Genesis single line Operation and Maintenance Manual

1

GENESIS

TM

SINGLE LINE

SMALL CHARACTER INK - JET PRINTER

OPERATION AND MAINTENANCE MANUAL

2 96622 Issue 4.0 Jan. 01

GENESIS

TM

S

INGLE

L

INE

SMALL CHARACTER

INK JET PRINTER

DECLARATION OF CONFORMITY

We, the manufacturer,

Digital Design, Inc., Cedar Grove, NJ

declare under our sole responsibility that the product,

Genesis SingleLine Ink Jet Printer

to which this declaration relates, is in conformity with the following standards:

EN60950 1992 : Safety of Information Technology Equipment, including

Electrical Business Machines

EN50082-1 1992 : Electromagnetic Compatibility, General Immunity

Standard

EN50081-1 1992 : Electromagnetic Compatibility (Conducted),

EN55022-1 1987 : Electromagnetic Compatibility (Radiated)

following the provisions of:

73/23/EEC : Low Voltage Directive

89/336/EEC : EMC Directive.

Cedar Grove

New Jersey

January, 1999 Edward Gerri

3 96622 Issue 4.0 Jan. 01

GENESIS

TM

S

INGLE

L

INE

SMALL CHARACTER

INK JET PRINTER

OPERATION AND MAINTENANCE MANUAL

This manual is for use in operating and maintaining the

S

INGLE

L

INE Small

Character Ink Jet Printer.

WARNING: PRINTING INKS SHOULD BE HANDLED WITH CARE.

O

Do not allow ink onto the skin, or into the eyes or mouth.

O

Some dried inks are 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 refer to the Quick Start

Card.

The print station has been designed, tested and certified in accordance with

NEMA 4 and IP66 standards. For those users who require it, this means the

printer can be subjected to washdowns. However, opening the cabinet will void

both the ratings.

For sales, service and inks, please contact your local representative.

4 96622 Issue 4.0 Jan. 01

retrieval system, or 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 improvement. The Company,

therefore, reserves the right to modify the specification contained in this manual

without notice.

5 96622 Issue 4.0 Jan. 01

GENESIS

TM

S

INGLE

L

INE

SMALL CHARACTER

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

Options Part 6

Parts List Part 7

Communications Protocol Part 8

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

1 - 1 96622 Issue 4.0 Jan

PART 1: DESCRIPTION

CONTENTS

INTRODUCTION Page 1–3

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

INK SYSTEM 1–7

EXTERNAL CONNECTIONS 1–7

Product Sensor 1–7

Bracketry 1–7

DESCRIPTION

1 - 2 96622 Issue 4.0 Jan 01

DESCRIPTION

1 - 3 96622 Issue 4.0 Jan 01

INTRODUCTION

The

G

ENESIS

SINGLELINE

Small Character Ink Jet Printer consists of:

O

The print head

O

The print station

O

The universal controller

O

The bracketry and external connections.

The print head is a small square assembly which, when supplied with an

electrical pulse, ejects ink. Ink is supplied from an ink cartridge through tubing.

The print head is adjustable for proper ink control.

The print station is made of a plastic-based material and contains the electronics

and a control 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 universal to all

G

ENESIS Small Character ink jet systems.

Communication between the print station and the controller is achieved by a

remote control, infra-red data transmission link.

The bracketry is supplied complete for mounting the print head, print station and

product sensor to your conveyor. The product sensor is a photoelectric device

that detects each item as it approaches the print head. The printer uses two fluids

in its operation:

O

Ink, for printing

O

Solvent, for print head flushing and general cleaning purposes

DESCRIPTION

1 - 4 96622 Issue 4.0 Jan 01

PRINTER SPECIFICATIONS

PRINT CHARACTERISTICS

Character Set: Full alphanumeric and 24 special symbols

Fonts Available: 5 x 5, 7 x 5 , 9 x 7 and 7 x 5 Bold dot matrices

Line Speeds: From 1 to 255 fpm

From 0.3 to 75 mpm

Character Height:

5 x 5 1/16” 1.5 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 photoelectric device for gable top applications

O

M400 transport for bottom coding

O

Host (personal) computer-to- printer interface kit

Optional Software Features:

O

Auto repeat

O

96 character message length

O

Programmable solid bar

O

Expanded memory

O

Sequential numbering with two counters

DESCRIPTION

1 - 5 96622 Issue 4.0 Jan 01

PRINT HEAD

Number of Print Heads: One

Spacing from Print Surface: Up to 1/4”

Up to 6.35 mm

PRINT STATION

Standard Finish: Molded in color, ABS

Dimensions: 9 3/4” x 3 1/2” x 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 C - 40 C

Humidity: up to 90% relative, non-condensing

ELECTRICAL SUPPLY

Controller: 4 high energy, ”AA” batteries

Print Station: 50-60 Hz; 115/230 V

~; 0.125/0.06A

GENERAL

Product Detector: Visual beam, LED convergent

DESCRIPTION

1 - 6 96622 Issue 4.0 Jan 01

PRINT HEAD

Each printed character consists of ink drops distributed in a ”dot matrix.” This is

made up of vertical lines of dots

(strokes) controlled electronically in the

print head. The strokes are spaced

apart by the movement of the print

surface past the print head.

The array plate is the part of the print head that you can see on the front of the

printer. It is a very thin piece of metal with holes that allow the ink to travel

from the printer and onto the target. The array plate is critical to the formation

of the ink droplets; care should be taken when handling it.

PRINT STATION

The

S

INGLE

L

INE print station is the brains of

the system. The print station contains a

circuit board, an LCD and external

connectors for the print head and the

photoelectric eye. The circuit board controls

and monitors the printing process. The print

station LCD is used to indicate the status

of the print head as well as to identify which

function is available when the operator is

altering the print head’s status.

The print station is a NEMA 4 and IP66 rated

cabinet; it is suitable for environments where

washdowns take place. There are no user-

serviceable components inside the print

station; opening the cabinet will negate the

NEMA 4 and IP66 ratings.

DESCRIPTION

1 - 7 96622 Issue 4.0 Jan 01

INK SYSTEM

The ink cartridge supplies the print head with ink; the cartridge is not refillable.

Your local representative can provide additional ink cartridges and the solvent

needed to clean the print head during the daily shutdown procedure.

EXTERNAL CONNECTIONS

PRODUCT SENSOR

All GENESIS printers are equipped with a photoelectric device, which senses

the item to be printed and alerts the print head. This ”electric eye” is mounted

on its own bracket; additional 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

S

INGLE

L

INE printer allows the operator to mount the

printer directly to the conveyor. The ratchet knob permits positioning of the

print station so that the operator can raise the station to allow for programming.

When done, this knob then positions the print station out of the way in a fully

vertical position. All hardware is supplied in small plastic bags.

There is an optional floor-mount stand. The

S

INGLE

L

INE printer can be

retrofitted with other optional mounting kits when conversion to bottom coding

from side or top coding is required.

- 1 96622 Issue 4.0 Jan

PART 2: INSTALLATION PROCEDURES

CONTENTS

INSTALLING THE PRINT STATION Page 2–3

General 2–3

Top Coding 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 DEVICE 2–11

CONVERSION TO 230V AC 2–11

INSTALLING OPTIONAL COMPUTER INTERFACE 2–11

INSTALLING THE ENCODER (OPTIONAL) 2–12

INSTALLATION

2 - 2 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 pole / Neutral Fusing

INSTALLATION

2 - 3 96622 issue 4.0 Jan 01

INSTALLING THE PRINT STATION

GENERAL

The printer should be mounted in a location that provides easy access to the print

head for start-up and maintenance. In areas of extreme vibration or shock, it is

advisable to mount the printer on a floor pedestal stand. Make sure that the unit

is mounted in a location which will allow the print head to be mounted within

1/4” inch (6.35 mm) of the product to be coded. Side rails must be adjusted to

ensure consistent clearance and product stability.

TOP CODING

Open the box containing the GENESIS equipment and inspect the contents. The

printer is packaged completely assembled for your convenience. In addition,

there is a top coding mounting kit which will be used to convert the printer,

packaged for side coding, to top 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 hardware

Included in the contents is another, smaller mounting kit (Part #96509-01)

containing the two bolts, nuts and washers to be used to install the printer onto a

conveyor. Check the contents of each mounting kit. Contact your local

representative immediately if any parts are missing. In order to complete the

installation, an Allen wrench set (English) is necessary. An Allen wrench set is

supplied in the Operations kit (optional).

Install the mount base onto your production line. In the package is a self stick

template (part no. 96694-01) that will assist in the location of the mounting

holes. Otherwise, drill and tap two (2) 5/16”-18 (6.5 mm) holes that are 2 1/2”

(63.5 mm) apart (center line to center line of the drilled holes). Bolt the mount

base onto the line using the hardware provided in the mounting kit.

INSTALLATION

2 - 4 96622 issue 4.0 Jan 01

. 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 provided in the second, smaller mounting

kit.

To adapt the ink cartridge holder for top coding applications, loosen the black

nylon tipped screw that holds in place the dovetail piece that is attached to the

print head sub-assembly. Slide the print

head assembly off the ink septum

dovetail plate. Hold on to the screw.

Attach the dovetail extension plate from

the mounting kit to the ink septum

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

for later use.

From the mounting kit, find the extension bar (Part #96291-01). With the flat

end flush against the dovetail (from the print head assembly), join the extension

bar to the dovetail pivot. Use the socket head screw that was set aside; the screw

will go through both the hole in the extension bar and the hole in the dovetail

pivot. The rounded end of the extension bar should now be joined to the pivot

mount using the socket head screw from the mounting kit. (See the picture on

the next page.) Once the print head assembly is re-mounted to the ink septum

assembly, the proper positioning of the print head can be effected.

INSTALLATION

2 - 5 96622 issue 4.0 Jan 01

The print head, photo eye and power cable are delivered with their full extension

available. Follow the cabling for the print head (two cables - one thick, the

electric cabling; one thin, the photoelectric eye cabling) back to the print station.

Loosen the bushings and carefully push the cable into the cabinet to remove the

slack or excess cabling. Re-tighten the bushings after extraction of cabling. The

extra cabling allows flexibility in positioning the print head for proper top code

registration.

Attach the newly-reassembled print

head, array plate down, to the dovetail

extension plate using the black nylon

screw provided in the mounting kit.

Make sure all socket head and the

nylon screws are secure and tightened.

Finally, remove the tubing that is attached to the ink septum assembly and

disassemble the ink line clamp from it. Find the longer piece of tubing 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 solvent. In the

maintenance kits, find the syringe, two

pieces of black tubing and a small plastic

filter. Assemble as shown at left: attach

tubing to the end of the syringe; fill the

syringe half-way with solvent; attach the

other end of this tubing to the filter; take

the other piece of tubing and attach one of

its ends to the filter. Take the free end of tubing and attach to the barb in the ink

well.

CAUTION: Barb is Sharp!!!

Empty the syringe watching the streams of solvent as they exit the print head.

There will be ten streams, straight and parallel to each other. After this

operation, fill the syringe with air and purge out all excess of 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 the ink supply.

Extension Bar

Array Plate

Dovetail Extension

Plate

INSTALLATION

2 - 6 96622 issue 4.0 Jan 01

SIDE CODING

Open the box containing the GENESIS equipment and inspect the contents. The

printer is packaged completely assembled for your convenience. Included in the

contents is a mounting kit (Parts #96509-01) containing two bolts, nuts and

lockwashers to be used to install the printer onto a conveyor.

Check the contents of the mounting kit. Contact your local representative

immediately if any parts are missing. In order to complete the installation, an

Allen wrench set (English) is necessary. An Allen wrench set is supplied in the

Operations kit (optional).

Install the mount base onto your production line. In the package is a self stick

template (part no. 96694-01) that will assist in the location of the mounting

holes. Otherwise, drill and tap two (2) 5/16”-18 (6.5 mm) holes that are 2 1/2”

(63.5 mm) apart (center line to center line of the drilled holes). Bolt the mount

base onto the line using the hardware provided in the mounting 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 provided in the mounting kit.

Before inserting the ink cartridge into the ink

well, we recommend flushing the system with

3400 solvent. In the maintenance kits, find the

syringe, two pieces of black tubing and a

small plastic filter. Assemble as shown at left:

attach tubing to the end of the syringe; fill the

syringe half-way with solvent; attach the other

end of this tubing to the filter; take the other

piece of tubing and attach one of its ends to

the filter. Take the free end of tubing and

attach to the barb in the ink well.

Empty the syringe watching the streams of

solvent as they exit the print head. There will be ten streams, straight and

parallel to each other. After this operation, fill the syringe with air and purge out

all excess of 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 the ink supply.

INSTALLATION

2 - 7 96622 issue 4.0 Jan 01

BOTTOM CODING

Open the box containing the GENESIS equipment and inspect the contents. The

printer is packaged partially assembled for your convenience. In addition, there

is a bottom coding mounting kit that will be used to convert the printer,

packaged for side coding, to bottom coding. The kit, Part #96316-01, contains

the bracketry (see Part 7: Parts Lists for a complete listing of these pieces) that is

used to mount the system to an M400 Transport System. For assistance on

installing the printer to a system other than the M400, please call your local

representative.

Included in the contents is another, smaller mounting kit (Part #96509-01)

containing the two bolts, nuts and lock washers to be used to install the print

station onto the M400 Transport System. Check the contents of each mounting

kit. Contact your local representative immediately if any parts are missing. In

order to complete the installation, an Allen wrench set (English) is necessary.

An Allen wrench set is supplied in the Operations kit (optional).

Note: If the M400 transport system still has a door on the operator’s 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 the two #10-32 socket head screws to match the holes in the

mounting plate. On the operator’s side of the M400, locate the two holes that

correspond to the holes in the mounting plate. Mount the fixed dovetail plate

onto the outside of the M400, using the two screws. Tighten the screws.

From the shipping box, find the ink septum assembly. The dovetail of the ink

septum assembly slides onto the matching dovetail of the mounting plate.

Tighten the nylon tipped screw, affixing the ink septum assembly onto the

mounting plate. The adjustment of the ink cartridge will take place after the

installation of the print head.

Install the print station onto the M400 right next to the ink septum assembly. In

the package is a self stick template (part no. 96694-01) that will assist in the

location of the mounting holes. Otherwise, drill and tap two (2) 5/16”-18 (6.5

mm) holes that are 2 1/2” (63.5 mm) apart (center line to center line of the

drilled holes). Bolt the mount base onto the line using the hardware provided in

the mounting kit.

Bolt the mount base of the print station onto the line using the hardware

provided in the mounting kit.

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Genesis single line Operation and Maintenance Manual

Genesis single line Operation and Maintenance Manual

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