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TrojanThree User Guide

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2.1.3

Mounting Print Engine

There are 2 mounting brackets to attach the print engine module to the machine cabinet. Each mounting

bracket has to be fixed with 2 screws.

After fixing the mounting brackets, the print engine module can be fixed by the mounting brackets with 1

screw on each side.

Left side mounting bracket

Right side mounting bracket

2x Mounting bracket

Summary of Contents for Trojan 3

Page 1: ...User Guide Revision 3 8 22834693 EN E...

Page 2: ...ments currently in effect with your organization Copies of this document any portion of this document or attachments may not be transmitted or disclosed to any third party without the prior written pe...

Page 3: ...Printhead 15 3 3 1 Installing ink tanks 15 3 3 2 Installing the printhead 16 4 Integrating the TrojanThree OEM Print Module 21 4 1 Over printer OP version 21 4 2 Label printer LP version 22 5 Sending...

Page 4: ...62 13 Maintenance 64 13 1 Emptying the Waste Ink Bottle 64 13 2 Replacing Micro Fiber Roller MFR 65 13 3 Manual Printhead Wiping 70 14 Troubleshooting 74 14 1 Error States List 74 14 2 Error Messages...

Page 5: ...he occurrence 85 18 1 1 The wiper roller 85 18 1 2 The maintenance cap 85 18 2 Wipe print head before start of job 86 19 Recommendations and expectations 87 19 1 Print speed 87 19 2 Web substrate clea...

Page 6: ...TrojanThree User Guide Page 5 1 Specification and General Information 1 1 Certificate and Compliance...

Page 7: ...of the employer the owner of the machine to ensure that anyone who is to operate service maintain or repair the machine have read the instructions As a minimum they should have read the part s releva...

Page 8: ...y The machine s purpose and intended use Application The machine is only to be used to print labels label printer LP version or to print on packaging materials over printer OP version which meet the m...

Page 9: ...cal Specifications Simple cleaning station ensures high print quality over long runs Ink drop size is 1 2 Pico liter Spring loaded blade for controlling media just before printhead Print head height a...

Page 10: ...t quality some non coated materials like cardboard or other packaging materials will also work Please contact Trojanlabel or your distributor for recommendations of suited materials It is imperative t...

Page 11: ...Printer in a metal cabinet Touchscreen with cables and screws 4 screw to mount Power Supply Cable matching with the regional standard Print Engine module Packing list 2 1 1 Setting the adjustable feet...

Page 12: ...et Then fix the touchscreen stand with 4 screws to the top of the machine cabinet Mounting touchscreen stand Connecting touchscreen cables A Ground cable B LVDS cable C USB Touch Control and D Screen...

Page 13: ...the print engine module to the machine cabinet Each mounting bracket has to be fixed with 2 screws After fixing the mounting brackets the print engine module can be fixed by the mounting brackets wit...

Page 14: ...connecting tubes and cables NOTE The luers are matching for the ink tubes at incoming and return ink lines so the tubes cannot be connected wrong Make sure the colors of the tubes are matching when co...

Page 15: ...encoder signals 4 I O port Only the power supply cable is necessary for powering up the machine The network cable is necessary for sending new print jobs to the TrojanThree and for remote support soft...

Page 16: ...tarts up TrojanControl touch screen and print engine 2 The machine is fully functional when the TrojanThree tab is visible on the TrojanControl software and at right side status bar the system state f...

Page 17: ...are not refillable and shall be treated as hazardous waste when empty 3 3 2 Installing the printhead Unpacking printhead 1 Open the end of the printhead package outer box and slide out the foil bag I...

Page 18: ...the printhead cartridge by the handle with one hand grasp the pull tab with the other hand and slowly and carefully peel back the plastic strip covering the electrical contacts NOTE Dispose of the re...

Page 19: ...ing Installing printhead 1 Open cover lid on TrojanThree to gain access to the print engine CAUTION DO NOT touch the printhead cartridge s ink couplings nozzle surface or the electrical contacts when...

Page 20: ...st likely break the latch Breaking the latch is considered as improper usage and therefore replacement is out of warranty Breaking the latch also causes the machine to be non operational until the bro...

Page 21: ...p the printhead with ink NOTE When the system is primed up for the first time first installation when there has not been any ink in the ink delivery system and the reservoir ink tanks printhead primin...

Page 22: ...is done by the local Trojanlabel distributor or by Trojanlabel directly in areas where there is no official Trojanlabel partner Trojanlabel has a separate technical integration document for detailed...

Page 23: ...ovement speed of the web path has to be synchronized with the TrojanThree printing speed Communication with the finishing line like job start stop pause signals print speed signal Unique features Comm...

Page 24: ...ware are stored in Job Library menu if feature is not disabled 2 Select Job library See section 11 3 3 for full Job Library description 3 Select a job by pressing the image the selection is indicated...

Page 25: ...rt immediately and print job progress is viewed in the Overview screen which is automatically displayed when starting a print when Auto switch to overview when printing from job library option is enab...

Page 26: ...ee tab Overview menu Pause Press the Pause Resume button Print state will change to Paused at status bar Print job paused Print state changed at status bar to Paused Resume of paused job Press the Pau...

Page 27: ...top Press the Stop Clear Error button Print state will change to NA and current print job is canceled and removed from print queue Print job canceled no job s loaded in print queue Status bar print st...

Page 28: ...nu 3 Press the big red Shutdown TrojanController button 4 Reconfirm by selecting ok 5 Green information button is displayed about shutting down process no need to press ok on that button 6 After shutt...

Page 29: ...thm how to detect the top of the next label Press Save Apply button to apply changes Continuous label material has no gaps or blackmarks between the labels The gap between the labels can be set at Tro...

Page 30: ...Label Printer LP version To select diecut printing mode go to TrojanThree Media Settings menu and choose Diecut as TOF mode TOF Top of Form to describe the top of form algorithm how to detect the top...

Page 31: ...n marks called Blackmarks preprinted between the labels Blackmark mode at LP version requires a label gap blackmark sensor installed at the application Blackmark mode selected at Media Settings menu S...

Page 32: ...g that the printer is ready to print but there is no media to print on This timeout period is necessary to protect the printhead nozzles from dehydration as in printing mode the printhead is not prote...

Page 33: ...with the TrojanThree package It is available for downloading on the Internet http www trojanextranet com media 58331 win_driver_13 sirius_r13 1 17nov2016 zip Open TrojanThree Driver installer on user...

Page 34: ...o print over the Network NOTE USB printing is not supported for the TrojanThree During the setup process the installer will detect the TrojanThree printer s on the network Select the desired TrojanThr...

Page 35: ...menu You might be asked a couple of times depending on Microsoft Windows OS version to give permission to proceed with setup Press Yes or Unblock each time and wait until the progress bar finishes th...

Page 36: ...em versions The TrojanThree printer can print from any software which is able to print from Microsoft Windows environment Handles ICM color profiles provided by Trojanlabel General driver settings Ori...

Page 37: ...00 x 800 dpi 18 meters minute Page Management Stitching Stitching images together make one continuous image This mode is for exceeding the maximum printable label length which is 762mm TIPS TRICKS The...

Page 38: ...ser should deselect Mask Optimization to correct this issue 10 3 Using Color Profiles Using ICC Color profiles are the way how we ensure to spray the right amount of ink for the certain label material...

Page 39: ...TrojanThree User Guide Page 38 Installing additional color profiles Download and install executable package Installed color profiles are available in media type list after installation...

Page 40: ...edia Speed 6 IPS or 12 IPS Maint state shows status of maintenance Maint Error shows error status TOF mode LP version only shows actual printing mode See section 8 for available printing modes Print Q...

Page 41: ...e 40 11 2 General Settings HOME menu 11 2 1 Overview Overview menu Information from currently printed job including Preview image of the label which is being printed at the moment Label counter Name o...

Page 42: ...cartridge price is the base of ink cost label calculation in statistics menu see section 11 2 3 The actual price of a 2 Liters ink tank should be typed here Print head price when filled up also inclu...

Page 43: ...e becomes unresponsive to restart print engine and software Advanced tab enables usage of Auto configuration scripts or Proxy Server wherever the local network policy requires these for network intern...

Page 44: ...in the job library however jobs that already been in the library will remain and be available for printing Auto switch to Overview when printing from job library Enabled When printing from the job li...

Page 45: ...n to enable authentication is required for accessing specific functions in TrojanControl A user with User Management rights like the built in admin user can create user accounts and can assign rights...

Page 46: ...are merged into 1 print job and printed out at once Batched print jobs show up as 1 print job in statistics Off default Batch mode is switched off by default On Batch mode is on Default batch mode tim...

Page 47: ...rint head cost label ink media print head cost label calculation Cost label ink only calculation is the cost 1 label or page in the actual print job based on ink tank price given at HOME Settings Cons...

Page 48: ...ne Printhead Usage button TrojanControl Total statistics for the TrojanThree printer for ink usage printed length printed area number of labels and printed jobs Engine Total statistics and history for...

Page 49: ...be set or acquired at HOME Settings Network menu see section 11 2 2 for network settings Current IP address displayed at HOME Settings Network menu NOTE IP address on screenshot above is an example o...

Page 50: ...Dehydration of nozzles in the printhead may result in print quality defects Shutdown process may take 1 2 minutes Shuts down the TrojanThree printer completely NOTE When shutting down the machine it...

Page 51: ...ting Information from currently printed job including Preview image of the label which is being printed at the moment Label counter Name of print job in job library Shows Print Queue state and Stop Cl...

Page 52: ...nance routines ink circulations and Light Cleanings are not enough to recover print quality Usually when medium clean is needed it is the sign of the particular printhead is getting aged Heavy Clean b...

Page 53: ...bout 15 minutes and process is indicated on status bar at the display Home Maintenance Module button Moving maintenance module into home position Maintenance module is sliding out from below the print...

Page 54: ...visited page and job when returning to the Job Library menu Stored labels Print change number of copies print from a certain page number Information about each print job size number of labels speed c...

Page 55: ...pages are printed in sequential order within a print job Print From button makes sense when job contains different pages variable data different images etc and user wants to print out the stored job...

Page 56: ...t queue is paused the jobs are pending in the queue and printing only starts when the queue is resumed Information button Same as in job library see section 11 3 3 Batch Mode on off Batch mode means t...

Page 57: ...ted to environmental temperature This field is filled up automatically based on the temperature sensor but can be overwritten by the user NOTE User defined temperature value remains active until next...

Page 58: ...ut gaps between labels either pre die cut roll media or packaging materials Blackmark pre printed blackmarkings on the media blackmarks can be outside or inside on roll TOF offset mm Top Of From top o...

Page 59: ...ter price for Continuous and Blackmark label material Used for total cost label calculation See section 11 2 3 The field changes from unit to square meter cost when TOF mode is changed from diecut to...

Page 60: ...tiny spots are not acceptable from the print quality point of view this function can be reduced or switched off completely NOTE See KWS levels on next page more detailed Mid job maint Distance meter...

Page 61: ...egree of KWS has effect on printhead life The higher KWS is set the more protection the printhead gets against dehydration of nozzles ALTHOUGH switching KWS off 0 does not result in loosing warranty f...

Page 62: ...he updater menu can be found in HOME Settings menu at TrojanControl Actual software version can also be checked at HOME Settings menu Actual TrojanControl software version in HOME Settings menu Make s...

Page 63: ...e updater package on a user PC which is connected to the same network as the TrojanThree printer Double click on OfflineUpdaterGUI jar to start the update server The update server window will open up...

Page 64: ...NEXT button when asked during the installation TrojanThree is being updated Check TrojanControl version number after installation NOTE The TrojanControl may restart several times during the update pr...

Page 65: ...ste ink goes to the waste ink bottle The waste ink bottle is located near at the lower right corner inside the cabinet It is advised to check waste ink bottle frequently depending on printed volumes b...

Page 66: ...er might needs replacement If surface of the wiper roller looks shiny and not fluffy anymore then wiper roller is worn down and needs replacement If printhead wiping routines like wipe printhead or li...

Page 67: ...TrojanThree User Guide Page 66 1 Open lid on top of the print engine Rubber gloves Lint Free cloth...

Page 68: ...TrojanThree User Guide Page 67 2 Press Home Maintenance Module button in TrojanThree Maintenance menu to gain access to the wiper module...

Page 69: ...move the used micro fiber roller Pull the micro fiber roller out from under the plastic latch Micro fiber roller out On the right side where there is a gear mounted to the micro fiber roller just lift...

Page 70: ...r roller Fit the gear on the right end of the micro fiber roller onto the proper place from above The gear has to fit to the gear of the wiper motor Push the axis of the micro fiber roller under the p...

Page 71: ...ticles Prevents dehydration of the printhead nozzles Forms a wet film layer on the printhead nozzle surface thus creates some vacuum and help to prevent air bubbles blocking some nozzles It is advised...

Page 72: ...id on top of the print engine 2 For manual wet wiping the printhead the printhead has to be removed from the TrojanThree Press Release Printhead button at TrojanThree Maintenance menu to de prime the...

Page 73: ...t free cloth wet with De Ionized or Distilled water 5 Wipe the printhead nozzles with the wet cloth with a single move from one end to the other Never wipe back and forth because that can transfer was...

Page 74: ...the cleaned printhead back and close the printhead latch 7 Press Insert Printhead button at TrojanThree Maintenance menu to prime the printhead with ink This process may take up to 5 minutes 8 Once s...

Page 75: ...than 1600x1600dpi as the driver or the RIP software will downscale the image anyways C Reduce compression rate when using the RIP software D Check design of artwork file Check for overreaching backgro...

Page 76: ...r more ink lines are not filling up with ink There is excess air introduced into the ink system and causes pressure loss A Do a manual wet wipe on the printhead see section 13 3 for manual printhead w...

Page 77: ...of user actions to solve the issue and to cancel or resume the actual print job Example Missed TOF Error occurred Bag Out error One of the ink tanks run out of ink during printing The printing contin...

Page 78: ...ank status bar Running out of disc space When new print job is sent to the machine but free disc space on hard drive reaches the 1 GB limit For example the amount of print jobs stored in the job libra...

Page 79: ...he firmware update please shutdown the full system and start again After the reboot power on the emergency restore process will take over and try to finish the update there is no visual feedback about...

Page 80: ...he quick summary of this document and the overall headlines to achieve optimal conditions when printing bags is the following Print only on flat surfaces i e not on the handles and bottom bump Feed th...

Page 81: ...smooth as possible crumbled paper bags will result in a poor print quality and smearing from touching the print head 16 2 Print head too far The image will look blurred often seen as sand bank fish b...

Page 82: ...surface See photo below 17 2 Optimal print zone Because of the issues described above the optimal zones for printing is outside those two areas However many bags will work fine when printing on botto...

Page 83: ...TrojanThree User Guide Page 82 3 2 Optimal print zone...

Page 84: ...experience that the handles will interfere with both the sensor and print head and the bottom bump will touch the print head completely 17 4 Print on the back side of a paper bag It is possible to pri...

Page 85: ...m has a tendency to pop up then this must be pressed in place in order for it not to pop up and touch the print head Figure 3 Printing on the backside optimal print zone 17 4 2 Printing across the bot...

Page 86: ...nd then cleaning the roller 1 Use clean fresh tap water to rinse the ink 2 When visually clean rinse with demineralized water to remove particles 3 Gently squeeze the microfiber materials 4 Finally pa...

Page 87: ...o ensure that all residual ink is removed before start of job Note that this will require that the cap and roller is in a good condition as explained in chapter 18 1 Cleaning the print head manually i...

Page 88: ...0 bags between maintenance cycles should be achievable 19 4 Printing on wood Print on plain wood works well However depending on the grain of the wood the ink may bleed a bit into the fibres but we fi...

Page 89: ...TrojanThree User Guide Page 88 20 Examples 20 1 Printing in print zone Figure 7 Print zone Figure 8 Small printzone due to large handles and bottom...

Page 90: ...TrojanThree User Guide Page 89 20 2 Printing on bags without bottom fold Figure 9 Bottomless bags 20 3 Printing in print zone smear from dirty Print head...

Page 91: ...de Page 90 20 4 Print on the bottom bend touching Print head 20 5 Print over bottom bump good scenario In the above case we are printing over the bump but due to the relatively thin paper there is no...

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