 24V (208mA).

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Section 10 – Software & Connectivity Network (Ethernet) interface The Ethernet interface is a standard 10/100 network interface provided by RJ45 connector X11 mounted on the control board. The shield of this connector is connected to chassis ground and the common 0V potential of the controller. Indicators are provided for RECEIVE (left LED, yellow) and LINK (right LED, green) status. The RECEIVE LED indicates that the port is receiving Ethernet data. The LINK LED indicates that the port is enabled and connected to another active port. If the light is off, this port is either not connected to an active port or the other port is disabled. There is no provision for power over Ethernet. Table 3 – Ethernet Network Connection Pin Number 1 2 3 4 5 6 7 8

Description Tx+ TxRx+ Termination Termination RxTermination Termination

Female

Relay Outputs Connector X7 on the control box is a 15 pin standard density male D-sub connector that provides three form-C dry contact relay outputs. Each relay is rated for +24V AC or DC at 100uA minimum to 2A maximum load. The shield of this connector is connected to chassis ground and the common 0V potential of the controller. Table 4 – Dry contact Relay Connector Pin Number Description 1 Warning Relay Common 2 Warning Relay Normally Closed 3 No connection 4 Fault Relay Common 5 Fault Relay Normally Closed 6 No connection 7 Verification Fail Relay Common 8 Verification Fail Relay Normally Closed

Pin Number Description 9 Warning Relay Normally Open 10 No connection 11 12 13 14 15

No connection Fault Relay Normally Open No connection No connection Verification Fail Relay Normally Open

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Section 10 – Software & Connectivity RS-232 Host communications Connector X6 on the control box is a 9 pin standard density male D-sub connector that provides an isolated RS-232 port for multiple uses such as NGPCL communications, wedge scanner interface and SICK scanner configuration. The port is galvanically isolated from the connected equipment on the connections to pins 2, 3 and 5. The shield of this connector is connected to chassis ground and the common 0V potential of the controller. Table 5 – Host Port Connector Pin Number 1 2 3 4 5

Description No connection Tx transmit Data (from controller) Rx receive Data (to controller) No connection RS-232 signal Common (isolated)

Pin Number 6 7 8 9

Description No connection No connection No connection No connection

OEU Interface Connector X5 on the control box is a 15 pin standard density female D-sub connector. The OEU interface is designed to connect to the Optional Expansion unit to provide a variety of expansion options to the controller depending on the application. This connector also provides an audible alarm output when the OEU is not connected. Table 6 – OEU Interface Connector Pin Number 1 2 3

Description +24Vdc power (0.36A Max load) Audible Alarm Output (+24Vdc Active High, 5W Max, fault protected) OEU_CS# (SPI Chip select, active low), LVTTL.

4

OEU_SCLK (SPI Clock) LVTTL

5

OEU_MOSI (SPI Master Out Slave In) LVTTL

6 7 8

OEU_MISO (SPI Master In Slave Out) LVTTL OEU Scanner Host Port Tx (RS-232) OEU Scanner Host Port Rx (RS-232)

Pin Description Number 9 OEU Scanner Terminal Port Tx (RS-232) 10 OEU Scanner Terminal Port Rx (RS-232) 11 OEU-GPO1 (general purpose output, 3.3V logic (LVTTL) 12 OEU-GPI1 (general purpose input, 3.3V logic (LVTTL) 13 OEU-GPI2 (general purpose input, 3.3V logic (LVTTL) 14 No connection 15 0V power/signal return

The shield of this connector is connected to chassis ground and the common 0V potential of the controller.

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Section 10 – Software & Connectivity Scanner connectors (2) Connectors X3 & X4 on the control box are a 15 pin high density female D-sub connectors. The scanner interface is designed to connect directly to the Sick scanners or to a Datalogic scanner use an adapter cable. The SICK scanners have two RS-232 serial ports, one for collection of scanned data (the HOST port) and another for scanner configuration (the TERMINAL port). On the 5600/5800 the terminal port is used in conjunction with the controller’s host port (X6) to allow the SICK application program to connect to the scanner without the need to disconnect the scanner from the controller. The scanner connectors also support two active high 24V inputs and one open collector output for optional use with the scanners. Table 7 – Scanner Interface Connector Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Description +24Vdc power (0.26A Max load) Terminal Port Tx (RS-232) Output to scanner Terminal Port Rx (RS-232) Input from scanner No connection 0V (power and signal return) No connection Host Port Tx (RS-232) Output to scanner No connection Host Port Tx (RS-232) Output to scanner No connection No connection Scanner Result 1 (Active High, +24V) Scanner Result 2 (Active High, +24V) Scanner Sensor (Open Collector, active low) 0V (power and signal return)

The shield of this connector is connected to chassis ground and the common 0V potential of the controller. Print Head 1 & 2 Communications Interface Connectors X1 & X2 on the control box are 20 pin female mini-D connectors designed to transmit up to 10 high speed differential pair LVDS signals. The LCIJ uses of 9 of these signal pairs. These connectors provide the serial communications to the print head’s microprocessor and also carry the clock, data and strobe signals to the jetting assembly. The encoder and product sensor signals are received prom the print heads on these connectors.

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Section 10 – Software & Connectivity Table 8 – LVDS communications to Print Head Pin Description Number 1&11 Transmit Data (MCPAP asynchronous communications) to print head. 2&12 Clock (to jetting assembly) 3&13 Data1 (to jetting assembly) 4&14 Data2 (to jetting assembly) 5&15 Strobe (to jetting assembly) 6&16 Receive Data (MCPAP asynchronous communications) from print head 7&17 Encoder A (from Printhead) 8&18 Encoder B (from Printhead) 9&19 Product Trigger (from Printhead) 10&20 Not Used (connected to 0V) The shield of this connector is connected to chassis ground and the common 0V potential of the controller

USB Device Interface Connector X9 is a USB Type B (downstream) device interface for use with the COLOS printer program. The USB operates at low and medium speeds. Table 9 – USB Device External Connection Pin Number 1 2 3 4

Description Vbus (5V) DataData+ Signal Common

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Section 10 – Software & Connectivity USB Host Interface Connector X8 is a USB Type A (upstream) host interface for use with memory sticks to transfer image data or program upgrades via the FUU. Table 10 – USB Host External Connection Pin Number 1 2 3 4

Description Vbus (5V) DataData+ Signal Common

Print Heat 1 & 2 Power supplies The power to the print heads is provided by high power connectors via harness 10037750. 24V DC is provided to power the print head electronics, pumps and valves. 24V AC is provided to power the heaters. The DC Current drawn by the print heads is 0.9A @24Vdc. AC current drawn by the heaters is 8.3A. Software and hardware in the print head prevents all three heaters from turning on at the same time. Table 11 – Power Connection to Printhead Pin Number 1 2 3 4 5

Description +24V DC @ 0.9A DC Return 24VAC @ 8.3A AC return Chassis

AC Mains Input The AC mains input is a standard filtered input module with a universal input connector. The fuse tray permits switching between 115 or 230V mains. The fuse size for 100V and 115V is 8A, for 200/230V is 4A. Note that the 24V DC supply operates over 90-240V AC input range. The system will appear to be fully functional if 115V is applied to a system configured for 230V; however the heaters will only see half-voltage (12V) and so will be starved of power.

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Power Board Voltage Conversion for 100/200V operation. The system is shipped from the factory configured for 230V operation. It can be configured for 100V/200V operation by moving the connector on the power board from X7 (default location) to X8 and setting the fuse location appropriately.

115v/230v

100v/200v

Printhead Input/Output ports Encoder Interface Product Sensor Interface

10.6 NextGen Communications Protocol Comparison Introduction NextGen Printers has been designed to be easily integrated with OEM equipment. There are several different options available, depending on the level of integration required. Two different communications protocols are supported: the Device Communication Protocol (DCP) and the NextGen Printer Control Language (NGPCL). A software application can use these protocols to configure and control the printer remotely. Two protocols are supported as each provides differing

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Section 10 – Software & Connectivity functionality suited to particular applications. Each is briefly described below, before presenting a table defining the specific functionality that can realized in each. The Device Communication Protocol (DCP) The Device Communication Protocol is an XML-based protocol allowing the host machine to take full control of the printer. This protocol is run over Ethernet using TCP/IP. Commands, responses and events within the protocol are variable length strings of 16bit Unicode characters. While DCP message lengths are comparatively higher than NGPCL, message content can be read more easily as command names are directly used (instead of codes) and arguments are named. DCP allows host applications to: -

send commands to the printer to control its configuration and operational state. listen for events sent by the printer to monitor its behavior and performance.

Request definitions of the printers’ functionality and how the printer can be configured (e.g. the list of available settings). As NextGen printers send unsolicited events over DCP, host applications concerned with monitoring the printer’s behavior need not operate a polling approach. Applications which listen for important events over DCP are expected to be more responsive and efficient compared to those which periodically send commands requesting required information. The DCP is best suited for full scale integrations where the OEM would like to hide the printer inside the host machine and provide the operator their own user interface. The NextGen Printer Control Language (NGPCL) The Next Gen Printer Control Language (NGPCL) is an ASCII-based protocol which provides secure communications and full handshaking. This protocol is run over and RS-232 serial data link. NGPCL messages sent to the printer can be of fixed or variable length while it is ensured that replies sent by the printer to the host application are always of a fixed length. NGPCL allows applications to send a limited set of commands to the printer to control and monitor its operational state. NGPCL is a light weight protocol best suited for integrations where the OEM system is using a PLC that does not have the processing power to support DCP. NGPCL is also a good choice for check/weigh type applications where the printed data is being updated every print at a high pack rate and systems where a barcode scanners is being used for job selection or for updating field data. DCP and NGPCL Command Comparison Table The follow table presents a breakdown of commands supported by DCP and NGPCL according to functional area.

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Section 10 – Software & Connectivity Functional Area File management

PackML Control

Job / Print Management

Settings Management

Diagnostic monitoring

Performance monitoring

Definitional Information Requests

DCP FileTransfer DeleteFile RequestFile RequestFileDirectoryListing RequestFileTimeAndDate RequestFileStats ChangeOperatingMode EnablePrinting DisablePrinting RequestPackMLStatus SelectJob SelectLocalJob UpdateSelectedJob RequestCurrentJobData RequestLoggedFieldData RequestFieldData RequestJobDownload ClearAllocation DeleteJobQueue RemoveJobFromQueue UpdateUserInputDefaults PrintOnce SetSettings RequestSettingValue RequestDefsetsFile RequestFacsetsFile RequestCursetsFile ResetSettings SetTimeDate RequestTimeDate DiagnosticCommand RequestStartDiagnosticsUpdate RequestStopDiagnosticsUpdate RequestCurrentDiagnostics

NGPCL Not supported

RequestCounts RequestSuppliesUpdate RequestLogFile RequestActiveEvents RequestStartStatisticsUpdate RequestStopStatisticsUpdate RequestCurrentStatistics RequestVersionInformation RequestStatisticsFile RequestDiagnosticsFile RequestDevcapsFile RequestConstraintFile RequestAppSpecificPrivilegesFile

Counts Request Device Status Request

State Change

JobSelect Job Request JobUpdate Field Request Logged Fields Request Print Go Print Status Request Clear to Send Data Request Allocation Clear

Setting Change Setting Request Clock Set Request Clock

Not Supported

Request Version

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Section 10 – Software & Connectivity Notes:

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Section 11 Inks & Consumables

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Section 11 – Inks & Consumables 11.1 Usage per Print Calculator Usage per Print Calculator information not currently available. Information will be added to subsequent revisions.

11.2 Ink Capabilities The 5601 Series ink is a fluid ink for the use in the Markem-Imaje Model 5600 Ink Jet printer. The ink absorbs into the porous substrate. The ink is available in black only and is supplied in a disposable sealed cartridge. The 5803 Series Touch Dry® jet ink is a hot melt ink for use in the Markem-Imaje Model 5800 Ink Jet printer. It dries ("solidifies") upon contact with the substrate. This ink is available in black only and is supplied as a puck in a plastic pouch. The 5803 ink is equivalent to the 5003 Series ink. The 5805 Series Touch Dry® jet ink is a hot melt ink for use in the Markem-Imaje Model 5800 Ink Jet printer. It dries ("solidifies") upon contact with the substrate. This ink is available in black only and is supplied as a puck in a plastic pouch. The 5805 ink is equivalent to the 5005 Series ink providing superior darkness, even at low density setting.

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Section 11 – Inks & Consumables Notes:

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Section 12 Bar Codes

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Section 12 – Bar Codes 12.1 TBD

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Section 12 – Bar Codes Notes:

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Section 13 Glossary

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13.1 Glossary of Terms 1. Allocation: An allocation is associated with a specific job and allows the user to tell the system how many times the job should be printed. 2. CoLOS: Markem-Imaje image creation and networking / control software 3. CPLD: Complex Programmable Logic Device 4. DCP: Device Communication Protocol - an XML-based protocol that allows between a Markem-Imaje machine and a host device

communication

5. Density: Also referred to as Print Density; This is the volume of ink applied per dot. Higher Density settings will yield a darker print but will in turn decrease the maximum allowable print speed for a given job. 6. DPI: Dots per Inch 7. Flash: nonvolatile memory used to store files such as those needed for jobs and settings. 8. FPGA: Field Programmable Gate Array 9. FUU: Field Upgrade Utility 10. ITF: Image Template File (CoLOS) 11. Jet Test: testing procedure which fires all array jets to check their operation 12. Job: A named set of files required by the system to create the bitmaps to be printed 13. Job Queuing: An extension of the Allocation mechanism; allows automatic job during batch printing.

selection

14. LCIJ: Large Character Ink Jet 15. LVTTL: Low Voltage Transistor-Transistor Logic 16. LUI chars: This file is in xml format and consists of an ordered list of characters. This list determines what characters are shown and the order in which they are shown on the keyboard display 17. LVDS: Low Voltage Differential Signaling 5600/5800 Service Manual Rev. 02 November 2009

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18. MASP: Markem Active Server Page 19. MCPAP: Markem Communications Printer and Applicator 20. NextGen: Next Generation Project; the specification and development of the new architecture for Markem-Imaje PI Products 21. NGE: NextGen Embedded: the portion of NextGen relating to the embedded hardware platform, software tools, and delivered software modules. 22. NGPCL: Next Generation Printer Control Language - an ASCII-based protocol, used via RS232 or Ethernet to allow communication between a Markem-Imaje machine and a host device 23. NVRAM: Non-Volatile Random Access Memory 24. OEU: Optional Expansion Unit 25. PackML: Packaging Machine Language 26. Purge: Process of forcing ink trough the array to clear restrictions or contaminates 27. Print Queuing: accommodates installations where two printheads are used and their arrangement is such that they could be printing on different products simultaneously. The print queue is defined to encompass all products that reside between the very first and the very last connected peripheral in the system (including product sensors, print heads, scanners, and the reject mechanism). The size of the queue refers to the number of products between the printheads and includes any products registering or currently being printed. 28. Resolution: Image Quality referenced in DPI 29. SSCC: Serial Shipping Container Code 30. TU: Traded Unit / in reference to “TU Lookup” scanner 31. UI: User Interface 32. USB FAT: Universal Serial Bus / File Allocation Table 33. WebUI: Web based User Interface 34. XML: Extensible Markup Language – general purpose specification for creating custom markup languages. 5600/5800 Service Manual Rev. 02 November 2009

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Notes:

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Markem-Imaje 150 Congress Street Keene, NH 03431 Tel: 603-352-1130 Fax: 603-352-0596 http://www.markem-imaje.com P/N 10053366