ITW FOXJET Solo 45 Series Operation Manual Download

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Thermal Jet

Thermal Jet Operations Manual Rev M

Appendix G: Uploading Files to the Print Head and File Management . . . . . . . . . . . . . . . . 47

Appendix H: Communicating Directly to the Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Appendix I: Aligning the 1" (25.4 mm) Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Appendix J: Bulk Ink Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Appendix K: Part Numbers - Consumables and Service Parts . . . . . . . . . . . . . . . . . . . . . . . 60

Consumables .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Summary of Contents for FOXJET Solo 45 Series

Page 1: ...1 Missouri Research Park Drive St Charles MO 63304 1 800 369 5384 Illinois Tool Works Inc 2013 Thermal Jet Ink Jet System 5780 329 Revision M Operations Manual ...

Page 2: ...ical specifications at any time and without notice 2013 Illinois Tool Works Inc All rights reserved Printed in the United States of America Ink Cartridge The SoloSeries has been engineered and designed to work with Foxjet ink cartridges The SoloSeries Smart Level Ink Detection System which provides ink level monitoring to ensure com plete ink usage and product safety will not be func tional if use...

Page 3: ...e specified carries a limited warranty The inks and conditioners used with the SoloSeries Thermal Jet system carry a limited warranty For all warranty terms and conditions contact Foxjet an ITW Company for a complete copy of the Limited Warranty Statement Warranty Thermal Jet ...

Page 4: ... GUI Functionality 13 Home Screen 14 Main Menu 16 Message Editor continued User Defined Time Codes 18 Status Screen 25 Section 4 Maintenance Shutdowns 26 Daily Maintenance Ink Cartridge 26 Weekly to Monthly Maintenance Print Head 27 Shutdowns Less Than 3 Days 27 Shutdowns More Than 3 Days 27 Section 5 Troubleshooting 28 Appendix A Specifications 29 Appendix B Theory of Operation 33 Thermal Jet Pri...

Page 5: ...he Print Head and File Management 47 Appendix H Communicating Directly to the Print Head 52 Appendix I Aligning the 1 25 4 mm Print Head 53 Appendix J Bulk Ink Supply 54 Appendix K Part Numbers Consumables and Service Parts 60 Consumables 60 Service Parts 60 Optional Equipment 63 ...

Page 6: ...ury and or equipment damage due to electrical hazard NOTE Will be followed by a brief comment or explanation ESD protection should be worn when servicing internal printed circuit boards After service to the equipment is completed replace all protective devices such as ground ing cables and covers before operating the equipment It is extremely important to Clean up all spills with the appropriate s...

Page 7: ...rt Thermal Jet Operations Manual Rev M Page 2 Section 2 Quick Start Contents Print Head Bracketry Kit Power Supply 15 V Power Supply Bracket Power Cord Software TYPICAL INSTALLATION CONTROLLER OPTIONAL HAND HELD TYPICAL INSTALLATION ...

Page 8: ...Thermal Jet Section 2 Quick Start Thermal Jet Operations Manual Rev M Page 3 Step 1 Assemble Bracketry Step 2 Assemble Bracketry to Conveyor ...

Page 9: ...Thermal Jet Section 2 Quick Start Thermal Jet Operations Manual Rev M Page 4 Step 3 Assemble Print Head and Power Supply to Bracketry Ensure bar is behind front face of print head ...

Page 10: ... Operations Manual Rev M Page 5 Step 4 Adjust Print Head to Substrate ADJUST THE PRINT HEAD TO THE SUBSTRATE WITH THIS BRACKET 1 2 5mm GAP RECOMMENDED Adjust print head vertically to meet requirement Adjust print head horizontally to set print gap ...

Page 11: ... place NOTE The pen is released by pressing down on the Finger Release Tab and pull ing up on the rear of the cartridge Close Cover PEN STOP When inserting cartridge aim nose at an angle towards black pogo pin component Slide pen cartridge up to Pen Stop Insert Pen Cartridge at an angle up to Pen Stop PEN STOP After pen cartridge is installed FINGER RELEASE TAB FINGER RELEASE TABS ...

Page 12: ... or an Hand held controller One com port can control up to eight 1 2 print heads four 1 print heads or any combination of the two totalling eight print cartridges Using the supplied serial cables connect the print heads daisy chain style by connecting the output port of one print head to the input port of the next Then connect the COM port of the PC or Hand Held Controller to the daisy chain A PC ...

Page 13: ...nt of the Print cartridge Print several purge images and validate that all channels are printing If not refer to Section 4 Maintenance Shutdowns on page 26 The power supply for the controller or the com puter may now be installed Serial Port Setup NOTE Depending on GUI Controller status this step may already be complete If a computer will be used install the PC software included with the print hea...

Page 14: ...if necessary Press the OK button to exit the Serial Port Setup screen If Serial Print Head Task x is not shown on theCOM1 Function button press the button and select the Serial Print Head option Press the OK button to exit the COM 1 Function screen Press OK again to exit the System Setup screen Press the System Setup button and then the Serial Ports tab ...

Page 15: ...and choose the desired encoder type Auto Speed Detect Line speed automatically detected via print head photo cells External Encoder Line speed measured by an externally mounted encoder and connected to the last print head in the daisy chain Touch this box then type in the desired speed On the home screen press the Control Panels button and then press the System Setup button On the Print Heads page...

Page 16: ...p Product Side Zoom Field Coordinates Field Selection Font Selection Count Code Date Code Time Code Alpha Numeric Quick Save Create and save the message and then exit the message editor Message Display Area From the home screen select the Messages button and then the New button to enter the message editor Logo Barcode ...

Page 17: ...Jet Operations Manual Rev M Page 12 Step 9 Print a Message Select the desired message to print and press the Print It button From the home screen press the Print button The message will print on the next photocell trigger ...

Page 18: ...ressed Arrow Keys Shifts focus between screen controls Moves highlighted fields or the cursor around in the Message Editor Tab Shifts focus between screen controls Shifts focus between fields in the Message Editor Backspace in Message Editor Normal functionality as QWERTY keyboard Deletes a highlighted field Ctrl Control in Message Editor Amplifies the movement of the arrow keys Holding the Ctrl k...

Page 19: ...eir respec tive numbering The header displays the task number and file name of the message being printed If no mes sage is loaded to print None is displayed Task Select Button Places focus on the selected task This allows one to view what is being printed on either task in the home screen Additionally items in the main menu vary from one task to the other Zoom Button Task 1 Print Pause Button Mess...

Page 20: ...ess the Print dialog box directly even with Restricted User Access enabled Simply select the desired message and press the Print It button The message will print at the next photocell trigger Zoom Expands the message window to full screen and magnifies the print message so that fine details may be seen F1 F2 F5 and F6 keys or the Arrow keys scroll the message left right up and down Press the Zoom ...

Page 21: ...box Closes this menu immediately Returns to Home Screen Message List Selected Message Returns to Home Screen Deletes Selected Message Opens Selected Message in the Editor Starts a new message in the Editor NOTE The Variable Field button is not available In order to update a variable field reselect the message to Print Main Menu Expanded Main Menu Collapsed Fires all jets for a short period of time...

Page 22: ... Clears contents of message editor Calculates estimated ink usage for the contents of the editor Prints the contents of this editor on the next photocell trigger Exits the editor to the Home screen Quick save of current message Moves from field to field in the display area Field or cursor coordinates Message display area Opens Field Properties dialog box for text fields ...

Page 23: ... Time Code button appears Tabular format codes printed taken from table Use default codes default Hour codes shown or edit table to suit your requirements Periodic format example above illustrates a shift code implemented by using a periodic quarter hour code A prints from 23 30 06 59 B from 07 00 15 29 and C from 15 30 23 29 Sequential format minute code shown Minute 00 AA 01 AB 02 AC etc ...

Page 24: ...ears The Fortnight code type is available for the Tabular format only Tabular format codes printed taken from table Use default codes default Day codes shown or edit table to suit your requirements Sequential format in example above Sunday A Monday B etc Periodic format example above illustrates a quarter year code implemented by using a periodic month code Q1 prints from Jan 1 Mar 31 Q2 from Apr ...

Page 25: ...variable field is selected to print COM1 COM2 Data is received though COM1 or COM 2 serial port Data must be received before the message is selected to print Data 1 10 Data is retrieved from corresponding system variable User has the option to change the data when the message is selected to print Maximum 9 digit count Incrementing Count Count increments when the Start at value is less than the Sto...

Page 26: ...tered when print message containing bar code is selected to print Dummy data entered when the bar code is created acts as a place holder COM1 COM2 Data is received though COM1 or COM 2 serial port Data must be received before the mes sage is selected to print Dummy data entered when the bar code is created acts as a place holder Data 1 10 Data is retrieved from corresponding system variable Dummy ...

Page 27: ...guration Set print direction number and type of print heads System Setup Screen Auto Speed Detect Line speed automatically detected via photocells dis ables the external product sensor External Encoder Line speed measured by an externally mounted encoder and connected to the last print head in the daisy chain COM port configuration options Optional externally mounted photocell connected to the las...

Page 28: ... Access Does not apply to Thermal Jet print heads Controls within this box set the user access level Buttons outside the box mirror the Home Screen and indicate which functions are password protected and which are open Padlock symbol indicates function is password pro tected The factory set password is Manager Passwords are case sensitive ...

Page 29: ...l Jet Thermal Jet Operations Manual Rev M Page 24 Time Date Setting Screens After performing the Restore default configu ration function the serial port must be reconfigured for a serial print head Utilities ...

Page 30: ...tridge type and status OK Date Y M D and time from print head List of fonts and logos on the print head Indications that head 3 is improperly connected or not communicating with the controller Heads 1 2 are 1 2 print heads Head 3 is a 1 print head one button for each print cartridge No date time No print head firmware version number Status Screen Note This set of status screens represents three pr...

Page 31: ...els of the ink cartridge and dampen the swab with ink The ink will act as its own solvent for cleaning 3 Rub up and down across the orifice face with light force several times with one side of the sponge swab 4 Turn the swab over and make one final light rub stroke top to bottom 5 Immediately press and hold the PURGE button on the rear of the print head for 5 10 seconds to reprime the orifices Bec...

Page 32: ...eionized water Take care NOT to wipe the cartridge orifice array Shutdowns Less Than 3 Days The ink cartridge can remain in the print head uncapped When restarting the print head follow the Daily Maintenance procedure Shutdowns More Than 3 Days For extended shutdowns follow the Daily Maintenance procedure remove the ink cartridge from the print head and store in the optional Cartridge Boot Cap Kit...

Page 33: ...n an 1 8 away from the substrate There are large air cur rents near the print head Adjust the print head according to Section 2 Quick Start See Step 4 Adjust Print Head to Substrate on page 5 Locate print head in an area where there are minimal currents or provide wind barriers Print image is missing channels or has multiple fractures Pen cartridge face is dirty Pen cartridge face is damaged at th...

Page 34: ...y have at least 3 52 character print fields number of fields per line increases as the number of charac ters per field decreases File Storage Twenty seven 256kB sectors per print head are available for font and logo file storage Files larger than 256kB use multiple sectors Factory installed fonts occupy 12 of the 27 sectors Five factory installed fonts Arial 30 75 150 225 and 300 0 1 in 2 54 mm 0 ...

Page 35: ...ast 3 52 character print fields number of fields per line increases as the number of charac ters per field decreases File Storage Twenty seven 256kB sectors per stall are available for font and logo file storage Files larger than 256kB use multiple sectors Factory installed fonts occupy 12 of the 27 sectors Five factory installed fonts Arial 30 75 150 225 and 300 0 1 in 2 54 mm 0 25 in 6 35 mm 0 5...

Page 36: ... Plumbing Port 1 Pressurized ink outlet to print heads Environment Ambient operating temperature 50 F to 104 F 10 C to 40 C Operating Humidity 10 80 RH Tubing Limitations Maximum horizontal tube length 10 ft 3 m Maximum vertical tube length 3 ft 1 m Print Head Limitations One daisy chain per Bulk Ink Supply each daisy chain may have up to 8 print head car tridge stalls eg eight 1 2 Print Heads fou...

Page 37: ... 108 inches 2743 mm Maximum Repeat Print Distance 108 inches 2743 mm Maximum Number of Print Heads Per Con troller Up to 8 print cartridges per COM port in any combination eg eight 1 2 Print Heads four 1 Print Heads four 1 2 Print Heads with two 1 Print Heads Ports 2 RS 232 ports 1 10 100Base T Ethernet port 1 USB port Electrical 15 VDC from power supply to controller Power Supply 90 260 VAC 50 60...

Page 38: ...ombination of the various print field types supported including fixed text date time codes product counts variable fields logos and a variety of bar codes including Data Matrix 2 D codes Unlike other inkjet technologies these print heads store and process the currently printing message internally This allows the print heads to be disconnected from the controlling device and operate stand alone onc...

Page 39: ...onal accessory hub or Bulk Ink System is used from the hub or ink system Alternately with no print heads attached the Controller may be powered by an optional 15VDC desktop power supply plugged into its power jack Battery Backup A 3V battery on the CPU Board maintains the contents of system SRAM and keeps the real time clock running during power outages or when the Handheld control ler is not plug...

Page 40: ...POWER SUPPLY 15V KIT EUROPEAN P N 5780236E DOMESTIC P N 5780236D ETHERNET CABLE Single task with accessory hub The Controller draws its power from the accessory hub and is plugged into the handheld connector on the accessory hub the accessory hub is plugged into the output connector of the last print head in the daisy chain HH Controller Cable P N 5780 616 06 DB9 F F Print Head Cable P N 5780 319 ...

Page 41: ...Thermal Jet Appendix B Theory of Operation Thermal Jet Operations Manual Rev M Page 36 Interconnect Diagram Handheld Controller CPU Diagram ...

Page 42: ...ommunicate with the Hand held on page 40 1 Obtain the Controller s IP address Most controllers have an IP address of 10 1 2 3 It may be different if the controller is networked with other Handhelds or other devices If the IP address is unknown go to the controller and from the Home Screen Touch the Control Panels button to open the Control Panels Menu Touch the Network button on the Control Panels...

Page 43: ...appear Click the Save button A Save As dialog appears The IJ3000 HH files backed up are compressed and put into a single file and are given the default name and file extension backup tgz Following normal Windows conventions the backup file may be renamed and given any extension and saved in any folder desired To save the backup file with an extension other than tgz open the Save as type combo box ...

Page 44: ...ntroller s backed up system files click the Restore files from backup link The web page shown below appears Click the Browse button to locate and select the backup file to be sent to the controller Click the Restore button to send the file to the controller If the file transfer is successful the web page shown below will be displayed ...

Page 45: ...andheld This appendix has instructions for setting the IP address and subnet mask of the PC so it can communicate with the Handheld Controller Included are instructions for Windows XP Windows 2000 Windows 98 and Windows 95 Windows XP 1 Open the Start menu select Settings then Network Connections 2 Click Local Area Connection then open the File menu and select Properties ...

Page 46: ...he Handheld Thermal Jet Operations Manual Rev M Page 41 3 Select Internet Protocol TCP IP then click the Properties button 4 Click the Use the following IP address radio button Enter an IP address of 10 1 2 4 a subnet mask of 255 255 255 0 and click the OK button ...

Page 47: ...to Communicate with the Handheld Thermal Jet Operations Manual Rev M Page 42 Windows 2000 1 Open the Start menu select Settings then Network and Dial up Connections 2 Click the desired connection then open the File menu and select Properties ...

Page 48: ...e Handheld Thermal Jet Operations Manual Rev M Page 43 3 Select Internet Protocol TCIP IP then click the Properties button 4 Click the Use the following IP address radio button Enter an IP address of 10 1 2 4 a subnet mask of 255 255 255 0 and click the OK button ...

Page 49: ...35 mm AaBbCcDdEeFf 1234567890 Arial 150 1 2 in 12 7 mm AaBbCcDdEeFf 1234567890 For best results printing the next two fonts use an external encoder The top images were printed with an external encoder The lower images were printed using the Auto Speed Detect mode without external encoder from the controller or GUI software Arial 225 3 4 in 19 05 mm Arial 300 1 in 25 4 mm ...

Page 50: ...xels For practical purposes the maximum height of a logo is150 pixels if the logo is prined with a 1 2 print head and 300 pixels if printed with a 1 print head The absolute maximum logo height is 1200 pixels but logos that cross print head boundaries will likely exhibit registration problems when printed Max imum logo width is 32 767 pixels or print columns 109 22 in 2 77 n when printed at 300 dpi...

Page 51: ...ent Bring up the Flip and Rotate dialog by selecting Image Flip Rotate Select Rotate by angle then 270 Click Ok From the File Menu select Save As and save the logo in a directory location that you will remember NOTE If the print heads are being controlled via a PC using the Demo software rather than a Controller or Handheld controller then store the logo in c Program Files InkJet bmps ...

Page 52: ...ger on the System Utilities screen In addition to uploading files the File Manager also allows removal of files from the print heads however files cannot be copied from a print head During the upload process files are simultane ously added to or removed from all print heads on the daisy chain being addressed Oper ations on an individual print head are possible only when it is the sole head on the ...

Page 53: ...both of the Controllers USB ports The controller will show only usb0 as it has only one USB port USB folders are not displayed when running the PC InkJet Demo program Adding Logo and Font Files So that they may be correctly selected displayed and printed logos and fonts must be stored on both the controller and the print head s On the controller logos are stored in the folder home bmps and fonts a...

Page 54: ...e available folders and files 2 The display shows a list of available files Highlight the bmps folder with the up down arrows and open it 3 Select the file to be uploaded to the print head s and then touch the Copy button 4 Close the bmps folder returning to the home folder level 5 Close the home folder returning to the top level Close folder go up one level Copy ...

Page 55: ...of all files on print head 1 only it is assumed that all print heads have the same files 7 Touch the Paste button The file is uploaded to all print heads on the task after which the file list is updated showing the newly added file While the file is uploading an hourglass is displayed and the red LED on the back of each of the print heads on the task s daisy chain blinks Open Paste ...

Page 56: ...ement Thermal Jet Operations Manual Rev M Page 51 Removing a File To remove a file from all print heads on a task 1 Select and open the task folder 2 Select the file to be deleted and then touch the Delete button 3 The file is deleted and the file list updated Open Delete ...

Page 57: ... 52 Appendix H Communicating Directly to the Print Head The 1 2 12 7 mm and 1 25 4 mm print heads can be controlled by direct serial commu nication Refer to the serial protocol document 5780 316N when communicating directly to the print head without the use of a controller or the pc GUI software interface ...

Page 58: ...en the halves rotate the bracketry clockwise 4 Snug the mounting screws and run another print sample If the overlap or gap is not acceptable then repeat the previous step 5 Repeat the previous two steps until the two cartridges are matched vertically 6 Fully tighten the mounting hardware 7 Now observe the horizontal alignment of the characters 8 Horizontal misalignment can be compensated electroni...

Page 59: ... the print system CAUTION Failure to properly bleed the air from the ink lines before connecting the septum fitting to the print cartridge could damage the print cartridge System Components Print Head Regulator Bulk Ink Supply Controller or PC Handheld controller requires the optional Hub below Beacon optional Hub optional Installation 1 Mount the print head s bulk ink supply and controller if app...

Page 60: ...L RISEFROMBULKINK SUPPLYTOPRINTHEAD BULKINKPRINTHEAD2 BULKINKPRINT HEAD1 BULKINKCARTRIDGE VALVE QDTO 1 8 BARB P N 1900 757 TRUNKLINE TUBING1 8 IDX 1 4 OD P N 1301 468 INKSERVICE PORT P N 1900 757 FITTING TEE REDUCER 1 8 TO3 32 P N 5361 354 TUBING 3 32 IDX5 32 OD 1303 564 ORIENT ASSHOWN FITTINGASSEMBLY SEPTUM TO1 8 BARB P N 5780 393 TUBING 1 8 IDX3 16 OD P N 1303 563 REGULATOR P N 5780 105 INK STAT...

Page 61: ...166 supplied with the bulk ink system to the septum fitting While holding the syringe and tubing above the regula tor slowly draw the air out of the ink line Once all of the air is out of the ink line and a small amount of ink is drawn into the syringe discon nect the syringe and plug the septum fitting into the print cartridge Repeat for each regulator Configuring system for bulk ink supply At th...

Page 62: ...ccom modate five half inch print heads or two one inch print heads 1 Mount the print head and regulator The regulator must be positioned appropriately in relation to the print head see figure If the regulator is positioned too high with respect to the print head then ink may seep out of the print head If this occurs sim ply lower the regulator until it is positioned properly 2 It will be necessary...

Page 63: ... pump will turn on and pressurize the ink supply up to 5 psi If the pump can not achieve 5 psi after running for 15 seconds the system goes into an Ink Low state beacon will turn on solid indicating the 350 ml ink cartridge is empty The print heads will continue to print because there is still ink in the print head cartridges this allows ample time to change the 350 ml ink cartridge Changing the 3...

Page 64: ...shut down It indicates that the ink cartridge is empty and needs to be replaced The pump will automat ically restart when the cartridge is replaced or power is cycled off and on LED beacon is blinking rapidly the system has experienced a rapid loss of pressure possibly due to a break in an ink line and has shut down The LED repeatedly blinks rapidly for one second then goes out for one second blin...

Page 65: ...Non Porous Media Black 5780 235FX Solo 200 Porous Media Barcode Black 5780 220FX Solo 100 Porous Media Bulk Ink Black 5780 219FX Solo 100 Porous Media Bulk Ink Black One 350ml Ink Cartridge 1 year SoloSeries45 Item Kit No Description 1 5760 302 Power Supply Print Head 2 5780 002FX SoloSeries45 Complete Print Head Kit with Mounting Bracketry Power Supply Data Cable PC Software 3 5780 203FX Cover En...

Page 66: ... 5780 218FX Print Head Replacement Bulk Ink 6 5780 208 Boot Cartridge Cap 7 5780 319 10 Cable Print Head 10 8 2464 182 25 Extension Cable Print Head 25 not shown 9 2464 182 50 Extension Cable Print Head 50 not shown 10 5780 231 Regulator Replacement Bulk Ink 11 5780 228FX Upgrade Kit Bulk Ink Print Head Includes Item 3 bottom 2 ea Item 10 SoloSeries IS Item Kit No Description 1 5760 302 Power Supp...

Page 67: ... 1 5780 015FX Marksman HHI Controller 2 5780 232 Color Display Replacement 3 5780 233 CPU PCB Replacement 4 5780 626 Battery CR1220 Bracketry Item Kit No Description 1 5780 234 Bracketry Marksman HHI Mounting 2 5780 200 Bracketry SoloSeries Print Head Mounting 3 5780 227 Bracketry Print Down 4 5780 230 Bracket Linear Tool less 4 1 2 3 2 3 4 1 ...

Page 68: ...ket 25 Cable 2 5765 206 Encoder O ring Replacement 3 5760 383 Photocell 4 5780 010FX Accessory Hub with Power Supply 5 5780 214 Beacon IJ3000 HH CONTROLLER OR PC POWER SUPPLY INK STATUS BEACON ENCODER PRINT HEAD PHOTOCELL ACCESSORY HUB ACCESSORY HUB CONNECTIVITY 4 2 1 3 5 TYPICAL ENCODER MOUNTING ON OPEN AREA OF CONVEYOR BELT TYPICAL ACCESSORY HUB MOUNTING TYPICAL BEACON MOUNTING TYPICAL PHOTOCELL...

Page 69: ...e 64 Roller Retractor Bracketry Item Kit No Description 1 5780 206 Roller Bracket Only 2 5780 207 Roller and Retractor Bracket Maintenance Item Kit No Description 1 1901 398 Hand Cleaner Reduran 2 5760 832 Sponge Swabs Qty 100 3 6600 171 Lint free Wipe Cloths Roller Bracket Only Roller Retractor Bracketry ...

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