Ice Torus 126 User manual

1-1
Ink Jet Printers
Getting Started Guide
for
ICE Torus 126 and ICE Torus 500
Ink Jet Printers
Part Number: 361816-01 AA
December 05

1-1
Table of Contents
2Introduction to the ICE Torus Printer ..............................................................................2-1
3About the Getting Started Guide......................................................................................3-1
4Safety Warnings.................................................................................................................4-1
5About the CLARiTY™ Operating System........................................................................5-1
6Equipment Operation .....................................................................................................6.1-1
6.1 Unpacking.....................................................................................................6.1-1
6.2 Installation Requirements.............................................................................6.2-1
6.3 Mounting Considerations..............................................................................6.3-1
6.3.1 ICE Torus 126.......................................................................................................
6.3-1
6.3.2 ICE Torus 500...............................................................................................6.3-2
6.3.3 The Mounting Bracket..................................................................................6.3-3
6.4 How Do I Ensure a High Quality Print?.......................................................6.4-1
6.5 Should I Select ‘Fixed Speed’ or ‘Encoder’ Mode of Operation?................6.5-1
6.6 Can I Change The Print Direction?...............................................................6.6-1
6.7 How Do I Connect The Print Signal?...........................................................6.7-1
6.8 How Do I Connect an Encoder? ...................................................................6.8-1
6.9 How Do I Connect to the Host Machine Interlocks?....................................6.9-1
6.10 How Do I Set the Correct Air Pressure?.....................................................6.10-1
6.11 How Do I Connect Data Communications?................................................6.11-1
7ICE Torus 126 Ink Fill & Prime..................................................................................... 6.11-1
7.1 Introduction...................................................................................................7.1-1
7.2 Removing Shipping Caps .............................................................................7.2-1
7.3 Initial Checks................................................................................................7.3-1
7.4 Powering up a ICE Torus 126.......................................................................7.4-1
7.5 Priming a ICE Torus 126..............................................................................7.5-1
8ICE Torus 500 Ink Fill & Prime....................................................................................... 7.5-1
8.1 Introduction...................................................................................................8.1-1
8.2 Removing Shipping Caps .............................................................................8.2-1
8.3 Initial Checks................................................................................................8.3-1
8.4 Powering up a ICE Torus 500.......................................................................8.4-1
8.5 Priming a ICE Torus 500..............................................................................8.5-1

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9Adding Ink ..........................................................................................................................9-1
10 What is CLARiTY™ Configuration Manager?...............................................................10-1
10.1 Installing CLARiTY™ Configuration Manager.........................................10.1-1
10.2 Connecting to a ICE Torus Printer..............................................................10.2-1
11 How Do I Select The Correct Printing Mode? ...............................................................11-1
11.1 Setting the Speed in ‘Fixed Speed’ Mode...................................................11.1-1
11.2 ‘Encoder’ mode...........................................................................................11.2-1
12 How Do I Select The Correct Print Direction? ..............................................................12-1
13 How Do I Enable or Disable the Printhead?.................................................................. 13-1
14 How Do I Change the Self Cleaning Frequency of Operation?...................................14-1
15 How Do I Create a ‘Job’ File in CLARiSOFT?................................................................15-1
15.1 Introduction....................................................................................................15-1
15.2 Creating a New ‘Job’ File...........................................................................15.2-1
15.3 Downloading a ‘Job’ File............................................................................15.3-1
15.4 How Do I Select a ‘Job’ For Printing?........................................................15.4-1
15.5 How Do I Change ‘Variable’ Information?................................................15.5-1
15.6 How Do I View Current ‘Job’ Details? ......................................................15.6-1
16 How Do I Prepare a ICE Torus Printer for Shipping?................................................... 16-1
16.1 ICE Torus 126 - Preparing for Shipping – (Dry)........................................16.1-2
16.2 ICE Torus 500 - Preparing for Shipping (Dry)...........................................16.2-1
16.3 ICE Torus 500 - Preparing for Shipping (Wet - Distributor to End User)16.3-1

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2-1
2 Introduction to the ICE Torus Printer
The ICE Torus 126 and 500 Self Maintaining Ink Jet coders have been designed to produce
high resolution, ink jet printed text, barcodes and graphics in a user friendly, cost effective
manner.
Print area for the ICE Torus 126 is 17mm X 1000mm and 70mm X 1000mm for the ICE Torus
500.
To aid ease of use, both the 126 and 500 printers utilise an icon based ‘in-built’ CLARiTY™
Operator interface as standard (with the exception of ‘Slave’ units).
The self maintaining printhead ensures no wasted ink (which can occur with competitor
equipment during purging and priming cycles) and a consistent, high quality code, throughout
a production shift. Ink is supplied via ‘screw in’, non pressurised ink canisters, further aiding
cleanliness and the user friendly nature of the printer.
PLEASE NOTE: There will be sections of the ICE Torus control board that will be
permanently powered via the on-board Lithium battery. It is essential that the board should
NEVER be placed onto nor stored in or on any conductive surface (including conductive,
plastic bags etc.) as this would flatten the battery and/or potentially result in battery
overheating.
If the control board or printer is to be stored for any extended duration, battery link LK5 can
be removed and put onto only one of the link posts until the board / printer is ready to be
used. This reduces battery drain. The battery has an expected 5 years lifespan at normal
ambient temperatures (0-40 deg C).

3-1
3 About the Getting Started Guide
The ICE Torus printer is a versatile ink jet coding machine, configurable for a wide range of
applications. Depending on the experience of the user and the nature of the application, it
may be advisable to seek assistance of trained specialists to install, configure and prepare
the printer for use.
However, in more straightforward circumstances, the Getting Started and User Guide offer
concise information to allow a distributor or End User get a ICE Torus printer ‘up and
running’.
If you are in doubt, call your local support centre and discuss your application before
installing the machine.
Below are photographs of a ICE Torus printer with the main components and connections
highlighted.
Figure 3.1-1
Ink Canister
Air Pipe
Connector
Remote Product Sensor Connector
Power Switch
Mains Power Inlet
I/O, Ethernet and
Comms Connectors
CLARiTY O
p
erator Interface
Printer Status LED

3-2
Figure 3.1-2
PrintheadDust Cap

4-1
4 Safety Warnings
WARNING BEFORE OPENING OR REMOVING ANY PRINTER COVERS,
ENSURE THAT MAINS POWER IS DISCONNECTED AND
COMPRESSED AIR SUPPLIES ARE SWITCHED OFF.
WARNING THIS EQUIPMENT MUST BE INSTALLED WITH A LOCALLY
POSITIONED MAINS SUPPLY ISOLATION DEVICE. THIS CAN BE
EITHER A PLUG AND SOCKET OR A SWITCH DISCONNECTOR
OR CIRCUIT BREAKER IN ACCORDANCE WITH IEC 60947-3 OR
IEC 60947-2.
WARNING ALWAYS ISOLATE EQUIPMENT FROM THE MAINS AND REMOVE
MAINS POWER CONNECTOR TO THE PRINTER BEFORE
ATTEMPTING ANY MAINTENANCE OR REPAIR ON ANY PART OF
THE PRODUCT.
WARNING BEFORE CONNECTING COMPRESSED AIR SUPPLY TO ICE
TORUS, ENSURE THE AIR REGULATOR ADJUSTMENT KNOB
HAS BEEN TURNED FULLY ANTI-CLOCKWISE.
WARNING ENSURE THAT ANY CABLES FROM THE PRINTER ARE
SECURED TO AVOID CHANCE OF MOVEMENT INTO WALKWAYS
AND BECOMING A TRIP HAZARD.
WARNING DO NOT POINT THE PRINTHEAD DIRECTLY AND IN CLOSE
PROXIMITY TO THE EYES, UNLESS THE PRINTER IS SWITCHED
OFF AND ISOLATED FROM THE MAINS AND COMPRESSED AIR
SUPPLIES.
WARNING THE PRINTER UTILIZES AN OPERATOR CONTROL CONSOLE
MOUNTED IN THE TOP OF THE UNIT. ENSURE THAT THIS
PANEL IS AT A HEIGHT WHERE ACCESS AND USE IS LEAST
RESTRICTED.
WARNING REGARD ANY WARNING OR HAZARD INFORMATION SUPPLIED
WITH ANY CLEANING FLUID OR CONSUMABLE PRODUCTS.
WHILST USING ANY CHEMICALS, ALWAYS WEAR PROTECTIVE
GLOVES AND ONLY USE IN WELL-VENTILATED AREAS.
WARNING THERE WILL BE SECTIONS OF THE 602004 ICE TORUS
CONTROL LITHIUM BATTERY – THEREFORE IT IS ESSENTIAL
THAT THE BOARD SHOULD NEVER BE PLACED ONTO NOR
STORED IN OR ON ANY CONDUCTIVE SURFACE (INCLUDING
CONDUCTIVE, PLASTIC BAGS ETC.) AS THIS WOULD FLATTEN
THE BATTERY AND/OR POTENTIALLY RESULT IN BATTERY
OVERHEATING

4-2
WARNING THE ICE TORUS PRINTER IS SUPPLIED WITH WARNING
SYMBOLS FOR POWER SUPPLY AND COMPRESSED AIR.
SHOULD ANY PART OF THESE SYMBOLS BECOME DAMAGED,
WORN OR REMOVED THEY MUST BE IMMEDIATELY REPLACED
WARNING ENSURE THAT ALL EXTERNAL ENERGY SOURCES ARE
ISOLATED FROM THE PRINTER BEFORE OPENING THE OUTER
CASING. THIS INCLUDES THE MAINS POWER CABLE AND I/O
CABLE ASSEMBLY (IF USED)

5-1
5 About the CLARiTY™ Operating System
CLARiTY™ is an intuitive touch screen, icon based operator control system.
It behaves much like web pages of a typical Internet Browser.
Each area of the screen is clearly shown and most areas are ‘active’, i.e. simply touching that
area of the screen is like pressing a ‘button’ on a traditional control panel.
As well as active areas, there are specific ‘button’ icons.
Figure 5.0-1 below, shows the normal Operator ‘Home’ screen
Figure 5.0-1

5-2
Shortcut buttons take you directly to key pages, no matter which page you are currently
using. These buttons are shown in Figure 5.0-2 below:-
Figure 5.0-2
- Home Page
- Tools Page
- Fault and Warning Pages
- Job Page (To load the next image (Job) to be printed and to enter any variable data)
- Current Job (shown as the Current Job Details)
The ‘Navigation Bar’ indicates the location of your current page in the menu tree. At any time
you can either:-
- press the ‘Back’ button to go back up one level, or
- press any level displayed on the Navigation Bar to take you directly to that level.
The ‘Scroll Bar’ will allow you to navigate up and down the page selected, particularly useful for
finding a ‘Job’ in the ICE Torus database.
Navigation Bar Back Button
Scroll Bar
U
p
/Down Ke
y
s
Home Tools
Status Window

5-3
On the left hand side is a ‘Control Frame’ of ‘buttons’ for immediate control of your printer.
These buttons are:-
Figure 5.0-3
There are two further areas showing ‘Production Performance’ and ‘Consumables’ status.
Pressing each of these areas takes you to pages containing further details and statistics.
Figure 5.0-4
Shutdown
Stop
Start
Production
Performance
Consumables

5-4
All user data entry is provided in CLARiTY™ by way of a screen based, alpha-numeric, ‘mobile
phone’ data entry pad.
Please see Figure 5.0-5 for Data Entry pad ‘map’
Key Characters (in turn)
1.,?/:!-&;+#()’"_@$¢£€¥%<>¿¡§=¤
ABC2abcÄÀÁÂÃÅÆÇäàáâãåæç¢
DEF3defÈÉËÊèéëê€
GHI4ghiÎÌÍîìí
JKL5jkl£
MNO6mnoÖÔÒÓØÑöôòóøñ
PQRS7pqrs$ß
TUV8tuvÜÙÛÚüùûú
WXYZ9wxyz
Cursor left
0*
Cursor right
Backspace Clear
Space
Figure 5.0-5

6.1-1
6 Equipment Operation
6.1 Unpacking
Contents
ICE Torus 126 Printer (part number - 402678)
CLARiTY™ Configuration Manager CD-ROM (part number - 400764)
Air Regulator (part number - 402320)
CD-ROM documentation (Getting Started, User Guide, Technical Guide and Illustrated Parts
Guide, part number - 902697)
QA documentation & CE certificate
Power Lead Retaining Clamp (part number - 402478)
OR:-
Contents
ICE Torus 500 Master Printer (part number - 402679)
CLARiTY™ Configuration Manager CD-ROM (part number - 400764)
Air Regulator (part number - 402320)
CD-ROM documentation (Getting Started, User Guide, Technical Guide and Illustrated Parts
Guide, part number - 902697)
QA documentation & CE certificate
Power Lead Retaining Clamp (part number - 402479)
OR:-
Contents
ICE Torus 500 Slave Printer (part number – 402680)
CLARiTY™ Configuration Manager CD-ROM (part number - 400764)
Air Regulator (part number - 402320)
CD-ROM documentation (Getting Started, User Guide, Technical Guide and Illustrated Parts
Guide, part number - 902697)
QA documentation & CE certificate
Power Lead Retaining Clip (part number - 402479)

6.2-1
6.2 Installation Requirements
In order to successfully install a ICE Torus printer, the following services must be available at
the site of the printer installation:-
Power: 90-264 VAC (+/- 10%), 1.5-0.5A, 1~47-63Hz
Compressed Air: 6 Bar, dry, uncontaminated
Print Signal – See notes below:-
Print signalling can be achieved by the following methods:
A 24VDC signal from a PNP sensor (supplied separately, part number - 402276 for a diffuse
sensor kit or part number - 402277 for a retro reflective sensor kit)
or
by utilising the ‘volt free‘ print signal contacts, standard with every ICE Torus printer
PLEASE NOTE:- ALL ICE TORUS PRINTERS CONTAIN AN ‘INTEGRAL’ PRODUCT
SENSOR. HOWEVER, IF THE INTEGRAL SENSOR IS TO BE USED, THE SELF-
CLEANING PRINTHEAD CYCLE WILL BE RENDERED INACTIVATE.
IN ADDITION, IF THE INK CANISTER IS REMOVED THE SELF-CLEANING PRINTHEAD
CYCLE WILL BE RENDERED INACTIVE.
It is highly recommended that a correctly screened, EMC Compliant, remotely mounted retro-
reflective product sensor is used wherever possible.
Operating with a remotely mounted sensor will allow sufficient time for the self-cleaning
printhead cycle to activate between products.
In addition, a retro reflective sensor will reduce the possibility of false print triggering, caused
by product undulations, which can occasionally occur with a diffused sensor.
Sufficient space to mount the printer allowing easy access to the ink canister and the
CLARiTY™ touch screen. Refer to the Technical Guide for printer dimensions.
If the product conveying equipment varies in speed, the ICE Torus encoder kit, part number -
402275, will be required.
IMPORTANT WARNING: It is essential that the ICE Torus 500/126 printers are only used
with a fully screened encoder, Part Number 402275. Failure to do so may result in equipment
damage and product malfunction. Any equipment damage resulting from the use of incorrect
or unscreened encoders will not be covered by the equipment warranty.”
A suitable storage area for replacement ink canisters, dry with a temperature between 10 -
40ºC.
If the printer is not being used, it should also be stored between 10 - 40ºC.

6.3-1
6.3 Mounting Considerations
6.3.1 ICE Torus 126
The ICE Torus 126 is shipped ‘dry’, i.e. all ink has been drained from the system after final
test.
In the shipped/dry state, the printer can be freely handled and positioned in any orientation.
However, extreme care should be taken around the printhead area during handling.
The printhead is designed to only operate in a vertical orientation and once filled with ink,
care must be taken to ensure that it is kept in its upright position.
The upright position presents a 17mm vertical printhead array, which is designed to print onto
vertical substrates, e.g. side wall of a cardboard case or tray.
Mounting holes are provided on the printer sidewall, indicated in Figure 6-3.1 below, for
securing to a conveyor.
The part number for the mounting bracket - 402283
ICE Torus 126 outline dimensions can be viewed in the Technical Guide
Figure 6.3-1
ICE Torus
126

6.3-2
6.3.2 ICE Torus 500
The ICE Torus 500 printer is shipped ‘dry’ to the Distributor, i.e. all ink has been drained from
the system after final test and shipped ‘wet’ from the Distributor to the End User, i.e. the
printer will be in a fully primed condition.
PLEASE NOTE: the Distributor must follow section 8.0, ‘Ink Fill and Prime – ICE Torus 500’
in this guide, before shipping the ICE Torus to the End User.
The printer is sealed for shipping purposes, to prevent ink spillage, however, it is
recommended to take extreme care when handling the printer, and wherever possible, keep
in an upright orientation.
The printer is designed to operate in a vertical orientation only. Once the shipping seals
(caps) are removed, the printer MUST be kept in an upright position.
The upright position of the ICE Torus presents a 70mm vertical printhead array, which is
designed to print onto vertical substrates, e.g. the side wall of a cardboard case.
Mounting holes are provided on the printer sidewall, indicated in Figure 6.3-2 below, for
securing to a conveyor.
The part number for the mounting bracket - 402283
ICE Torus 500 outline dimensions can be viewed in the Technical Guide
Figure 6.3-2
ICE Torus
500

6.3-3
6.3.3 The Mounting Bracket
It is recommended to mount the printer to the side of the conveyor using the recommended
printer bracket, part number - 402283, as illustrated below.
Conveyor Mounting Bracket
The Mounting Bracket for the ICE Torus printer has been specifically designed to allow quick
and easy installation.
The mounting bracket allows the ICE Torus printer to be adjusted in the vertical and
horizontal planes, to allow for a variety of product widths and heights to be accommodated.
X
Z Y
Figure 6.3-3

6.3-4
‘User friendly’ locking handles on the mounting bracket allow the position of the ICE Torus
printer to be quickly and easily adjusted during production set up.
The upright pole of the bracket may be angled up to +/- 30 degrees from the vertical axis
(The Y axis on the picture above) to accommodate inclined conveyors. This is a rotation of
the printer about the Z axis, in the X-Y plane.
The printer must not be pitched up or down in the opposite direction (i.e. a rotation about the
X axis in the Y-Z plane)

6.4-1
6.4 How Do I Ensure a High Quality Print?
It is essential to convey products past the ICE Torus printhead in a consistent manner.
A high grip, flat belt conveyor with pack guidance is recommended.
Sufficient spacing must be allowed between packs for correct print signalling and to reduce
the possibility of unprinted packs
‘Gravity’ roller conveyors are not recommended the box speed and spacing may be
inconsistent depending upon pack speed and weight
Powered roller conveyors may compromise print quality and are not recommended for
barcode or high resolution graphic applications
ICE Torus 126
- Minimum speed: 10 mm/sec (0.6 m/min)
- Maximum speed: 550 mm/sec (33 m/min)
ICE Torus 500
- Minimum speed: 10 mm/sec (0.6 m/min)
- Maximum speed: 550 mm/sec (33 m/min)
Should clarity of print quality degrade, the most common causes are listed below:-
Inconsistent product movement past the printhead (e.g. gravity conveyors, roller conveyors)
Slippage between conveyor and product
Inconsistent distance between printhead face and printed surface, typically caused by:-
a) Inadequate product guidance (pack handling), or
b) Distorted products (e.g. “bowed” cardboard box)