Page is loading ...
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
All rights reserved. No part of this publication may be reproduced, stored on a
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.
/
