Genesis single line Operation And Maintenance Manual Download Page 60

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4 -1

96622 Issue 4.0 Jan

PART 4: MAINTENANCE PROCEDURES

CONTENTS

SCHEDULED MAINTENANCE

Page 4–2

Short Periods of Shut-down

4–2

Long Periods of Shut-down

4–2

NOZZLE FACE CLEANING

4–2

CLEANING THE ARRAY PLATE

4–3

PRINT HEAD FLUSHING

4–4

PRINT HEAD DISASSEMBLY AND CLEANING

4–6

CLEAN AND INSPECT PRINT HEAD

4–8

PRINT HEAD ASSEMBLY

4–8

CONTROLLER MAINTENANCE

4–8

Battery Installation

4–8

Summary of Contents for single line

Page 1: ...1 GENESIS TM SINGLE LINE SMALL CHARACTER INK JET PRINTER OPERATION AND MAINTENANCE MANUAL...

Page 2: ...ation relates is in conformity with the following standards EN60950 1992 Safety of Information Technology Equipment including Electrical Business Machines EN50082 1 1992 Electromagnetic Compatibility...

Page 3: ...e highly inflammable Clean up all ink spillage immediately Do not allow the ink to dry O Do not use the printer in wet or explosive environments For basic start up and maintenance instructions please...

Page 4: ...r transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior permission of Digital Design Inc Digital Design has a policy of continuous product...

Page 5: ...INK JET PRINTER OPERATION AND MAINTENANCE MANUAL TABLE OF CONTENTS Description Part 1 Installation Procedures Part 2 Operation Procedures Part 3 Maintenance Procedures Part 4 Troubleshooting Part 5 Op...

Page 6: ...6 96622 Issue 4 0 Jan 01 AMENDMENT RECORD Amendment Date All Parts at Issue 2 0 October 95 All Parts at Issue 3 0 October 96 All Parts at Issue 3 1 January 99 New Bracket at Issue 4 0 January 01...

Page 7: ...3 PRINTER SPECIFICATIONS 1 4 Print Characteristics 1 4 Print Head 1 5 Print Station 1 5 Data Input 1 5 Environmental Conditions 1 5 Electrical Supply 1 5 General 1 5 PRINT HEAD 1 6 PRINT STATION 1 6 I...

Page 8: ...DESCRIPTION 1 2 96622 Issue 4 0 Jan 01...

Page 9: ...rol panel The control panel is the top of the print station it consists of a small LCD and six touch activated keys External connections are made from the top of the print station The controller is un...

Page 10: ...5 mm 7 x 5 3 32 2 5 mm 9 x 7 1 8 3 2 mm Message Length 32 characters Print Head to Product Distance Up to 1 4 Up to 6 35 mm Optional Features O Operations kit O Floor stand O Dairy bracket and photoel...

Page 11: ...3 1 8 247 6 mm x 88 9 mm x 79 4 mm Weight 1 lb 10 oz 75 kg Control Panel Membrane touch button SERIAL DATA INPUT Interface RS485 Rate 9600 baud ENVIRONMENTAL CONDITIONS Temperature Range 40 F 100 F 5...

Page 12: ...he formation of the ink droplets care should be taken when handling it PRINT STATION The SINGLELINE print station is the brains of the system The print station contains a circuit board an LCD and exte...

Page 13: ...onal bracketry for the eye is provided and when mounted on this bracket the eye is fully adjustable in all print attitudes BRACKETRY The bracketry for the SINGLELINE printer allows the operator to mou...

Page 14: ...oding 2 3 Side Coding 2 6 Bottom Coding 2 7 INSTALLING INK SUPPLY 2 9 PRIMING THE SYSTEM 2 10 ADJUSTING PRINT HEAD ANGLE 2 10 ADJUSTING PRINT HEAD TO INK CARTRIDGE 2 10 INSTALLING THE PHOTOELECTRIC DE...

Page 15: ...96622 issue 4 0 Jan 01 Note The printer must be installed near to the socket outlet into which it will be plugged Access to the socket outlet must be easily gained from the printer CAUTION Double pol...

Page 16: ...coding The kit Part 96293 01 contains the following pieces of bracketry see Part 7 Parts Lists for part numbers O a dovetail extension plate O an extension bar O piece of tubing O all necessary hardw...

Page 17: ...dovetail plate Tighten the nylon tipped screw With a 9 64 Allen wrench loosen the socket head screw and disengage the dovetail and pivot mount of the print head assembly Set this steel screw aside fo...

Page 18: ...in the mounting kit and install having threaded the ink line clamp onto this new piece of tubing Before inserting the ink cartridge into the ink well we recommend flushing the system with 3400 solven...

Page 19: ...unting kit Please note it is recommended that the printer be mounted in an area free of dust that has easy access for maintenance and programming Bolt the mount base onto the line using the hardware p...

Page 20: ...side remove the door The print station and the ink assembly will be mounted on the inside where the door is was From the bottom coding mounting kit find the ink septum mounting plate Part 96315 01 and...

Page 21: ...eye block mount the block For older units without these holes use the block as a template and drill two holes for 10 32 screws Ideally the photoelectric eye will be positioned just before the print he...

Page 22: ...solvent Difficulties in printing will result if excess solvent remains in the print head After this operation you are ready to prime the system Instructions for priming are found after installation of...

Page 23: ...ent screw after the desired print head angle has been set ADJUSTING PRINT HEAD TO INK CARTRIDGE Make sure to turn off the print station The height of the ink cartridge is crucial for proper ink flow t...

Page 24: ...o the right of the on off switch lies the 115V 230V switch With the screwdriver ease off the black plastic access plug With this port fully open the 115V 230V switch is visible Using the screwdriver t...

Page 25: ...ated on the cable is a grommet bushing This bushing fits into the hole vacated by the plug Insert the bushing into the hole and turn until tight Close the box taking care to place the gasket around th...

Page 26: ...When the encoder is in use the parameter Character Width will be unavailable The print station LCD will then display three dashes in lieu of the character width icon For assistance in installing the e...

Page 27: ...3 8 PROGRAMMING 3 9 Definitions 3 9 Setting Up Basic Parameters 3 10 Set Date 3 11 Set Time 3 11 Menu Structure 3 12 Editing Print Parameters 3 13 F1 Menus 3 13 AIMS Control 3 14 Multi Dots 3 14 Chara...

Page 28: ...Entering the Time in the Message 3 26 Entering a Sequential Number in the Message 3 27 Entering the Shift Code in the Message 3 27 Entering Special Symbols in the Message 3 28 Deleting the Message 3 2...

Page 29: ...OPERATIONS 3 3 96622 Issue 4 0 Jan 01...

Page 30: ...s important that the lenses of both the print station and the Controller see each other The 6 keys are described This is the print enable disable key Use it to start and stop printing This is the purg...

Page 31: ...will imprint as are the space key the period and the colon Special characters can be accessed by the S1 and S2 keys This key is called the Message Storage key You will use it to store individual codes...

Page 32: ...re are seven font choices for the SINGLELINE use this key to select the font for all or part of the code This is a dual function key In Message Entry Mode this is the Sequential Number key For the SIN...

Page 33: ...means the print head is ready to print If however it is desired to have the print head powered up but not able to print in a print disabled mode press the print enable disable key on the print station...

Page 34: ...for Genesis AIMS is a system designed to prevent the ink that is exposed to the atmosphere from clotting in the nozzle face AIMS can be adjusted to fit the environment of your production line Right af...

Page 35: ...he Controller keypad Each function key contains three or four parameters which are described fully in the next section When inputting the values for parameters that will determine what the printer wil...

Page 36: ...on the display Using the left and right arrow keys the language options will scroll across the display To accept a language the Enter key is pressed Once the Enter key is pressed after a parameter is...

Page 37: ...r wait until you have finished loading all data into the Controller and transfer all to the print station at the same time SET TIME In order to load the time into the print station press the Time key...

Page 38: ...ressed brings up the following parameters In order to select one of the parameters press the number key that corresponds to the desired parameter Inputting these values is explained after this section...

Page 39: ...will disappear on the Command Mode screen F1 MENU The parameters listed under the F1 key are shown in the illustrated screen at left If while programming it becomes necessary to start anew reset the...

Page 40: ...lected press the enter key and your value will be accepted You can transfer this value immediately to the print station or wait until all parameters have been selected and then transfer the data to th...

Page 41: ...d The pulse mode will pulse all 9 nozzles at a variable number of pulses at variable time intervals in seconds The operator will input values for the number of pulses and then for the number of second...

Page 42: ...print station DIRECTION It is important to let the print station know in which direction the product will travel Upon selecting the Direction parameter the screen illustrated at left will appear If th...

Page 43: ...to a minimum 1 2 or 3 the ink being used is not suitable for such a low dot intensity Try a higher value for this parameter F3 MENU The parameters listed under the F3 key are shown in the illustrated...

Page 44: ...4 hour clock Once the values for start and stop times are correct press the N key The counter is automatically set for zero and after transferring this set of programmed instructions to the print stat...

Page 45: ...ond shift the printer will print 01 in the code and so on Similarly if the shift code is chosen to be A for the first shift at the start of the second shift the printer will print B in the code and so...

Page 46: ...key Press y Press y See dm dd dy on screen See mmm dd dy on screen Press Enter Press Enter For Julian Press j For January 95 Press m See jjj on screen Press space Press Enter Press y For 1 10 95 Same...

Page 47: ...ted screen at left If while programming it becomes necessary to start anew reset the print station shut it off and then while pressing the Print enable and Cycle keys turn the print station back on CA...

Page 48: ...u desire Upon acceptance of the value for Group the screen will appear as illustrated below The default value for Address is 1 the range of values is from 1 to 8 Once the desired value is displayed on...

Page 49: ...values for this parameter is from 1 dot minimum to 255 dots maximum Using the left or right arrow key the desired value can be found when done press the Enter key for acceptance Note There is a prope...

Page 50: ...t input into the queried print station ENTERING A MESSAGE To exit the Command Mode and enter the Message entry Mode press the Message entry key Upon doing this the screen of the Controller will look l...

Page 51: ...done the message is accepted by pressing the Enter key After acceptance the display on the Controller changes to The presence of the exclamation point indicates that the Controller contains data that...

Page 52: ...at is desired before inputting the date offset in the message To enter the date offset into the message in the Message Entry mode press the Product Delay key Notice the date format will be entered int...

Page 53: ...ed text or press Enter again to exit the Message Entry Mode Each time the printer imprints a code the sequential number will be incremented and the successive product will be marked with the next numb...

Page 54: ...specific symbol is desired position the cursor on top of it and press Enter Then continue entering the rest of the message or press Enter if the message is complete DELETING THE MESSAGE If a new messa...

Page 55: ...press the Enter key and then send to print station O If the message is to be edited press the Message Entry key O If the message is to be deleted the current stored message must be over written with...

Page 56: ...he V key on the controller The version of the software will be displayed on the controller s LCD IMPORTANT FUNCTIONS USING THE PRINT STATION KEYPAD There are several functions or operations that can b...

Page 57: ...re drops of ink from the nozzles O The print head will continue to fire ink until the purging is completed To complete purging the printer press the Purge key for the second time The Print Disable ind...

Page 58: ...UCT DELAY In the event that a Controller is not handy product delay can be changed through the print station as well as by the Controller The toggle key is pushed until the character width indicator i...

Page 59: ...onth Day Year Time Format Hours minutes seconds Actual Time 00 00 00 Actual Date 00 00 00 AIMS Control 5 Multi Dots 0 Character Spacing 1 Pulse Mode 0 dots 1 second Direction Left to right Code Orient...

Page 60: ...2 Short Periods of Shut down 4 2 Long Periods of Shut down 4 2 NOZZLE FACE CLEANING 4 2 CLEANING THE ARRAY PLATE 4 3 PRINT HEAD FLUSHING 4 4 PRINT HEAD DISASSEMBLY AND CLEANING 4 6 CLEAN AND INSPECT...

Page 61: ...has an ink build up Cleaning procedure for the nozzle face is given in the next section LONG PERIODS OF SHUT DOWN When the printer will be shut down for an extended period of time 4 days or more the i...

Page 62: ...rn off the power to the print station and loosen the cover screw and remove the cover Release the spring clip holding the hanger mount bracket Remove the bracket Remove the array plate from the nozzle...

Page 63: ...y plate Power up the unit and run a sample print If code quality is not acceptable the print head will have to be flushed PRINT HEAD FLUSHING Turn off the power to the print station Disconnect print h...

Page 64: ...T WITH THE FILTER IN PLACE ANY CONTAMINATION IN THE SOLVENT WILL BE CAUGHT IN THE FRONT OF THE FILTER AND CAN BE INTRODUCED INTO THE PRINT HEAD Install the filter crown of filter away from syringe and...

Page 65: ...d to assure thorough cleaning of print head parts Release the hanger mount spring and remove the hanger mount bracket Remove the array plate and the O ring below the array plate Remove the 4 screws ho...

Page 66: ...01 Printhead Exploded View 90533 01 90158 01 90003 01 90532 01 90530 01 90258 01 96297 01 90531 01 90232 01 90473 01 90474 01 90181 01 90159 01 43079 01 507DHC Items not marked with a part number are...

Page 67: ...ifold to align it with the nozzle module Place the rear manifold seal onto the rear side of the manifold Place the rear plate onto the manifold followed by the back plate Install the 4 screws through...

Page 68: ...UBLESHOOTING CONTENTS NO DISPLAY ON PRINT STATION S LCD Page 5 2 NO DISPLAY ON CONTROLLER S LCD 5 2 PRINT STATION WILL NOT PRINT 5 2 POOR PRINT QUALITY 5 2 PRESENCE OF SATELLITE DOTS 5 2 MISALIGNED OR...

Page 69: ...Station and verify parameters Poor Print Quality Print head dirty or clogged Refer to Part 4 for cleaning the print head Bad array plate Refer to Part 4 for replacing the array plate Incorrect cartri...

Page 70: ...ng Dots Dot intensity too low Refer to Part 3 for adjusting dot intensity Print Head too high Refer to Part 2 for adjusting Print Head height Transfer Error Infra red lenses not aligned Aim Controller...

Page 71: ...ONS CONTENTS OPERATIONS KIT Page 6 2 FLOOR STAND 6 3 DAIRY BRACKETRY AND PHOTO EYE FOR GABLE TOP APPLICATIONS 6 3 M400 TRANSPORT SYSTEM FOR BOTTOM CODING 6 3 SOFTWARE OPTIONS 6 4 HOST COMPUTER INTERFA...

Page 72: ...42470 01 9 key Allen Wrench Set 1 43029 01 Utility Knife 1 43030 01 Plastic Enclosure 1 507DHS 4 40 Pan Head Slotted Screw 4 43112 01 1 16 Tee Fitting 2 70900 01 Fuse 2 73063 01 1 4W Submin Fuse 2 73...

Page 73: ...on necessary for the floor stand making it very easy and convenient to use To order a floor stand call your local representative DAIRY BRACKETRY AND PHOTOELECTRIC DEVICE FOR GABLE TOP APPLICATIONS Thi...

Page 74: ...s option Part No 96350 01 and factory installation is recommended Upon ordering these features you will receive an instruction packet For further information and to order please call your local repres...

Page 75: ...Number Description 96340 01 Junction Box See Note Junction Box Cable in 25ft increments 96572 01 S L T L RS485 Cable Note A junction box cable must be ordered to the necessary length up to a maximum...

Page 76: ...Top and Side Coding continued 7 5 Print Head Part 96522 01 7 6 Print Head Part 96522 01 continued 7 7 Controller Part 96501 01 7 8 Controller Part 96501 01 7 9 Mounting Kit Part 96509 01 For All Orie...

Page 77: ...01 Single Cabinet with Keypad 1 96503 01 Power Supply Printed Circuit Board 1 96504 01 CPU Printed Circuit Board 1 96505 01 Print Head Cable Assembly 1 96506 01 Power Cable Assembly 1 96507 01 Power S...

Page 78: ...8 3 96622 Issue 4 0 Jan 0 GENESIS SINGLELINE PRINT STATION PART 96502 01 CONTINUED Cabinet Lid Gasket Lower PCB On Off Switch Plug marked Pg7 Print Station Mounting Plate Cabinet Box Grommeted Bushing...

Page 79: ...rizontal Rod 1 501JES 10 32x3 8 Hex Socket Screw 2 43067 01 3 8 Locking Fastener 4 502JES 10 32x3 8 Button Head Screw 2 41808 01 Ink Line Clamp 1 60417 01 3 8 16x1 1 2 Hand Knob 1 43070 01 20x1 Dog Po...

Page 80: ...S 4 40 x Print Head Screw 2 96690 01 20x1 2 T Handle screw 1 96283 01 SL TL SC Barb Assy 1 509DCS 4 40X1 4 Flat Head Screw 1 96337 01 Tubing 1 16 ID x 3 16 OD 7 1 520AEA 1 8 x 3 8 Dowel Pin 2 96012 01...

Page 81: ...8 6 96622 Issue 4 0 Jan 0 GENESIS SINGLELINE BRACKETRY PART 96701 01 FOR TOP AND SIDE CODING continued...

Page 82: ...1 90530 01 Clamp Plate 1 90532 01 Hanger Bracket 1 90003 01 Array Plate 1 90158 01 O Ring 1 90533 01 Hanger Bracket Spring 1 90181 01 Screen 1 90474 01 Screen Plate 1 90159 01 Ink Channel O Ring 1 90...

Page 83: ...PRINT HEAD PART 96522 01 CONTINUED 90533 01 90158 01 90003 01 90532 01 90530 01 90258 01 96297 01 90531 01 90232 01 90473 01 90474 01 90181 01 90159 01 43079 01 507DHC are not available for separate...

Page 84: ...96501 01 Part Number Description Quantity 94029 01 Controller PCB Assembly 1 94028 01 LCD Assembly 1 94027 01 Controller Keypad 1 94049 01 Display Bezel 1 73198 01 AA Battery Cells 4 96512 01 Micropro...

Page 85: ...8 10 96622 Issue 4 0 Jan 0 GENESIS SINGLELINE CONTROLLER PART 96501 01 CONTINUED Keypad Cabinet LCD Microprocessor Cabinet PCB Assembly Batteries...

Page 86: ...Hex Nut 2 62496 01 Flat Washer 2 GENESIS SINGLELINE MOUNTING KIT PART 96293 01 FOR TOP CODING Top coding applications require the parts listed below in addition to the parts listed above Part Number D...

Page 87: ...1 41808 01 Ink Line Clamp 1 96262 01 Septum Block 1 96289 01 Cartridge Clip 1 61381 01 Disc Washer 4 96273 01 Dovetail Plate 1 96315 01 Septum Mount 1 43075 01 8 32 x 1 Nylon Screw 1 501JGS 10 32 x 5...

Page 88: ...Clean 1 42009 01 3 8 Acid Brush 1 90003 01 Array Plate 1 90158 01 O Ring Array Plate 1 3400SL2 Pint D3400 Solvent 1 Not included with international shipments GENESIS SINGLELINE MANUAL AND QUICK START...

Page 89: ...S PROTOCOL CONTENTS GENESIS COMMUNICATIONS PROTOCOL 8 1 Hardware Interface 8 2 Data Word Definition 8 2 Software Protocol 8 2 Error codes 8 3 List of Commands 8 5 Print Message Data 8 10 Print Attribu...

Page 90: ...OL In the following pages all references to characters or digits pertain to the standard ASCII character set The forward slash character is used as a field separator it is not part of the transferred...

Page 91: ...ically interconnected In a single point system where only one print station is connected to one host port format 1 should be used When multiple print stations are connected to the same host port forma...

Page 92: ...leaving significant data in the lower nibble and zeroes in the upper nibble Then a 30H is added to form the first character to be transmitted The second character consist of masking off the upper nibb...

Page 93: ...Revision Level PRINTER CONFIGURATION SL TL Read only ESC EOT ESC X Y EOT X Head typeO SingleLine 1 TwinLine Y Head size O Small Char 1 Large Char LINE 1 PRINT DATA ESC EOT ESC X X CR EOT X X Line 1 pr...

Page 94: ...nge 1 9 ESC EOT ESC xx EOT xx Number of dot time spaces between characters NUMBER OF MULTIDOTS Valid Range 1 3 ESC EOT ESC xx EOT xx Number of multidots ACTIVE LANGUAGE Valid Range 0 4 ESC EOT ESC xx...

Page 95: ...art minutes XX Stop hours YY Stop minutes ZZZZZZ Product counter value 0 SHIFT CODE ESC 0 EOT ESC 0 HH MM XX YY EOT HH Start hours MM Start minutes XX Duration hours YY Duration minutes 1 AUTO REPEAT...

Page 96: ...of vertical columns in logo XX XX Logo data The format for downloading a logo is described below under the Logo Download section 6 SOFTWARE PRINT GO Write Only ESC 6 EOT ESC 6 EOT INITIATE PRINT CYCL...

Page 97: ...Read Only ESC EOT Response ESC W X Y EOT W Valid Message 0 1 1 Valid Printable Message X Previously Loaded Message Activity State 0 Message has been Printed 1 Message Waiting to Print Y Product Curren...

Page 98: ...otice in the table that some special fields require the attribute character be present at both the start and end of the field The following examples illustrates how to create a message string To print...

Page 99: ...used 19H 1 or 2 Shift Code Field 1AH N Standard 5x5 Font 1BH N Standard 7x5 Font 1CH N Standard 9x7 Font 09N N Multi Dot 5x5 Font 1DH N Multi Dot 7x5 Font 1EH Field Length Field Descriptor Hex Code N...

Page 100: ...ertical column consist of three bytes The first byte after the length is data for vertical column 1 pixels 5 6 7 and 8 followed by the next byte with data for pixels 1 2 3 and 4 and finally the third...

Page 101: ...aded message was received USE COMMUNICATIONS CHANNEL 2 OPEN COM2 9600 E 7 1 DS CS FOR RANDOM AS 1 ERROR R0UTINE FOR TIMEOUT MAIN ON TIMER 4 GOSUB TIMEOUT SEND ESC COMMAND DATA EOT A INPUT LOC 1 1 CLEA...

Page 102: ...Y GOTO MAIN GET ACK OR NAK PROM HEAD GETRESP TIMER ON WHILE LOC 1 1 WAIT FOR STRING FROM HEAD WEND TIMER OFF FOR N 1 TO 10000 NEXT N SOME PROCESSING TIME A INPUT LOC 1 1 GET A CHARACTER FOR INPUT PORT...

Page 103: ...8 15 96622 Issue 4 0 Jan 0 TIME OUT ERROR ROUTINE TIMEOUT INPUT TIMEOUT ERROR TRY AGAIN Y N A IF A Y OR A Y THEN RETURN MAIN IF A N OR A N THEN SYSTEM SYSTEM...

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