Citronix ci5200 Operating manual

ci5000 Series Printer Technical Service Manual
Version 0.1 1
Citronix ci5000 Series Printer
Technical Service Manual
ci5200
ci5300
ci5500
ci5650
Revision 0.1
Part Number:
012 - 1002-007

ci5000 Series Printer Technical Service Manual
Version 0.1 2
THIS PAGE INTENTIONALLY LEFT BLANK.

ci5000 Series Printer Technical Service Manual
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Preface
The Citronix team welcomes you to the ci5000 Series Continuous Inkjet Printer range. We are proud of
this product range and the features it has to offer and are confident that this product will exceed the high
expectations that you, our customers, have placed with us.
We have prepared this manual to provide comprehensive technical information on the ci5000s printers. It
contains important information on how to:
- Operate the equipment safely.
- Care for and maintain the printer.
- Use the day to day functionality of the printer.
- Calibration & troubleshooting.
All rights reserved. No part of this publication may be reproduced, stored on a retrieval system, or
transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise,
without the prior permission of Citronix Inc.
To the best of our knowledge, the information contained in this guide was correct at the time of printing.
Continual enhancement of our products may result in some differences between instructions represented
in this guide and your ci5000 Series Printer.
Citronix and Codes of Excellence are trademarks of Citronix Inc.
This guide was written by:
Citronix Inc.
2241 S. Watson Road, Suite 111
Arlington, Texas 76010
United States of America
www.citronix.com
[e-mail]
© Copyright Citronix Inc. 2003 –2016

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DECLARATION of CONFORMITY
Issuer’s name:Citronix Inc.
Issuer’s Address: 2241 S. Watson Road, Suite 111, Arlington, Texas 76010, United States of America
Tel: [phone] Fax: [phone] Email: in[email protected]
Declare under sole responsibility that the products identified herein, have been designed, manufactured
and tested in accordance with the following documents:
EN55022:2011
Information Technology Equipment –Radio Disturbance Characteristics
–Limits and Methods of Measurement.
EN55024:2010 A1:2015
Information Technology Equipment –Immunity Characteristics –Limits
and Methods of Measurement.
IEC60950-1:2005(2nd ed)/
A1:2009/A2:2013
Information Technology Equipment - Safety - Part 1: General
Requirements.
2014/35/EU
Low Voltage Directive
2014/30/EU
EMC Directive
CE-Marked accordingly certification date May 20, 2016
Each product marketed, is identical to the representative unit tested and found to meet the standards.
Trade Name: Citronix
Type of Product: Continuous Ink Jet Printer
Model: ci5200, ci5300, ci5500, ci5650
Signed for and on behalf of
Citronix Inc.
2241 S. Watson Road, Suite 111
Arlington, Texas 76010
*Original signed and available from local distributor*
____________________
Michael Embree
Engineering Director
Signature Dated May 20, 2016
FCC Notice

ci5000 Series Printer Technical Service Manual
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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, may cause harmful interference to radio communications. 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 own expense.
Any changes or modifications not expressly approved by the manufacturer could void the user's authority
to operate the equipment.
FCC/Industry Canada Statement
This device complies with FCC Part 15 and Industry Canada license exempt RSS standard(s). Operation
is subject to the following two conditions: (1) this device may not cause interference, and (2) this device
must accept any interference, including interference that may cause undesired operation of the device.
This device complies with Health Canada’s Safety Code. The installer of this device should ensure that
RF radiation is not emitted in excess of the Health Canada’s requirement.
Changes or modifications not expressly approved by the party responsible for compliance could void the
user’s authority to operate the equipment.
French Version:
Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts
de licence. L'exploitation est autorisée aux deux conditions suivantes : (1) l'appareil ne doit pas produire
de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le
brouillage est susceptible d'en compromettre le fonctionnement
Cet appareil est conforme avec Santé Canada Code de sécurité 6. Le programme d’installation de cet
appareil doit s’assurer que les rayonnements RF n’est pas émis au-delà de I’exigence de Santé Canada.
Les changements ou modifications non expressément approuvés par la partie responsable de la
conformité pourraient annuler l'autorité de l'utilisateur à utiliser cet équipement.
European EMC Statement
This product may cause interference if used in residential areas. Such use must be avoided unless the
user takes special measures to reduce electromagnetic emissions to prevent interference to the
reception of radio and television broadcasts.

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CONTENT
GENERAL INFORMATIONSECTION 1:
GRAPHICAL USER INTERFACESECTION 2:
PRINTER OPERATIONSECTION 3:
INSTALLATION AND COMMISSIONINGSECTION 4:
STATUS BAR/TROUBLESHOOTINGSECTION 5:
CLEANING AND MAINTENANCESECTION 6:
COMMUNICATIONSSECTION 7:
SPARES & ACCESSORIESSECTION 8:
CALIBRATIONSECTION 9:
ci5650 AIR SYSTEMSECTION 10:
REFERENCESECTION 11:

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GENERAL INFORMATIONSECTION 1:
CONTENTS
Page
Introduction............................................................................................................................ 1-3
Before You Begin........................................................................................................................... 1-3
Safety Information ................................................................................................................. 1-3
Specific Warnings .......................................................................................................................... 1-4
Health and Safety.................................................................................................................. 1-4
Introduction.................................................................................................................................... 1-4
Basic Requirements....................................................................................................................... 1-4
Storage .......................................................................................................................................... 1-5
Fire Risk ........................................................................................................................................ 1-5
Printer Overview.................................................................................................................... 1-5
Controller Cabinet ................................................................................................................. 1-7
Hardware Specification: ................................................................................................................. 1-8
Interfaces:...................................................................................................................................... 1-8
Inputs (opto-isolated, open collector or TTL type): ......................................................................... 1-8
Outputs: ......................................................................................................................................... 1-9
User Interface and Firmware Capabilities: ..................................................................................... 1-9
Operating Environment: ................................................................................................................. 1-9
Electrical Requirements: ................................................................................................................ 1-9
Controller and Printhead Physical Characteristics:......................................................................... 1-9
Printhead and Umbilical....................................................................................................... 1-11
Printhead: .................................................................................................................................... 1-11
Umbilical: ..................................................................................................................................... 1-11
Printhead Dimension Drawings: ................................................................................................... 1-11
Print Speeds and Print Quality Charts ................................................................................. 1-13
Print Speed Chart - Drop Size: Normal/Internal Encoder.............................................................. 1-14
Print Speed Chart - Drop Size: Normal/External Encoder ............................................................ 1-14
Print Speed Chart - Drop Size: Macro/Internal Encoder ............................................................... 1-15

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Print Speed Chart - Drop Size: Macro/External Encoder.............................................................. 1-16
Print Speed Chart - Drop Size: Micro/Internal Encoder ................................................................ 1-17
Print Speed Chart - Drop Size: Micro/External Encoder ............................................................... 1-18
Print Speed Chart - Drop Size: HS50/Internal Encoder ................................................................ 1-19
Print Speed Chart - Drop Size: HS50/External Encoder............................................................... 1-20
Consumables and Delivery.................................................................................................. 1-21
Ink System........................................................................................................................... 1-22
Ink and Makeup Tanks................................................................................................................. 1-24
Ink Pump ..................................................................................................................................... 1-24
Ink System Valves & Manifold...................................................................................................... 1-24
Pressure Transducer ................................................................................................................... 1-26
Viscometer................................................................................................................................... 1-26
The ciEasyServ Filter Module ...................................................................................................... 1-26
Ink System Diagram..................................................................................................................... 1-28
Print Head ........................................................................................................................... 1-29
Drop Generator............................................................................................................................ 1-30
Nozzle.......................................................................................................................................... 1-30
Charge Electrode and Strobe....................................................................................................... 1-30
Phase Detector ............................................................................................................................ 1-30
Deflector Plates ........................................................................................................................... 1-30
Gutter........................................................................................................................................... 1-30
Printhead Valve ........................................................................................................................... 1-30
Phase Circuit Board ..................................................................................................................... 1-31
Printhead Cover Sensor............................................................................................................... 1-31
Printhead Temperature Sensor .................................................................................................... 1-31

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Introduction
The Citronix ci5000 Series Continuous Ink Jet Printer applies identifying marks such as “best before”
dates, traceability codes, logos and batch codes onto almost any kind of material or surface. The printers
comprise of hardware, software, and printing fluids that work seamlessly together to provide reliable, high
quality, product coding.
This guide applies to all ci5000 Series Printers, namely ci5200, ci5300, ci5500 and ci5650 as well as
specialty Printers (micro, HS50, Pigment and Heavy Pigment). Any differences between product variants
are identified or highlighted.
It is intended for use by Maintenance and Distributor Service Department technicians and contains
important information on how to:
- Operate the equipment safely.
- Care for and maintain the printer.
- Use the day to day functionality of the printer.
- Calibration & troubleshooting
- Component replacements
Before You Begin
Before printing, make sure:
1. All warnings and notes have been read and understood.
2. The ci5000 Series Printer is correctly installed and integrated with your production line.
3. At least one message has been created, programmed and saved (refer to Section 3 Printer
Operation) or select the default message.
Safety Information
The following symbols are used in this manual. Where they appear next to a procedure or instruction,
they have the significance and importance of written warnings and cautions. WARNINGS, CAUTIONS
and NOTES are provided to avoid hazards and to safely operate the Printer.
A WARNING symbol identifies an operating procedure that if not strictly followed could
result in injury or death. Warnings will be identified by a general warning symbol or a
specific warning symbol.
A CAUTION symbol identifies an operating procedure that if not strictly followed could
result in equipment damage.

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Specific Warnings
The following Warnings should be read and understood by all personnel involved in the operation and
maintenance.
PERSONAL INJURY: The Printer uses extremely high voltages. Only trained and
authorized personnel are allowed to perform maintenance work.
PERSONAL INJURY: Use safety goggles or a face mask when using Ink, Make-up or
Cleaning Solvents to prevent fluids from entering the eyes.
FIRE HAZARD: The Ink, Make-up and Cleaning Solvents are flammable; do not smoke or
use a flame in the vicinity of the Printer, servicing area or chemical storage.
PERSONAL INJURY: Wear protective gloves and clothing when handling Ink, Makeup or
Cleaning Solvent.
Health and Safety
Introduction
Citronix supplies Safety Data Sheets (SDS) giving specific safety information with each of its ink, make-
up and wash fluids. There are also warnings on each container. The following notes are for general
guidance only.
Basic Requirements
When used correctly, printing inks do not cause problems. However, everybody using them should be
familiar with the appropriate safety standards and be aware of the precautions that should be taken. The
following are basic requirements:
Proper standards of industrial practice relating to cleanliness and tidiness must be maintained.
Inks and their containers must be stored and handled with care.
Smoking or the use of open flames (or other sources of ignition) in the vicinity of any inks or
solvents is highly dangerous and therefore strictly inadvisable.
All who come into contact with inks must be properly instructed in their use.
Directions for safe working practices vary according to the environment. The following are broad
principles so that necessary precautions may be taken:
Contact with the mouth must be avoided. Therefore, eating, drinking or smoking, or any personal
habits or actions which may transfer ink to the mouth, must be avoided.
Contact with the eyes must be avoided. Suitable eye protection must always be worn whenever
there is any risk of splashing or misting. If ink does get into the eyes, first aid treatment is to flood
the affected eye for 15 minutes with saline solution, (or clean water if saline solution is not

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available), taking care not to allow the water to run into an unaffected eye. Medical aid must be
obtained immediately.
After exposure to ink, all possible traces must be washed off as soon as possible at the nearest
washing facility.
Most inks contain solvents which may injure the skin. Good working practice must always be
employed and risk assessments carried out. Safety Data Sheets are available that give advice on
personal protective equipment. Most gloves only offer limited and short term exposure protection
and must be changed after any splashing and on a frequent basis.
Many inks contain materials which vaporize easily and can be inhaled. Good ventilation is
necessary.
Any used cleaning materials, e.g. rags, paper wipes, are a potential fire hazard. They must be
collected for safe disposal after use.
Certain inks are allowed for use where they can be in indirect contact with food. In these cases,
the following precautions must be observed in addition to those appropriate to hygiene:
The inks must only be used in printers supplied from new for use with these inks. Any repairs and
replacements must use genuine, new and unused spare parts.
The inks must not be used in printers which have previously been used, at any time, for any other
purpose.
Storage
Printing inks must be stored in well-ventilated buildings, in areas set aside for the purpose, chosen for
safety in case of fire. Materials based on volatile, flammable solvents must be stored in accordance with
local regulations.
Fire Risk
For an electrical fire, do not use water. If water must be used, such as in the case of a Nitro-cellulose ink
fire (see below) the power MUST BE REMOVED first.
Many inks contain Nitro-cellulose as the binder and remain highly flammable when dry. Observe all
warnings given on the machine and the following safety instructions:
If there has been an accumulation of dried ink, do not use metal scrapers to remove it, as they
can produce sparks.
If dry Nitro-cellulose based ink ignites, it will generate its own oxygen and can only be
extinguished by lowering the temperature with water.
If a Nitro-cellulose fire occurs, ENSURE THAT THE ELECTRICAL POWER IS IMMEDIATELY
REMOVED FROM THE PRINTER BEFORE water is used to extinguish the fire. Fire risk is a
most important consideration where printing inks are stored and used. The degree of fire hazard
will vary considerably from one type of ink or wash to another. Solvent-based inks offer a greater
degree of hazard depending on the particular solvent or solvent combination. When there is a
particular hazard the appropriate information is given on the SDS.
Printer Overview
The Printer consists of a Controller cabinet and a print head that are connected by a Flexible conduit.
They work seamlessly together to create reliable product coding. The cabinet is split into an electronics
compartment and a fluid compartment. The electronics compartment houses the controller PCB, has the

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touch screen interface and all interfacing connectors, Low & High voltage power supplies, Pump Motor,
and the power switch.
The fluids compartment houses the ink system, filter module and the ink and make up tanks. These
tanks are filled using their respective fill ports located on the top of the printer.

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Controller Cabinet
The front half of the controller cabinet consists of the electronics compartment. The cover, also known as
the tablet has the touchscreen display, ciSafeFill Reader and controller PCB. The right hand side of the
electronics cabinet houses the air filter. The left side has the accessory connectors (Beacon, Photocell
and encoder) power plug and the power on/off button.
Power On/Off
Button.
Flexible conduit
Touch Screen
Print Head
Reader
Tablet
External Interface
Connectors
Power Cord
Socket

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Hardware Specification:
Single Printhead Control
55-88 KHz
Processor
Cold Fire V4
Speed
250Mhz
Memory
256Mb Flash and 256Mb RAM
Interfaces:
ci5200
Ci5300
Ci5500/ci5650
1 RS232
1 RS232
1 Ethernet
1 RS232 (1200 up to 115.2KB)
USB
USB
USB
SB Card
SB Card
SB Card
Inputs (opto-isolated, open collector or TTL type):
ci5200
ci5300/ci5500/ci5650
1 photocell
2 photocell*
1 shaft encoder
1 shaft encoder
6 programmable**
*Programmable options for Photocell 2
**Remote message selection –255 possible selections
Air Filter
Ink System
Cover

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Outputs:
3 programmable alarms –Warning, Failure, Print Ready (Open Collector, 150mA
sinking)
Programmable dry contact relay
External Power (+24VDC 500mA)
User Interface and Firmware Capabilities:
Color Capacitance touch screen
Graphic downloadable
On board Help/Diagnostics
Integrated graphic creator / editor
Intuitive icon based operation
Automatic diagnostics
WYSIWYG message editing
Event log
Pick and place by pixel field based formatting
Service reminders
Message/Graphic Storage –up to 1000
messages*
Tower Printing Functions
Single button start and stop operation
Continuous print capability
Programmable Password security
Backup / restore functions
Real and expiration time and date coding
Multiple operator languages
Shift and rollover time and date coding
Multi-national character printing (Unicode)
Product and batch counting coding
Downloadable firmware updates (Ethernet or
USB)
Internet browser interface for ci5500/ci5650
*Depending on the size of the messages
Operating Environment:
Temperature
35° –113° F (5° –45° C)
% Relative Humidity
10-90% (non-condensing)
Electrical Requirements:
Auto Ranging
90-260VAC (3 Amp)
Frequency
50-60 Hz
Controller and Printhead Physical Characteristics:
ci5200
ci5300
Enclosure
Black Powder Coated Steel
304 grade Stainless Steel
Environmental
IP55
IP55
Printer Weight
38.4 lbs.*
38.4 lbs.*
Weight Printhead*
2 lbs.
2 lbs.
ci5500
ci5650

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Enclosure
304 grade Stainless Steel
316 grade Stainless Steel
Environmental
IP55
Designed to IP65
Printer Weight
38.4 lbs.*
40.3 lbs.*
Weight Printhead *
2 lbs.
2 lbs.
* The weight of the Printhead and conduit is included in the Printer weight.
Ci5200/ci5300/ci5500 Side View ci5650 Side View
Ci5200/ci5300/ci5500 Front View ci5650 Front View
Cabinet Dimensions
ci5200, ci5300 & ci5500
ci5650
Height
14.2 inches (361mm)
14.2 Inches (361mm)
Width
16 inches (406mm)
17.7 inches (450mm)
Depth
15.9 inches (404mm)
15.9 inches (404mm)

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Printhead and Umbilical
Printhead:
Technology
Continuous Ink Jet (CIJ)
Print
Text, Graphics, Bar codes, Autocodes
Printhead Orientation
Omni-directional
Umbilical:
Three Umbilical lengths are available on all printer types; 9 feet (2.7 meters), 15 feet (4.5 meters), or 20
feet (6 meters).
IP55 –Protected against dust and has limited ingress (no harmful deposit). Protected against low-
pressure Jets of water from all directions; limited ingress permitted.
IP65 –Totally protected against dust. Protected against low-pressure Jets of water from all directions;
limited ingress permitted.
Printhead Dimension Drawings:
Straight Printhead Umbilical Fitting
(ci5200/ci5300/ci5500/ci5650)
Access for Straight Printhead Umbilical Fitting
(ci5200/ci5300/ci5500/ci5650)

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90 Degree Printhead Umbilical Fitting
(ci5500/ci5650 option)
Right Angle Printhead
(ci5500/ci5650 option)

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In-Line Right Angle Printhead
(ci5500/ci5650 option)
Print Speeds and Print Quality Charts
The line speed at which the product passes the Printhead will affect print quality. The following pages
show how to determine the maximum line speeds for each print quality setting. These speeds charts are
calculated at 50 dpi (dots per inch).
When determining the Print settings for the application, the following factors need to be considered:
•Line Speed
•Pixel Setting (vertical resolution)
•Print Resolution or dpi (horizontal resolution or raster pitch)
•Whether an external or internal encoder is used
*For more details reference Section 3 Printer Operation
NOTE: Print Quality/Speed may be selected in increments of 20 to optimize for each application.
300 is the best quality; 0 is the fastest speed. The Speed Chart shows speeds at 0, 100, 200 and
300.
NOTE: ci5200 is available only in Macro mode. Micro and HS50 models are available only with
ci5500 and ci5650.
NOTE: In the following Charts the Characters per second are based on 50 dpi.

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Print Speed Chart - Drop Size: Normal/Internal Encoder
Maximum Line Speed
Pixel Setting
Print Speed / Quality
Selection
Characters per
second
Feet per minute
Meters per minute
1L5
0
3213
1928
588
1L5
100
1428
857
261
1L5
200
989
593
181
1L5
300
756
454
138
1L7
0
2142
1285
392
1L7
100
989
593
181
1L7
200
676
406
124
1L7
300
514
308
94
1L9
0
1224
857
261
1L9
100
648
454
138
1L9
200
441
308
94
1L9
300
334
234
71
1L12
0
876
701
214
1L12
100
419
335
102
1L12
200
283
227
69
1L12
300
214
171
52
1L16
0
292
350
107
1L16
100
178
214
65
1L16
200
126
151
46
1L16
300
97
117
36
2L7
0
1285
771
235
2L7
100
756
454
138
2L7
200
494
297
90
2L7
300
330
198
60
1L19
0
237
308
94
1L19
100
145
188
57
1L19
200
101
131
40
1L19
300
77
100
31
1L25
0
104
188
57
1L25
100
71
129
39
1L25
200
51
92
28
1L25
300
40
71
22
3L7
0
559
335
102
3L7
100
494
297
90
3L7
200
313
188
57
3L7
300
207
124
38
1L31
0
56
157
48
1L31
100
37
104
32
1L31
200
26
74
23
1L31
300
21
58
18
4L7
0
476
286
87
4L7
100
389
234
71
4L7
200
214
129
39
4L7
300
143
86
26
Print Speed Chart - Drop Size: Normal/External Encoder