DuraCode Series

Continuous Inkjet Printer

SERVICE MANUAL

www.inkjetinc.com | 1-800-280-3245

1
 Compliance Information
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction manual.
Operation of this equipment in a residential area is likely to cause harmful interference, in
which case the user will be required to correct the interference at his own expense.

*This equipment is not approved nor has the capability to connect to a browser or used as a portal
into the internet. The interface function can only to be used as a guide to operate or navigate the
machine for its intentional use.

2006/42/EC Machinery Directive

2014/35/EU Low Voltage Directive
2014/30/EU Electromagnetic Compatibility Directive

EN ISO 12100:2010 Safety of machinery – General principles for

Design – Risk assessment and risk reduction

EN 60204-1:2006+A1:2009+AC:2010 Safety of machinery – Electrical equipment of

machines – General requirements

EN 55032:2015 Electromagnetic compatibility of multimedia

Equipment – Emissions requirements

EN 55024:2010+A1:2015 Information technology equipment –

Immunity characteristics – Limits and methods
of measurement

EN 61000-3-2: 2014 Electromagnetic compatibility – Part 3-2 Limits

for harmonic current emissions

EN 61000-3-3:2013 Electromagnetic compatibility – Part 3-3 Limits

of voltage changes, voltage fluctuations and
flicker in low-voltage supply systems

2
 Technical Parameters

Electrical Specifications

Voltage 100V – 240V AC

Frequency 50Hz – 60Hz
Energy Consumption 120W Maximum Value

Weight

Net Weight 27Kg (59.5 Lbs.)

Dimensions

Case 460mm x 230mm x 565mm

(18.1” x 9.1” x 22.24”)
Sprayer Diameter 41mm (1.61”)
Sprayer Length 260mm (10.24”)
Nozzle Diameter 70, 60, 50, 40 Micron
Umbilical Length 2700mm (106.3”)

Environment Specifications

Operating Temperature 5◦C to 45◦C (41◦F to 113◦F)

Ambient temperature
replacing rate
Relative Humidity
Storage Temperature
10◦C per hour maximum
0-90%, non-frosting
5◦C to 45◦C (41◦F to 113◦F)

3
 Table of Contents
Chapter 1 .............................................................................................................................................................. 7

Safety .................................................................................................................................................................... 7
Introduction ............................................................................................................................................................. 7
General Safety Guidelines ........................................................................................................................................ 7
Electrical Safety Guidelines ...................................................................................................................................... 8
Electrical Power Supply ................................................................................................................................... 8
Electrical Cables............................................................................................................................................... 8
Grounding ....................................................................................................................................................... 8
Bonding ........................................................................................................................................................... 9
Fluid Safety Guidelines ............................................................................................................................................. 9
Material Safety Data Sheets ............................................................................................................................ 9
Ink and Make-up Fluid ..................................................................................................................................... 9
Cleaning Fluids .............................................................................................................................................. 10
Additional Guidelines ............................................................................................................................................. 10
User Interface Safety Guidelines ................................................................................................................... 10
Machine Performance ................................................................................................................................... 11
In Case of Emergency ............................................................................................................................................. 11

Chapter 2 ............................................................................................................................................................ 12

About the DuraCode DC-60K Printer System ....................................................................................................... 12

Printer Overview .................................................................................................................................................... 12
Operating Simplicity ............................................................................................................................................... 12
Printhead Design .................................................................................................................................................... 12
Viscosity Control ..................................................................................................................................................... 12

Chapter 3 ............................................................................................................................................................ 13

Main Parts of System .......................................................................................................................................... 13

Printer Overview .................................................................................................................................................... 13
Control Panel .......................................................................................................................................................... 13
Power Switch .......................................................................................................................................................... 14
Electronics Compartment Door .............................................................................................................................. 14
Ink Compartment Door .......................................................................................................................................... 14
Electronics Compartment ....................................................................................................................................... 14
Ink Module ............................................................................................................................................................. 15
Umbilical ................................................................................................................................................................ 15
Printhead................................................................................................................................................................ 15
Connector Panel ..................................................................................................................................................... 16
Control System Main Board ................................................................................................................................... 17
Positive Air Pump (Optional) .................................................................................................................................. 17

4
Chapter 4 ............................................................................................................................................................ 18

Printer Menus ..................................................................................................................................................... 18

Before You Start ..................................................................................................................................................... 18
Mains Power Supply Button ................................................................................................................................... 18
Switching On and Starting Up ................................................................................................................................ 18
Switching the Printer On ........................................................................................................................................ 18
Navigating the System Menus ............................................................................................................................... 19
Main Screen ........................................................................................................................................................... 19
PRINT DATA .................................................................................................................................................... 20
USER FIELD .................................................................................................................................................... 20
PRINT SET ...................................................................................................................................................... 21
INK SYSTEM ................................................................................................................................................... 22
MACHINE SET ................................................................................................................................................ 23
F4 PASSWORD ............................................................................................................................................... 24
W) USER-DEFINED ......................................................................................................................................... 24
Photocell 1 Set............................................................................................................................................... 25
Photocell 2 Set............................................................................................................................................... 25

Chapter 5 ............................................................................................................................................................ 26

Operating the Printer .......................................................................................................................................... 26

How to start the printer ......................................................................................................................................... 26
How to perform a clean stop.................................................................................................................................. 27
How to stop and clean (after abnormal shutdown) ............................................................................................... 27
How to stop and clean (long-term storage) ........................................................................................................... 27

Creating and Editing Messages............................................................................................................................ 28

Create a Sample Message ...................................................................................................................................... 28
Message Edit Additional Instructions ..................................................................................................................... 29
Bold, Reverse, Etc. for Specific Characters .................................................................................................... 29
How to Edit / Create User Field .............................................................................................................................. 29
Timer User Field ........................................................................................................................................... 29
Definition of Time User Field Code ......................................................................................................................... 30
How to Print Barcode User Field........................................................................................................................... 31
Additional Remarks for Barcode User Field .......................................................................................................... 32
How to use Counter User Field ............................................................................................................................. 33
Instructions for setting items in the Counter User Field ...................................................................................... 34
Logo user Field ...................................................................................................................................................... 35
Additional remarks for setting pattern size: .......................................................................................................... 36
Code User Field ...................................................................................................................................................... 36
External data User Field (Communications function) .......................................................................................... 38
Message Parameters ............................................................................................................................................. 39
Modify information parameters and contents ............................................................................................ 39
Printing Mode Setting ............................................................................................................................................ 40
Single Printing Mode .................................................................................................................................... 40
Continuous Printing Mode ........................................................................................................................... 40
Measure Printing mode: .............................................................................................................................. 41
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 Traverse Printing Mode ............................................................................................................................... 42
Repeat Printing Mode ................................................................................................................................... 43

Chapter 6 ............................................................................................................................................................ 45

Maintenance ....................................................................................................................................................... 45
How to clean the Nozzle ......................................................................................................................................... 45
Ink Jet Adjustment.................................................................................................................................................. 45
Ink Jet Observation ................................................................................................................................................. 46
Drops Observation ................................................................................................................................................. 47
Draining Ink System ............................................................................................................................................... 48
System cleaning ..................................................................................................................................................... 49

Chapter 7 ............................................................................................................................................................ 49

System Commissioning ....................................................................................................................................... 50

Chapter 8 ............................................................................................................................................................ 50

Troubleshooting .................................................................................................................................................. 51
Diagnostic Screen ................................................................................................................................................... 51
Failure and warning icons ...................................................................................................................................... 52
Failure icons .................................................................................................................................................. 52
Warning icons ............................................................................................................................................... 53
Troubleshooting without Icons ................................................................................................................................ 54
Troubleshooting in Debug ...................................................................................................................................... 55
Ink Module Flow Diagram ...................................................................................................................................... 56
Ink Module Valve Layout ........................................................................................................................................ 58
Electrical Pinouts .................................................................................................................................................... 61

Chapter 9 ............................................................................................................................................................ 65

Speed Chart ........................................................................................................................................................ 65

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 Chapter 1
Safety

Introduction

The intended use of the DuraCode series printer is to print information directly onto a product.
Use of this equipment in any other fashion may lead to serious injury.

The safety guidelines provided in this manual are intended to educate the operator on all safety
issues, so that the printer is operated in a safe manner.

All personnel operating equipment must be aware of the hazards associated with inkjet
printers. All safety information contained within this document should be made available to all
personnel and is applicable to any person in the printers operating environment. Only
personnel who have been fully trained on the equipment are qualified to operate it.

General Safety Guidelines

Only InkJet Inc. trained personnel should provide maintenance and
installation of equipment. Work performed by unauthorized personnel may
cause damage to the printer and may invalidate the warranty.

• ALWAYS ensure that the printer electrical supply is isolated prior to

performing cleaning or maintenance activities. Lethal voltages are present in
the printer cabinet and printhead when mains power is applied, which can
cause death or serious injury if the correct electrical procedures are not
observed.

• The printhead must be completely dry before starting the printhead to

prevent damage.
•
• Only use lint free cloths when cleaning equipment to avoid damage to the
printhead.

• DO NOT fit or remove any connector on the printer when the power is turned
on to avoid damage to printer.

• AVOID personal injury and equipment damage by using the main power
cable supplied with the equipment. The end of this cable must be an
approved, three-pole, main plug that has a protective ground conductor.
Sockets and plugs must remain clean and dry. Always inspect cables for
damage, wear, corrosion, and deterioration.

• The printer must be connected to an AC power supply that has a protected

ground conductor and must be according to IEC requirements or applicable
local regulations.

• AVOID personal injury and equipment damage by using a suitably grounded

antistatic wrist strap when working on or handling PCBs.

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Electrical Safety Guidelines
This section explains the safety guidelines related to the electrical power
supply and cables

Electrical Power Supply

WARNING

Lethal voltages are present within this equipment when it is connected to the
mains electrical supply. Only training and authorized personnel must carry
out the maintenance work. Observe all statutory electrical safety codes and
practices. Unless it is necessary to run the printer, disconnect the printer
from the mains electrical supply before removing the covers or attempting
any service or repair activity. Non-adherence to this warning can result in
death or personal injury.

Electrical Cables
WARNING

Use only the power cable supplied with the printer. The end of this cable
must have an approved, three-pole plug that has a protective ground
conductor.

The electrical power cables, sockets and plugs must always be kept clean
and dry.

Always inspect cables for damage, wear, corrosion, and deterioration. Make
all grounding connections void of areas of paint, ink buildup, and corrosion.

Grounding
WARNING

The printer must be connected only to an AC power supply that has a

protective ground conductor and must be according to the IEC requirements
or applicable local regulations.

Do not use this printer if there is damage to the protective ground conductor
or if the protective ground conductor has been disconnected. Failure to
follow this warning can cause electrical shock.

Always ground conductive equipment to earth ground or to a building

grounding system with approved cables as per NEC standards in order to
drain all potential static discharge. An example would be to ground a metal
service tray to earth ground.

In the case of the grounded service tray, the equipment chassis or mounting
bracket should be 0 to less than 1 ohm.

To ensure proper grounding, the resistance between the main lead earth
wire and the test points must be less than 1 ohm.

8
 Bonding
WARNING

Always prevent static discharge from occurring by using proper grounding

and bonding methods.

Always bond conductive equipment together with approved cables to

maintain them at the same potential and minimize static discharge. For
example, printhead to metal service tray.

Fluid Safety Guidelines

The effects of solvents and inks are potentially harmful, therefore safety precautions
must be followed to prevent hazards.

Material Safety Data Sheets

Always read and understand the MSDS before using any ink, make-up fluid, or
cleaning solution.

Ink and Make-up Fluid

WARNING

Ink and make-up are irritating to the eyes and respiratory system. To
prevent personal injury when handling these substances:

ALWAYS wear protective clothing and rubber gloves.

ALWAYS wear goggles with side-shields or face masks.
APPLY barrier hand cream before handling ink.

If ink or make-up fluid contaminates the skin, wash area immediately with
soap and water. DO NOT use washdown or solvent to clean ink stains from
the skin.

WARNING

Ink and make-up fluid are volatile and flammable. They must be stored and
handled in accordance with local regulations.

DO NOT smoke or use an open flame in the vicinity of these substances.

IMMEDIATELY remove any tissue or cloth that become saturated in these

substances after use. Dispose of all such items in accordance with local
regulations.

If any ink or make-up fluid container is not completely empty after use, it
should be resealed.

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 WARNING

When setting up the nozzle, direct the ink stream into a beaker or suitable
container. Dispose of all waste ink in accordance with local regulations.

WARNING

Prolonged breaking of make-up fluid or cleaning fluid vapor may cause

drowsiness and/or effects similar to alcohol intoxication. Use in open well-
ventilated areas.

Cleaning Fluids
WARNING

The cleaning agent is irritating to the eyes and respiratory system. To

prevent injury when handling this substance, please do the following:

ALWAYS wear protective rubber gloves and protective clothing

ALWAYS wear goggles with side-shields or a face mask. It is also advisable
to wear safety glasses when performing maintenance.

APPLY barrier hand cream before handling the cleaning agent.

If the cleaning agent comes in contact with skin, rinse off with running water
for at least 15 minutes.

CAUTION

To prevent damage to the printhead, make sure that the cleaning agent is
compatible with the ink used.

Additional Guidelines

User Interface Safety Guidelines

CAUTION

To prevent unauthorized access to the software, ensure that CLEAR

PASSWORD is executed when exiting from a higher-level password.

Ensure that the correct message name is selected when deleting a

message. The delete option does not ask for confirmation before deleting
messages.

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 Machine Performance

1. EXCESSIVE USE OF MAKE-UP FLUID.

As solvent is used during the stop cycle, repeatedly starting and stopping
and starting the printer can lead to excessive use of make-up fluid or solvent.
This makes the viscosity go out of the range and can lead to ink Mixer Tank
Full error.

2. QUICK STOP JET

The quick stop feature allows the printer to be stopped without going through
the entire shutdown procedure. This is useful during diagnostics to stop
printer without the solvent flush cycle. However, the machine must not be
left in the same state for any length of time as drying ink may make restarting
difficult. Please start the jet and use the full shutdown procedure so solvent
can be flushed through the printhead.

3. DAMAGE TO GUTTER
NEVER attempt to bend the gutter. Its position is fixed.

4. DAMAGE TO CHARGE ELECTRODE

The charge electrode is not adjustable, do not attempt to bend or make any
mechanical adjustments.

5. EQUIPMENT DAMAGE
DO NOT fit or remove any connector on the printer when the power is on,
otherwise printer may become damaged.

6. RISK OF EXPLOSION
If the battery is replaced by an incorrect type, it can lead to an explosion.
ONLY use batteries specified for the system. Always dispose of used
batteries according to the instructions and local regulations.

In Case of Emergency
• In an emergency you may need to stop the printer quickly. To do this:

• Switch the printer’s wall mounted electrical isolator to the off position to shut off
the electricity supply to the printer.

• Alternatively, switch the printer mains power supply switch at the side of the
printer.

• Call for medical assistance as required

If possible, the printer should not be left in this state for a long period of time and
should be restarted at the earliest possible opportunity to prevent ink blockages.
If there is a hazard that prevents safe access to the printer’s power supply, do
not attempt to shut down the printer, just vacate the area. WARNING: IN ALL
EMERGENCY CASES, REMOVE THE CASUALTY FROM THE HAZARD AND
CHECK THE MATERIAL SAFETY DATA SHEETS FOR IMMEDIATE ACTION.
EVACUATE THE CASUALTY TO MEDICAL AID IF REQUIRED.

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 Chapter 2
About the DuraCode DC-60K Printer System

Printer Overview

The DuraCode DC-60K printer system is a fast, reliable, non-contact inkjet printer
designed to provide versatile, uninterrupted operation in factory environments. It is
used to apply sell-by dates, batch codes, logos, barcodes, and other variable
information to a wide range of substrates on the production line using a continuous
inkjet printing technology. It is designed with a stainless-steel enclosure with an
IP55 rating (International Protection rating against dust and water).

Operating Simplicity

• Convenient side panel ‘Power On/Power off’ button

• Simplistic message creation using the full-size QWERTY keyboard, function
keys, and general control keys.

Printhead Design

• Minimal ink build-up and longer intervals between cleaning.

• Robust sleek design for use in the harshest industrial environments.
• Standard 3-meter umbilical, with other optional lengths.
• Nozzle sizes available in 50, 60 and 70 micron.
• Design features an automatic flush cycle when stopping the system to clean
the printhead and maintain clean starts allowing for longer intervals between
manual cleaning.

Viscosity Control
• Advanced system for monitoring and controlling ink viscosity.

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 Chapter 3
Main Parts of System

Printer Overview

Control Panel
The control panel provides the user interface to the printer.

13
Power Switch
The power switch is a push button used to turn the power supply to the
printer on or off. The button is located on the ride side of the printer cabinet
if you are looking directly at the printer.

Electronics Compartment Door

The electronics compartment door is mounted on two hinges. The door has
a seal that is water resistant and prevents any dust from entering the
cabinet.

The door is closed using two M4 x 30 socket head screws. The door
contains the control panel and front panel interface board.

The front panel interface board provides the interface between main control
board and the LCD and keyboard. The assembly is located inside the
electronics compartment door.

Ink Compartment Door

The ink compartment door is mounted on a hinge pin. The door has a seal
that is water resistant and prevents dust from entering the cabinet.

Electronics Compartment

14
Ink Module

Umbilical
The umbilical connects the printhead to the printer cabinet. The umbilical
connects to the ink module which is connected to the main board. It is
through the umbilical that the fluids and control signals are sent to the
printhead.

Printhead
The printhead supports nozzle sizes 50, 60 and 70 microns.

15
Connector Panel

The connector panel provides inputs for several types of external devices.

• Print Trigger 1
• Optional Print Trigger 2 Bi-directional input
• Shaft Encoder
• Status Output (Alarm Light)
• USB
• Optional Ethernet
• Optional I/O

16
Control System Main Board

Positive Air Pump (Optional)

The positive air pump assembly provides dust free air to the printhead which
prevents the accumulation of dust in the printhead and contamination of the
ink.

17
 Chapter 4
Printer Menus

Before You Start

The power supply should already be connected when you come to use the
printer.

WARNING: IF THE PRINTER IS NOT ALREADY CONNECTED AND YOU

ARE IN DOUBT AS TO YOUR ABILITY TO CONNECT POWER, CONTACT
YOUR SUPERVISOR FOR GUIDANCE.

Mains Power Supply Button

The mains power supply button is located at the side of the printer cabinet.
Use this button to power on and power down printer.

WARNING: PLEASE BE SURE TO USE THE STOP PRINTER BUTTON

ON THE FRONT SCREEN BEFORE SHUTTING THE MAIN POWER OFF
TO ENSURE THE CLEANING SHUTDOWN SEQUENCE HAS BEEN
PERFORMED. FAILURE TO RUN THE STOP SEQUENCE COULD
RESULT IN CLOGGING.

Switching On and Starting Up

Switching the Printer On
The printer is started by pressing the power button located on the side of the
printer cabinet. To confirm the printer has power applied, check for the red
LED power indicator located on the control panel

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Navigating the System Menus

Main Screen

The main screen is the default screen after the ink jet printer is powered on,
as shown in the following figure:

1. The current status description area of the device

2. A shortcut function key includes a user-defined function
3. The name of the message
4. The contents of the current message, it’s a WYSIWYG
message box. The contents are completely consistent with the
contents printed by the ink jet printer.
5. The printer Icon display area contains icons that represent
printer state, consumables, warning, failures
6. The counter of the cumulative number of prints. This can be
reset.

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PRINT DATA

1. Used to select and recall the stored messages, which is

equivalent to "F2 Select Print Message" on the main screen;
2. Used to create and edit messages
3. Used to set the default message parameters
4. Used to delete the messages stored in the printer
5. Used to copy the messages in the printer to the USB storage
device
6. Used to copy the messages on the USB to the printer

USER FIELD

1. Used to create and edit user fields

2. Used to delete user fields that have been stored in the printer
3. Used to transfer the custom pattern in the printer to the USB
storage device
4. Used to copy the picture files (Monochrome BMP) on the USB
device to the printer
5. Used to set the date and time codes. For example, if January is
printed as JAN, in the time user field, the date and time codes can
be referenced by referring to a specific letter. RR can refer to the
year code, and SSS can refer to the month code. TT can
reference the day code, UU can reference the hour code, and VV
can reference the minute code.

20
PRINT SET

1. Used to enable or disable the printer function, if set to “Disable”,

the printer will disable the printing function and prompt “High
voltage not activated” in the status bar.
2. Used to select the print quality, standard and high quality 1-15.
Th higher the high-quality selection, the better the printing quality
will be, however it will lower the print speed.
3. Used to set whether "F1 manual start / stop printing" of the main
is activated. If you need to use an external sensor such as a
photocell, you need to set this option to disable.
4. Photocell 1 settings
5. Photocell 2 settings
6. Set the encoder mode, you can set "internal", "external". When
set to "External", it is effective to use an encoder.
7. Used to reset the counter used in the current message to any
value within the counter range.
8. Used to reset the product counter on the main screen to the value
to be reset;
9. It is used to set the printing mode of the printer, which can be set
to “Single”, “Repeat”, “Continuous” and “Traverse”. When the
printing mode is set as "counting", use the menu to set the
"printing times" to control the printing times triggered each time;
10. When the print mode is set to “Continuous”, use this menu to set
“Internal Interval” (valid when the shaft encoder is internal),
“External Interval” (valid when the shaft encoder is external) and
“Measure” related options. Used to set the corresponding word
width, delay and rate of actual effective value and set value of
information interval, the default is 1.

21
 11. When the print mode is set to “Repeat”, use this menu to set the
“Print times” to control the print times per trigger.
12. When the print mode is set to “Traverse”, use this menu to set the
options for traverse printing.
13. It is used to set the ratio between the actual effective value and
the set value of the message width, delay and message interval.
Default value is 1.

INK SYSTEM

1. This selection will flush solvent through the nozzle to clear

blockage.
2. This selection is used to manually clean the printhead by back
flushing the nozzle with solvent.
3. Used to control the pump, valve and other parts separately
4. Used for cleaning umbilical. ONLY for engineers during
debugging.
5. Used to quick start jet
6. Used to quick stop jet without auto cleaning
7. For setting ink type
8. Used to set the viscosity of the ink. Manual or auto
9. Used to calibrate the standard reference pressure
10. For the entire ink system cleaning
11. Used to exhaust the air, usually during commissioning
12. Open/Close the positive air to the printhead (optional positive air)
13. Used to fill the mixer tank with ink to the OK level. It is used when
the machine is commissioned.
14. For emptying the ink in the ink module.

22
MACHINE SET

1. Used to disable the automatic shutdown caused by charge fault.

2. Used to disable the automatic shutdown caused by the gutter
fault.
3. Used to set the modulation value, manual/auto optional, auto
mode only takes effect during startup.
4. Used to set the charge value.
5. Used to set the running pressure.
6. Used to set the heater target temperature.
7. Used to set the phase charge value.
8. Used to set the phase offset value.
9. Used to check the current software information.
10. Used to define the shortcut function on main screen.
11. Used to enable /disable the keyboard buzzer.
12. Used to set the system time and date;
13. Used to set the extra high voltage leakage alarm value.
14. Used to set the output range of the 7KV extra high tension.
15. Used to change the gutter mode.
16. Used for serial port configuration.
17. Used for Ethernet configuration.
18. Used to set the printer language.
19. Used to view equipment maintenance time.
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F4 PASSWORD

Only “Enter Password” menu is displayed before the password is

entered.

1. Used to enter password

2. Used to exit the password to level 0 (The lowest permission).
3. Used to set the password protection level of each function of the
system.
4. Used to modify the user password
5. Used to modify the maintenance password

W) USER-DEFINED

The user can customize frequently used functions to this area.

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Photocell 1 Set

1. Select photocell 1 to be active by high or low level when triggering

printing.
2. The way the external photocell triggers printing, Gate or Trigger
options.
3. This is the time interval between the trigger level and when trigger
level can be obtained again (such as avoiding secondary sensing
in the same product).
4. Select how to handle the photocell signal
5. Open/Close the secondary sensing prompt
6. Set the number of times the photocell is sensed before it is
triggered effectively.
7. This option is associated with the sixth “Signal Times” setting, and
the first few times within the set number of sensing times are valid

Photocell 2 Set

1. Select photocell 2 to be active by high or low level when triggering

printing.
2. Disable, reset counter, Traversing print control, Reset traversing
print, Opposite print, Reset detection, and counting are optional
settings
3. The way of the external photocell triggers printing, Gate or Trigger
are optional.

25
 Chapter 5
Operating the Printer
How to start the printer

1. Connect the printer to an appropriate power source.

2. Remove the printhead cover and check that the various components are
clean and dry. Replace printhead cover.

3. Press to start the jet. This procedure takes approximately 3

minutes. The screen will look as follows:

4. Check the Status Bar on the screen and the LED light, once the jet has
completely started, the Status Bar changes from Starting to Waiting and
the Green LED is lit as follows:

NOTE: Frequent start/stops will cause the ink to over thin, therefore will
affect print quality.

26
How to perform a clean stop

1. Press button, this stops the jet and initiates a clean stop.
During this sequence, the nozzle and ink lines are flushed
with solvent to help alleviate clogging issues. This sequence lasts
approximately four minutes. The main screen will appear as follows:
2. During cleaning after shutdown, remove the printhead cover and
observe if printhead is dirty. If needed, clean the printhead with the
appropriate solvent.

3. During cleaning after shutdown, remove the printhead cover and

observe if printhead is dirty. If needed, clean the printhead with the
appropriate solvent.
4. Only after the sequence has stopped and the main screen appears as
the one below, can the power button can be used to turn the printer off.

How to stop and clean (after abnormal shutdown)

If abnormal shutdown of the printer has occurred due to loss of power, the
printer must be started after the power is back on and the jet needs to be
started. At this time the printer can continue to be used, or can be shutdown
normally.

How to stop and clean (long-term storage)

Due to the quick dry properties of the ink, if long-term shutdown exceeding 3
months is needed, it is suggested to empty the ink tank and clean the
system.

27
Creating and Editing Messages
Create a Sample Message
For example: Create the following message with a fine name “TEST” to
create this message

1. Enter PRINT DATA main menu, select E) Edit/Create followed by

Create New Message. Confirm and enter the interface as shown in
the following figure:

2. Input file name TEST then press the enter key, as shown in the
following figure:

3. Press F1 repeatedly. When the editing state is displayed as “16

High” then input ABCDEF 12345.
4. Press F2 to select in the event you want to select a user code.

5. After the content is entered, press the to switch to the

Save Exit button and confirm.

28
Message Edit Additional Instructions

Combination key, to move the cursor with a

pixel point as the unit.

Combination key, to move the cursor left and

right in units of 100 pixels

Bold, Reverse, Etc. for Specific Characters

In the editor , Press to switch to the “Select” mode.

b. Use to select the characters you want to adjust.

c. After selected, press to adjust the property of characters.

d. After adjusted, press to continue editing the normal

content.
In the editing interface, press key to enter "select character"
mode.

How to Edit / Create User Field

Timer User Field

Follow the steps below to create:

1. Enter the USER FIELD menu, select E) Edit/Create User Field.
Select N) New User Field, as shown in the figure below:

2. Input a file name, switch “ATTR” to “TIME” then confirm, as shown

below.

29
 3. Fill the “Time Code” in the “Text”, and switch the “Type” to the type
needed. If the printing result is digital numbers, just keep it as “value”

4. Press "ENTER" key to complete, then press F2 while editing

message to insert this field into the message.

Definition of Time User Field Code

1. Actual printing date and time = system current time + number of

days of Expiry term. If it is required to print the current time, the
Expiry term is set as 0.
2. In the printing information, the time user field size is determined by
the fonts selected during insertion.
3. When the “Print Form” is Data Matrix or QR Code, the “Width” and
‘Height” shall be set according to the standard.

30
How to Print Barcode User Field
The standards of QR code and bar code supported by the model include:

QR Code (Figure 1), Data Matrix (Figure 2), Code39 (Figure 3), Code128
(Figure 4), EAN8 (Figure 5), EAN13 (Figure 6), EAN128 (Figure 7).

1. Enter the USER FIELD menu, select E) Edit/Create User Field.

Then select New User Field, as shown in the figure:

2. Input a file name, switch “Attr” to “Text” then confirm, as shown in

figure below:

3. Fill the contents of the Barcode to “Text” field, and switch the “Type”
to the barcode required.
4. When the “Type” is Data Matrix or QR Code, it is required to set the
“Width” and “Height”

31
Additional Remarks for Barcode User Field
1. The size (Height x Width) supported by Data Matrix include 10x10,
12x12, 14x14, 16x16, 18x18, 20x20, 22x22, 24x24, 26x26, 32x32,
8x18, 8x32, 12x26, 16x36, 16x48.

2. The size (height x width) supported by QR Code include 21x21,

25x25, 29x29, 33x33.

3. If the prompt of “Unsupported size" or "Coding error" appears,

please modify it to larger height and width for saving.

4. Code39 and Code128 are the Barcodes with variable length, EAN8
can code the character string with length of 7, and EAN13 can code
the character string with length of 12.

5. The width of the Barcode is automatically generated with the

printer, and the height is determined by the current font when the
message is inserted in the User Field. It is not required for the user
to adjust the "Width" and “Height”.

32
How to use Counter User Field
1. Enter the USER FIELD menu, select E) Edit/Create User Field,
then select N) New User Field as shown in the figure below:

2. Input a file name, switch “Attr” to “Text” then confirm, as shown in

the figure below:

33
Instructions for setting items in the Counter User Field

1. Start value: Start value of the counter.

2. End value: End value of the counter
3. Reset value: Value to be reset when the function of "Reset
Counter" of the Photocell 2 is used.
4. Step size: 1 at default, if set as 2, the counter will become "1, 3, 5,
7, ...".
5. Direction: Increase or decrease can be selected.
6. Repeat Count: 1 at default, printing times of each current value.
For example, if set as 2, each counter will be printed for 2 times.
7. Leading Char: Leading character in front of the counter. For
example, a counter ranges from 1 to 999, when the print counter is
“1" and the leading character is "blank space", the printing result is
"1". When the leading character is "0", the printing result will
become "001".
8. INC/DEC: It is used for nesting use between all the counters in the
printer.
9. Type: The counter can be converted to printing in special form,
such as 1D barcode and 2D Barcode. For more details please refer
to “3.5.4 Additional remarks for Barcode User Field”.
10. Mod Count: 10, 16, 26, 32, 34, 36 optional.
11. Exclude Char: When 32 or 34 Mod is selected, 4 or 2 unprinted
letters can be customized.
12. Alarm Delay: Set the delay of the counter alarm, available for
system build-in “COUNTER" only
13. Alarm Duration: Set the duration of the counter alarm, available for
system build-in “COUNTER" only
14. Alarm Value: Set the value of the counter alarm, which needs to be
within the Start and End Value.
15. Hidden Times: Set the number of times this counter needs to be
hidden in the message. The default value is "0", indicating that it is
not hidden.
16. Print Times: Set the number of times this counter needs to be
printed in the message. The default value is 1. For example, when
the Hidden Times and the Print Times are 1, the print is performed
once and disappears once.
17. Trailing Char: Set the suffix following the counter, the default is
empty.

34
Logo user Field
The Logo User Field can create the customized logo of maximum 34 dots
high.

1. Enter the USER FIELD menu, select E) Edit/Create User Field,

then select – N) New User Field, as shown in the figure below:

2. Input a file name, switch “Attr” to “Logo” then confirm, as shown in

figure below:

* Press CUSTOM key in the interface to call "help" window.

3. Operation instructions for logo are shown in the following table:

35
 4. After drawing, press the "F1" key to set the logo size, as shown in
the following figure:

5. Complete the logo size setting, press "ENTER" key to confirm the
size, press the key "F2" to save and exit. Then it can be called and
printed.

Additional remarks for setting pattern size:

1. The default canvas size is 100 dots wide and 25 high

2. Use key to rapidly move the box for setting logo

size.
3. In the message editor, press F2 to call the user fields list.

Code User Field

The function can integrate multiple User Fields (clock, counter and text) in to
generate a code.

1. Enter the USER FIELD menu, select E) Edit/Create User Field,

then select N) New User Field, as shown in the figure below:

36
2. Input a file name, switch “Attr” to “Code” then press Enter to
confirm. When the cursor hovers between Content 1 and Content 6,
press F2 to insert in sequence the User Fields to be combined. as
shown in the figure below:

NOTE:
When the code type is selected as Data Matrix or QR code, the
Barcode Width and Height shall be set.

37
External data User Field (Communications function)
The function can receive the external data predefined by the user and print
them in sequence. The preparation steps are as follows:

1. Enter USER FIELD menue, select E) Edit/Create User Field, then

select N) New User Field, as shown in the figure:

2. Input a file name, switch “Attr” to “External Data” then press

Enter to confirm, as shown in the figure below:

Setting Analysis:
• Number of Char: the bit of data transmitted from the computer
to the ink jet printer.
• "X0" at the upper right corner of the external data editing
interface is the identification code for communications with the
external data User Field. Please correspond it with the setting of
"User Field" in the computer software.
• When the Type is selected as Data Matrix or QR code, the
Width and Height shall be set.

38
Message Parameters

Modify information parameters and contents

In the main interface, press the F3 key to enter the interface to modify the
current message contents and parameters, as shown in the figure below:

1. "WYSIWYG" information editing area;

2. Information parameter editing area;
3. Information file operation area;

Tip: Press key for cycle switching among three areas, and
press the cursor key to move the cursor in the area.

For more details about Message Parameters, please read the following table:

39
Printing Mode Setting
Single Printing Mode
The mode is used to product one print per trigger.
1. Press PRINT SET main menu button to enter the following setting
interface:

The GRAY options indicate that the setting is invalid for the single print mode.

2. Switch the "Print Mode" to "Single" then the printer is in the single
printing mode.
3. If you want to use a sensor to trigger products, the P) F1 Manual
Print must be disabled.

Continuous Printing Mode

The mode is commonly used for building materials, pipe, steel material and
other industries. The common feature is continuous processing of message
at an automatic interval printing.

1. Press PRINT SET button to enter the following setting interface:

40
 2. Switch the "Print Mode" to "Continuous" then printer is in the
continuous printing mode.
3. Enter C) Continuous Print CONFIG " submenu, as shown in the
following figure:

Setting Analysis:
a) This option sets the printing interval time between each piece of
information, in "ms";
b) Enabled when “Shaft Encoder” is set to external or meter counting
c) Enabled when “Shaft Encoder” is set to external or meter counting
d) Enabled when “Shaft Encoder” is set to external or meter counting
e) Enabled when “Shaft Encoder” is set to external or meter counting

Measure Printing mode:

The mode is commonly used in the wire cable, pipe and other
industries requiring labelling of number of meters. The setting method
is as follows (the rotary encoder must be selected):
1. Press PRINT SET button to enter the following setting interface:

41
 2. Select the "Shaft Encoder" as "external", and select "Print Mode"
as "Continuous";

3. Enter "Continuous Print Configure" submenu, as shown in the

following figure:

a) The setting is invalid for the "Measure Printing" mode.

b) Measure: The item shall be set as "Open".
c) The setting is invalid for the "Measure Printing" mode.
d) For example, if the perimeter of the wheel is 250mm, the encoder
with 2000 pulses then the value of pulse per meter is: (1000÷250)
x 2000 ＝ 8000
e) After the value of pulse per meter set, the length of each message
interval within 1000mm can be set in this option.

Traverse Printing Mode

1. Press PRINT SET button to enter the following setting interface:

2. Switch the "Print Mode" to "Traverse" then the printer is in the

traverse printing mode.
3. Enter I) Traverse Print CONFIG submenu, as shown in the
following figure:

42
 The printing effect is:

When the photocell obtains 1 signal, the printer will print 6 times, 3 of
them are forward printings (each printing interval is 200), 3 times
opposite printings (each printing interval is 500), the delay of the first
printing is 16 and the delay of the fourth printing is 100.
If the printing sequence is disturbed, try using Print Reset to reset the
forward and opposite printings.

Repeat Printing Mode

In this mode you can set the specific numbers of prints per trigger.

1. Press PRINT SET button to enter the following setting interface:

2. Switch the "Print Mode" to "Repeat" then the printer is in the

repeat printing mode.

43
Setting analysis:

a) This option sets the internal interval between each message.

f) This option sets the number of repeat prints.

Options b, c, d, and e take effect after “Shaft Encoder” is set as

“external”.

44
 Chapter 6
Maintenance

How to clean the Nozzle

When the nozzle is blocked, manual cleaning is required for the
function. The operation procedures are as follows:
1. Press INK SYSTEM, select and perform F) Wash Nozzle program.
2. After the program is started, manually clean the position shown in
the following figure with cleaning agent.

Ink Jet Adjustment

1. Horizontal alignment: Slightly loosen the screw “A” and rotate the
screw “B” slightly, then the jet stream can be horizontal moved.
2. Vertical alignment: Loosen the screw “C” and rotate the screw “D”
slightly, then the jet stream can be vertical moved.

45
Ink Jet Observation

46
Drops Observation

47
The drops are generated after printer has started normally. It directly affects the
printing effect and printing durability. Good drops roughly depend on the following
three factors:

• Appropriate and stable pressure

• Correct ink viscosity
• Correct modulation value

The observation method is as follows:

1. Take out the magnifying glass in the standard and place it on the
red LED light about 15 mm.
2. Adjust the distance from the magnifying glass up and down slightly
to observe the drops shown in the figure below:

3. The drops are disconnected at the middle of the charge electrode.

The shape of the drops before disconnection can refer to the
following figure:

The shape of the drops can be adjusted through the “Modulation Set
Level” in the MACHINE SET menu.

Draining Ink System

48
 Press Ink System button perform the R) Drain program. Finish the drain
operation according to the system prompt.

System cleaning

Press "Ink System", select "C) System Cleaning", complete the system
cleaning operation according to screen prompt.

Chapter 7
49
System Commissioning

1. Open the lower cabinet door and install the correct ink and makeup
cartridges, lined up to the proper labels.
2. Pull out the ink system, remove the exhaust air plug at the bottom
(Refer to step A) and use a screwdriver to open the top exhaust air
switch (Refer to step B) as shown in the figure below:

3. Push the ink system into the cabin and close the lower cabin door.
4. Enter the INK SYSTEM menu and perform the A) Fill Mixer
program wait for about 30 minutes until the screen shows “Fill Mixer
Tank Finish”.
5. Enter the INK SYSTEM menu and perform E) Exhaust Air program
to complete ink line priming. Screen prompt will advise when
complete. NOTE: Ink will come from the gutter, place waste
container under the printhead prior to exhausting.
6. Clean the printhead

During normal use of the printer, the exhaust vent plug A needs to be
removed, and the exhaust air switch B needs to be opened, otherwise it will
cause printer failure.

Executing a Fill Mixer may result in an ink remaining percentage deviation.

Chapter 8
50
Troubleshooting

Diagnostic Screen
In any interface, press button to enter the diagnostic screen, and
the interface is a follows:

1. Ink pressure and Ink Temperature.

2. Temp Cabinet: Actual upper cabinet temperature.
3. Head: Heater temperature.
4. Phase angle and Phase Profile.
5. Levels: Cavity tank level status.
6. Chamber: VMS tank level status.
7. VMS Set: the optimum viscosity value calculated by the system
according to ambient temperature and ink type.
8. Now: current actual viscosity of ink calculated by the Printer.
9. Mix: Level status of mixer tank, the normal situation is OK: ON,
Low: ON, High; OFF.
10. Solvent Level: Flushing level status.
11. Freq: The Frequency of the printer.
12. Modulation: The current modulation value.

51
Failure and warning icons

Failure icons

52
Warning icons

53
Troubleshooting without Icons

Turn on the power supply, there is no display on screen.

Reason Solution

No voltage of the power supply Check the power supply and related fuse

Poor jet printing character quality or incomplete character

Reason Solution

The printhead is too far from the product Adjust the distance between the
printhead and the printing surface

The character height is too small or too

Reset the character height
large
The character width is too small or too large
Reset the character width

Wrong breakpoint shape Observe and adjust the drop break-up

Clean the gutter pipe deposited with ink,

Ink deposited on the gutter pipe check and adjust the ink position in the
gutter.
The print varies in width and height Determine the printing position again or
select the rotary encoder

No failure prompt but printing is not clear

Reason Solution
Error in print width or wrong print on
product position Adjust the print width or printing delay

No print on product Check sensor sensitivity

Wrong or unstable Ink jet position

Reason Solution

Nozzle blockage Clean the nozzle.

The trained operator can replace the

Filter blockage filter under guidance of the service
engineer.
Wrong ink jet position Check ink jet alignment

54
 Troubleshooting in Debug

Debug Procedures
Procedure Steps Notes
Turn on Gutter Pump
Turn on V2 Watch Mixer level in the diagnostic screen. Stop sequence when Mix
Fill Mixer Manually
Turn on V4 tank shows OK On, Low On, High Off
Turn on V5
Turn on Pump
Turn on Gutter Pump
Turn on V6 This will run the jet as if you pressed the start button. If you want to see
Start Jet Manually
Turn on V8 the modulation, just scroll down and you can turn on modulation.
Turn on V11
Turn on V12
Turn on Pump
Fill VMS Chamber Manually This process should take less than 30 seconds
Turn on V3

Turn on Pump Check solvent level in diagnostic screen, it will fil first. If the cavity tank
Add Makeup to Cavity Tank
Turn on V1 can not fill full in 1 minute, it will say makeup cartridge 0%
Turn on V4
Turn on Pump
Add Ink to Cavity Tank Turn on V2 If cavity can not fill full in 1 minute it will say ink cartridge 0%
Turn on V4
Turn on Gutter Pump
Suck Ink/Makeup from Cavity to Mixer Tank If cavity can not empty in 1 minute, the system will show a "suction error"
Turn on V5
Turn on Gutter Pump
Turn on V6
Empty Damper inside Ink Core Run for about 5 minutes, then drain from tube in front of ink module
Turn on V11
Turn on V12

55
Ink Module Flow Diagram

56
57
Ink Module Valve Layout

58
59
60
 Electrical Pinouts

PEC1 - SENSOR 1
TE Connector
Receptacle Wire Color Signal (Board)
1 Brown Power 24V 1
2 White N/C N/C
3 Blue 0V 3
4 Black A Signal 2
5 Gray N/C N/C

PEC2 - SENSOR 2
TE Connector
Receptacle Wire Color Signal (Board)
1 Brown Power 24V 1
2 White N/C N/C
3 Blue 0V 3
4 Black A Signal 2
5 Gray N/C N/C

ALARM
TE
Connector Field Light stack
Receptacle Wire color Signal (Board) Wireable Wire Color
1 Brown Power +24V 1 1 Gray
2 White 0V Red LED 6 2 Red
3 Blue 0V Yellow 5 3 Yellow
4 Black 0V Blue 4 4 Green
5 Gray 0V Buzzer 3 5 Pink

SENC - ENCODER
TE Connector Field Encoder Wire
Receptacle Wire Color Signal (Board) Wireable Color
1 Brown Power 24V 1 1 Red
2 White Case Ground 4 2 Black
3 Blue Common 4 3 Blue and White
4 Black A Signal 2 4 N/C
5 Gray N/C N/C N/C N/C

61
 EHT
Pins Wire Color Signal Function
1 Red EHT + High Voltage Input Positive
2 N/C N/C N/C
3 Black EHT - 0V
4 N/C N/C N/C

COG - CONSUMABLE DETECTION

Pins Wire Color Signal Function
1 Yellow 0V Signal Ground
2 Green i.ink Ink Detect
3 Yellow & Green 0V Sheild Ground
4 N/C N/C N/C
5 Blue i.solvent Solvent Detect
6 N/C N/C N/C

GEAR PUMP CONTROL - ON THE TOP OF THE INK MODULE GND1

Pins Wire Color Signal Function
1 Brown B Out Stator Drive B (Green) J-17
2 Purple A Out Stator Drive A (Black) J-18
3 Yellow C Out Stator Drive C (White) J-16
4 Red 6V Hall Sensor Positive Voltage J-15
5 Green HC Hall Sensor C Position Signal (Green) J9-14
Ground J9-5, 9, 11, 19
6 Black 0V J8-11, 12, 13, 14
7 White HB Hall Sensor B Position Signal (White) J9-13
8 Blue HA Hall Sensor A Position Signal (Blue) J9-12

GP - GUTTER PUMP GND1

Pin Wire Color Signal Function

1 Red 24V 1
2 N/C N/C N/C
GND J9-5, 11, 19
3 Black 0V
J8-11, 12, 13, 14

62
 LVVSM - VISCOCITY LEVEL DETECT
Pin Wire Color Signal Function

1 Red LV3 Viscocity Tank High Level J8-4

2 White LV1 Viscocity Tank Low Level J8-2

3 Black GND Level Detect GND J8-9, 10

LVSI – CAVITY LEVEL DETECT

Pin Wire Color Signal Function

1 Red LV5 Cavity Tank High Level J8-6

2 White LV2 Tank Low Level J8-3

3 Black GND Level Detect GND J8-9, 10

LVL – SOLVENT (EXTENDER) LEVEL

Pin Wire Color Signal Function

1 Red LV2 Solvent (Extender) Level Signal J8-1

2 N/C N/C N/C

3 Black 0V GND J8-9, 10

CH/MOD – TO PRINTHEAD
Pin Wire Color Signal Function

1 Red Mod 2b Modulation Signal

Charge
2 Yellow & Green 0V Charge Signal 0V
Yellow & Green
3 & Black Mod 1a Modulation Signal 0V
4 White Charge Charge Signal

J7 – PHASE DETECTION
Pin Wire Color Signal Function

1 Silver Phase Signal Phase Signal

63
 P/TRANS – INK PRESSURE AND TEMPURATURE SENSOR GND1
Pins Wire Color Signal Function
1 Brown 12V Pressure Sensor Power J9-4
2 White +ve Pressure Sensor Output J9-3
3 Yellow +ve Pressure Sensor Output J9-2
4 Green 0V Pressure Sensor 0V J9-1
Ink
5 Black Temp Temp Sensor Output J9-8
Temp Sensor 0V J9-5, 9, 11, 19
6 Blue 0V J8-11, 12, 13, 14
7 Red 5V Temp Sensor Power J9-7
J9-5, 9, 11, 19
8 - GND J8-11, 12, 13, 14

P/TRANS – INK PRESSURE AND TEMPURATURE SENSOR GND1

Pins Wire Color Signal Function
1 Green (6 Core) Lid Switch Lid Switch Power
2 White (6 Core) 0V Lid Switch 0V
Gutter
3 Yellow (6 Core) Detect Gutter Detect Signal
4 0V Gutter Detect 0V
Yellow & Green
5 (Shield for 6 Core) 0V GND

6 Blue (6 Core) 0V PH Temp Sensor 0V

Yellow & Green
7 (Shield for 8 Core) 0V GND
8 Black (6 Core) HE TEMP PH Temp Sensor Detect Output
9
10 Red (6 Core) 5V PH Temp Sensor Power
11
12 Red (8 Core) Strobe LED Strobe LED Positive Electrode
13
14 Blue (8 Core) 0V Strobe LED Negative Electrode
15 Green (8 Core) V11 Valve 11 Power
16 Brown (8 Core) V12 Valve 12 Power
17 Gray (8 Core) 0V Valve 11 GND
18 Black (8 Core) 0V Valve 12 GND
19 Yellow (8 Core) 24V PH Heater Power
20 White (8 Core) Signal PH Heater Feedback

64
 Chapter 9
Speed Chart

65