BUSKRO Apollo BK-IDM-4H User manual

Apollo Ink Delivery System
Part No. 9103326 User’s guide V1.2

Buskro Ltd. Apollo Ink Delivery System
Apollo Ink Delivery System User’s Guide
Published by:
Buskro Ltd.
1738 Orangebrook Court, Unit #1
Pickering, ON, L1W 3G8
Canada
Tel.: [phone]
Fax: [phone]
All Rights Reserved. No part of this book may be used or reproduced in any form or by
any means, electronic or mechanical, or stored in a database or retrieval system,
without prior written permission of Buskro Ltd. except in case of brief quotations
embodied in critical articles or reviews. Making copies of any part of this book for any
purpose other than your own personal use is a violation of copyright laws.
Copyright © 2004, Buskro Ltd.
First Edition, 2004
Printed in Canada
This manual is sold as is, without warranty of any kind, either express or implied,
respecting the contents of this manual, including but not limited to implied warranties for
the manual’s quality, performance, merchantability, or fitness for any particular purpose.
Neither Buskro Ltd. nor its dealers or distributors shall be liable to the purchaser nor any
other person or entity with respect to any liability, loss, or damage caused or alleged to
be caused directly or indirectly by this manual.
Manual History
Version Date Description ECO No.
1.0 30-Nov-04 Manual Released as Preliminary. N/A
1.1 10-Dec-04 First Final Release. N/A
1.2 14-Jan-05 Updated section 2.5 to include multiple IDS setup. 715

Apollo Ink Delivery System
Buskro Ltd. Apollo Ink Delivery System
Table Of
Contents
1.0 General Information.............................................................................1-0
1.1 Description ............................................................................................................ 1-1
1.2 Features................................................................................................................. 1-2
1.2.1 Ease of Installation........................................................................................... 1-2
1.2.2 Convenient Ink Management........................................................................... 1-2
1.2.3 On-the-Fly Refill and Level Sensing............................................................... 1-2
1.2.4 Common Ink Distribution................................................................................ 1-2
1.2.5 Reduced Intervention....................................................................................... 1-2
1.2.6 Lower Consumable Costs................................................................................ 1-2
1.3 Specifications......................................................................................................... 1-3
1.3.1 Apollo Ink Delivery System and Component Specifications.......................... 1-3
1.3.2 Ink Cartridge and Pen Specifications............................................................... 1-3
1.3.3 Production and Consumption Rates................................................................. 1-4
1.4 System Drawings................................................................................................... 1-5
2.0 Ink Delivery System Installation .........................................................2-0
2.1 Regulator Module................................................................................................. 2-1
2.1.1 Mounting the Regulator Module Bracket........................................................ 2-1
2.1.1.1 Mounting onto a Bridge........................................................................................................ 2-1
2.1.1.2 Mounting onto a Base........................................................................................................... 2-3
2.1.2 Regulator Module Height ................................................................................ 2-4
2.2 Ink Delivery Module............................................................................................. 2-6
2.2.1 BK460/660 Controller Installation .................................................................. 2-6
2.2.1.1 Attaching the IDM bracket to the BK460/660 Controller.................................................... 2-7
2.2.1.2 Securing the IDM into the BK700 IDM bracket.................................................................. 2-8
2.2.2 BK700 Controller Installation ......................................................................... 2-8
2.2.2.1 Attaching the IDM bracket to the BK700 Controller........................................................... 2-8
2.2.2.2 Securing the IDM into the BK700 IDM bracket................................................................ 2-10
2.2.3 BK760 System Installation............................................................................ 2-11
2.2.3.1 Attaching the IDM bracket to the BK760 Controller......................................................... 2-11
2.2.3.2 Securing the IDM into the BK760 IDM bracket................................................................ 2-11
2.2.4 BK1700 Controller Installation ..................................................................... 2-14
2.2.4.1 Attaching the IDM into the BK1700 Controller................................................................. 2-14
2.3 Cable Attachment Instructions......................................................................... 2-15
2.3.1 Power Cable................................................................................................... 2-17
2.3.1.1 BK460/660 Power Cable.................................................................................................... 2-17
2.3.1.2 BK700 Power Cable........................................................................................................... 2-17
2.3.1.3 BK760 Power Cable........................................................................................................... 2-17
2.3.1.4 BK1700 Power Cable......................................................................................................... 2-17
2.4 Communication Cable Setup............................................................................. 2-18
2.4.1 RS232 COM Serial Cable Connection .......................................................... 2-18
2.4.1.1 Serial Ribbon Cable Attachment........................................................................................ 2-18
2.4.1.2 Serial Ribbon Cable Software Setup .................................................................................. 2-19

2.4.2 Serial-to-USB Cable Connection................................................................... 2-21
2.4.2.1 Serial-to-USB Cable Attachment ....................................................................................... 2-21
2.4.2.2 Serial-to-USB Cable Software Setup.................................................................................. 2-21
2.4.3 Serial Cable Setup (to Comtrol RocketPort Card)......................................... 2-22
2.5 Compose IQ Software Setup.............................................................................. 2-23
2.5.1 Compose IQ – Multi-Apollo Ink Delivery System Setup.............................. 2-24
2.6 Installing Module Ink Lines .............................................................................. 2-25
2.7 Using the Ink Pens.............................................................................................. 2-27
2.7.1 Ink Pen Installation........................................................................................ 2-27
2.7.2 Ink Pen Removal............................................................................................ 2-28
2.8 Using the Quick Disconnects Fittings............................................................... 2-29
2.9 Alarm Module (Optional).................................................................................. 2-30
3.0 Operating Instructions..........................................................................3-0
3.1 Apollo Ink Delivery Module (BK-IDM-4H)....................................................... 3-1
3.2 Front Panel Indicators......................................................................................... 3-1
3.2.1 LOW-ON-INK Condition................................................................................ 3-2
3.2.2 INK OUT Condition........................................................................................ 3-3
3.3 Ink Cartridge........................................................................................................ 3-3
3.3.1 Inserting an Ink Cartridge into the IDM.......................................................... 3-4
3.3.2 Removing an Ink Cartridge from the IDM...................................................... 3-5
3.3.2.1 Activating the Ink Delivery System ..................................................................................... 3-5
3.3.3 Cartridge Replacement .................................................................................... 3-5
3.3.3.1 Replacing an empty ink cartridge......................................................................................... 3-6
3.4 Ink Pen Assembly................................................................................................. 3-6
3.4.1 Pen Replacement.............................................................................................. 3-7
3.4.1.1 Replacing a defective ink pen............................................................................................... 3-7
4.0 Printhead Maintenance ........................................................................4-0
4.1 General Maintenance........................................................................................... 4-1
4.1.1 Ink Pen Cleaning.............................................................................................. 4-1
4.1.2 Interconnect Pad Cleaning............................................................................... 4-2
4.1.3 Printhead Purging ............................................................................................ 4-2
4.1.4 Ink Line Priming.............................................................................................. 4-3
4.1.5 Ink Pen Disposal and Clean-up........................................................................ 4-4
4.1.6 Ink Pen Storage................................................................................................ 4-4
4.2 Lifetime of Components....................................................................................... 4-4
5.0 Troubleshooting Guide.........................................................................5-0
5.1 Troubleshooting.................................................................................................... 5-1
Appendix A – Assembly Drawings
Appendix B – Assembly Drawings
Buskro Ltd. Apollo Ink Delivery System

General Information Chapter 1
1.0 General Information
Buskro Ltd. Apollo Ink Delivery System

Chapter 1 General Information Page 1-1
1.1 Description
The Apollo Ink Delivery System includes a centralized, rack-mount compatible ink
delivery system (p/n BK-IDM-4H) that pumps HP Versatile inks from a 350 ml ink
cartridge (p/n BKINK-VERBK350) and distributes it to a number of ink pens (p/n BKINK-
VERBKPEN), up to a maximum of 8 pens, for a total vertical coverage of 4”. It
communicates with Buskro Inkjet Controllers (Compose V6.04 or later) via a serial
RS232C connection to provide level sensing and cartridge status information.
A bracket is provided for attachment to existing Buskro BK700 controllers and
BK760/660/460 systems while the BK1700 controller houses the unit on a sub-rack. The
Apollo Ink Delivery System is an optional item on new BK700-series systems (665, 765,
776) or BK760/660/460 systems and is included with BK1700-series systems (1665,
1765, 1776). Power to the unit is provided via a universal IEC connector with input
voltage ranging between 100 – 240 V, 50/60 Hz. The system is comprised of 3 major
elements including the following:
• Ink Delivery Module. Operator accessible module that pumps and delivers
ink from a single 350 mL ink cartridge into a common 4-channel manifold for
distribution to a maximum of 8 ink pens over a maximum distance of 15’.
• Regulator Module. A unit whose function is to regulate the flow of ink into the
individual ink pens. The module(s) whose ink feed line connects directly into
the ink delivery module via a quick-disconnect connector is mounted on a
bracket at an optimal height near the ink pens. Each regulator module
delivers ink to 2 pens for a vertical coverage of 1”.
• Ink Pens. A detachable, print head based on the 45A cartridge design. This
filled ink unit (42mL) has an ink feed line equipped with a quick-disconnect
connector that attaches to the regulator module for refill of the pen during
operation. Its life expectancy is estimated to be between 10-15 complete
refills (>400mL of ink).
Buskro Ltd. Apollo Ink Delivery System

Chapter 1 General Information Page 1-2
1.2 Features
1.2.1 Ease of Installation
The system is equipped with a series of brackets for installation onto existing BK700
inkjet controllers or BK760/660/460 systems. It includes a universal IEC connector with a
100-240 VAC input power requirement for worldwide compatibility. All ink line elements
are connected together with quick-disconnect connectors.
1.2.2 Convenient Ink Management
The ink is distributed and pumped, both vertically and horizontally, over a maximum of
15’ distance from an operator-accessible point to all remotely located ink pens.
1.2.3 On-the-Fly Refill and Level Sensing
The replaceable 350 ml ink cartridge is equipped with level sensing that alerts the operator
for on-the-fly removal and replacement during operation
1.2.4 Common Ink Distribution
The Ink Delivery Module features a common manifold that distributes ink up to a total of
8 ink pens ensuring uniform ink fill to all ink pens, for reduced individual failure.
1.2.5 Reduced Intervention
The large 350 mL supply and the ability to perform on-the-fly exchanges reduces operator
intervention during operation.
1.2.6 Lower Consumable Costs
In addition to improving operational reliability through reduced downtime, ink costs,
including both cartridge and pen replacement, can result in a 20-30% saving over
traditional HP Versatile Ink Pens.
Buskro Ltd. Apollo Ink Delivery System

Chapter 1 General Information Page 1-3
1.3 Specifications
1.3.1 Apollo Ink Delivery System and Component Specifications
1.3.1 Printing Capacity
Minimum Width 1” of print 25.4 mm
Maximum Width 4” of print 101.6 mm
1.3.2 Physical Weight
Regulator Module 0.5 kg 1.1 lbs.
Regulator Bracket 0.86 kg 1.9 lbs.
Ink Delivery Module 4.3 kg 9.4 lbs.
Ink Pen 0.20 kg 0.44 lbs.
Ink Cartridge 0.61kg 1.35 lbs.
1.3.4 Electrical requirements
Line Voltage 100-240 V, 50/60 Hz
Line Current 0.3 Amps maximum
Power 20 W
1.3.5. Operator controls
Main Power Switch Main Power
1.3.2 Ink Cartridge and Pen Specifications
Item Specification Note
Vertical Resolution 600 DPI
Horizontal Resolution 150, 200, 300, 400, 600 DPI Software-selected
Ink Supply Ink Cartridge (350 ml)
Ink Composition Pigmented, water based
Pen Type 42 ml, Thermal ink-jet 2.5
Buskro Ltd. Apollo Ink Delivery System

Chapter 1 General Information Page 1-4
1.3.3 Production and Consumption Rates
Resolution1
(DPI) Production2 (Pieces/hour) Consumption3 (Pieces/84 mL) Surface Speed (in/s) Print Swath (Horizontal)
110 (100) 40,000 150,000 130 (3.4 m/s) 39.5” (1003 mm)
165 (150) 25,000 100,000 87 (2.2 m/s) 39.5” (1003 mm)
220 (200) 21,000 75,000 65 (1.7 m/s) 39.5” (1003 mm)
330 (300) 14,000 50,000 43 (1.1 m/s) 27.8” (706 mm)
440 (400) 10,600 37,500 33 (0.9 m/s) 20.5” (521 mm)
660 (600) 7,100 25,000 22 (0.6 m/s) 13.1” (333 mm)
Note: 1. The Apollo Print head can operate at either a 600 or 660 native resolution. The
resolution used on a particular system depends on the encoder arrangement.
2The Production value is based on a No. 10 envelope (9.5” Long) with a 1.5” gap
between pieces. Longer pieces would decrease the production rate. The
production rating is based on operating frequencies and is the theoretical
maximum based on software constraints. Actual production rates may differ
based on acceptable print quality.
3Ink consumption is based on a 6-line address containing on average 100
characters using an Arial 11 point font. Specifications are based on empirical
study, and where not obtainable, on manufacturer’s specifications.
Buskro Ltd. Apollo Ink Delivery System

Chapter 1 General Information Page 1-5
1.4 System Drawings
4 Channel Ink Port
IEC Power Receptacle
RS232 Connector (DB9)
Alarm Connector
Power Switch
6
5
4
1
7
8
2
3
9
Led Indicator
Figure 1-1: Apollo Ink Delivery System Components (700-IDM4H-06NA shown)
Table 1-1:Apollo Ink Delivery System Components (700-IDM4H-06NA shown)
Item Description Part Number
1 Ink Cartridge, HP Versatile Black, 350 mL BKINK-VERBK350
2 Apollo Ink Delivery Module, 4-Channel BK-IDM-4H
3 Bracket, Ink Delivery Module, BK700 9103267
4 Regulator Module, 6’ BK-BULKREG-06
5 Bracket, Regulator Module 9103243A
6 Ink Pen, Bulk, HP Versatile Black, 42mL BKINK-VERBKPEN
7 Cable, IDM Serial Communication BK-CAB-IDMCOM
8 Cable, IEC Type, 120 VAC BK-CAB-IEC120
9 Priming Tool BK-BULKPRIME
Buskro Ltd. Apollo Ink Delivery System