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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.
2
Technical Parameters
Electrical Specifications
Weight
Dimensions
Environment Specifications
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
Chapter 3 ............................................................................................................................................................ 13
4
Chapter 4 ............................................................................................................................................................ 18
Chapter 5 ............................................................................................................................................................ 26
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
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
6
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.
• 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.
7
Electrical Safety Guidelines
This section explains the safety guidelines related to the electrical power
supply and cables
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
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.
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 read and understand the MSDS before using any ink, make-up fluid, or
cleaning solution.
Ink and make-up are irritating to the eyes and respiratory system. To
prevent personal injury when handling these substances:
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.
If any ink or make-up fluid container is not completely empty after use, it
should be resealed.
9
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
Cleaning Fluids
WARNING
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
10
Machine Performance
3. DAMAGE TO GUTTER
NEVER attempt to bend the gutter. Its position is fixed.
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.
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.
11
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
Printhead Design
Viscosity Control
• Advanced system for monitoring and controlling ink viscosity.
12
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.
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.
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
17
Chapter 4
Printer Menus
The mains power supply button is located at the side of the printer cabinet.
Use this button to power on and power down printer.
18
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:
19
PRINT DATA
USER FIELD
20
PRINT SET
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
22
MACHINE SET
W) USER-DEFINED
24
Photocell 1 Set
Photocell 2 Set
25
Chapter 5
Operating the Printer
How to start the printer
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.
27
Creating and Editing Messages
Create a Sample Message
For example: Create the following message with a fine name “TEST” to
create this message
2. Input file name TEST then press the enter key, as shown in the
following figure:
28
Message Edit Additional Instructions
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”
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).
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.
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.
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:
33
Instructions for setting items in the Counter User Field
34
Logo user Field
The Logo User Field can create the customized logo of maximum 34 dots
high.
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.
The function can integrate multiple User Fields (clock, counter and text) in to
generate a code.
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:
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
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:
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.
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.
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
41
2. Select the "Shaft Encoder" as "external", and select "Print Mode"
as "Continuous";
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.
In this mode you can set the specific numbers of prints per trigger.
43
Setting analysis:
44
Chapter 6
Maintenance
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:
The shape of the drops can be adjusted through the “Modulation Set
Level” in the MACHINE SET menu.
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.
Chapter 8
50
Troubleshooting
Diagnostic Screen
In any interface, press button to enter the diagnostic screen, and
the interface is a follows:
51
Failure and warning icons
Failure icons
52
Warning icons
53
Troubleshooting without Icons
Reason Solution
No voltage of the power supply Check the power supply and related fuse
Reason Solution
The printhead is too far from the product Adjust the distance between the
printhead and the printing surface
Reason Solution
Error in print width or wrong print on
product position Adjust the print width or printing delay
Reason Solution
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
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
CH/MOD – TO PRINTHEAD
Pin Wire Color Signal Function
J7 – PHASE DETECTION
Pin Wire Color Signal Function
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
64
Chapter 9
Speed Chart
65