Kortho GraphicJet X Series User manual

MANUAL
GraphicJet X-series
Edition: H550 AE Rev.:007
English
kortho

kortho KGJ X-series H550 AE Rev.: 007
ii
bv korthofah
P.O. box: 3040
2220 CA, Katwijk
The Netherlands
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.kortho.com,www.kortho.eu
Document date: 16/08/2019
Manual: H550 AE KGJ TSC20 EN 006.doc
Number of pages: 236
The basis for this manual is:
Series: KGJ X-series
Production year: 2016 - 2018
Original language: English
Standard models: KGJ X18 / X18+ / X18si / X54 / X72 series + TsC20-X / TsC20-X duo
QiC Control version: V1.0-06032018a
Copyright
©
2019 bv korthofah
All Rights Reserved
The kortho logo and the bv Korthofah logo are trademarks of Korthofah BV. All other brand and product
names in this manual are the trademarks or registered trademarks of their respective holders.
Printed in the EC 2019
In light of continuous development and improvement, Korthofah BV reserves the right to modify the
specifications without prior notice. The figures printed in this manual may slightly differ from the Kortho
GraphicJet. Information in this document is subject to change without notice.
No part of this document may be reproduced or transmitted in any form or by any means, electronic or
mechanical, without the written permission of Korthofah BV.

H550 AE Rev.: 007 kortho KGJ X-series
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▪Preface
Welcome to the GraphicJet X-series manual.
Read the manual before you start and read it carefully. This will avoid unnecessary problems and loss of
performance.
This manual is meant for all personnel who are involved with the GraphicJet X-series, which includes the
control units TsC20-X and TsC20-X duo and the coding units X18, X18+, X18si, X54 and X72. The purpose of
this manual is to get familiar with the GraphicJet X-series. This involves operational, safety, transport &
storage, installation, commissioning, fault diagnosis and maintenance instructions.
The general construction for the different types of coding units of the GraphicJet X-series is the same.
Because of this there is no need to show pictures of each individual model. Functions which are typical for a
particular control unit and/or coding unit will be marked by the type identification between brackets e.g.
[TsC20-X duo] if the function is only available for the Control unit TsC20-X duo or [X72] if the function is not
available for the coding unit X72.
All personnel must read the first four sections named INTRODUCTION, TECHNICAL DESCRIPTION,
PRINT PROCESS DESCRIPTION and SAFETY. The other sections provide instructions or information for
different aspects of the GraphicJet X-series.
Keep this manual on a sensible and safe place for future use.
Contact Korthofah BV or your local distributor if you have any questions.
Conventions in this manual:
▪The GraphicJet X-series will be referred to as the printer.
▪Any material the printer is used to print on is called substrate.
▪The customer is the person or company who is the owner of the printer.
▪Follow the instruction order as indicated when you carry out any of the procedures described.
Instruction format:
1. Instruction. Comment(s).
a. Sub-instruction. Comment(s).
b. Sub-instruction. Comment(s).
2. Instruction. Comment(s).
▪Symbols in this manual
In this manual, the following symbols are used:
WARNING:
This symbol indicates a potentially hazardous situation which, if instructions are not followed,
could result in death or serious injury.
CAUTION:
This symbol indicates a potentially hazardous situation which, if instructions are not followed, may
result in minor or moderate injury or damage to property.
The statements above are notes for your safety.
Beware:
A notice with useful information for the user in relation to the product. It attends the user to
possible problems.

kortho KGJ X-series H550 AE Rev.: 007
iv
Note:
Gives the user suggestions and helps the work to be carried more rapidly.
▪Glossary
Bitmap: A data file or structure. A set of bits that represents a graphic image, with each bit
or group of bits corresponding to a pixel in the image.
Datum: Drawing term for a fixed reference point from which measurements are taken.
Encoder: This is a shaft encoder. It converts shaft rotations to pulses for accurate and precise
measurements. The encoder generates pulses from which the control unit can
extract the product speed information in order to match the print speed.
Host: A machine or production system that handles the product or substrate and can be
connected by an interface to the printer, e.g. a printer alarm to stop the machine.
Label: A design file from which the printer generates the bitmap to print. This design file
can contain a unique combination of text, numeric, date, time, barcode and/or
graphical items.
Label memory: Memory on the CPU board in which the labels, fonts and graphics can be stored.
From this memory labels can be selected for printing (stored in the printlab
memory).
Nozzle: A narrow piece attached to the end of a tube so that the liquid that comes out can
be directed in aparticular way. In this case a small hole in a nozzle plate. The
printhead comprises an array of channels containing ink. Ink droplets are ejected
from a nozzle at the end of each channel as a result of pressure waves generated in
the ink by deflection of the channel walls.
Nozzle plate: A polymer film in which the nozzles are formed.
Pixel: A pixel is the smallest portion of a bitmap. For a printer one pixel represents one
dot.
Print: The result of printing a label on a substrate.
Print memory: Memory on the CPU board in which the label that one likes to print will be stored.
Print request: A signal generated by a sensor or host machine. It is a trigger to start a print cycle.
Print cycle: The moment from which the printer accepts a print request until the printer is
ready to accept a new print request.
Product: In this manual, the substrate the printer prints on, e.g. a box, package etc.
Sensor: A product detection device connected to the control unit, usually a photocell.
Substrate: This is the material of a product to print on, e.g. cardboard, wood, paper, and
packaging foil.
i

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v
▪Table of contents
▪Preface..................................................................................................................................iii
▪Symbols in this manual.........................................................................................................iii
▪Glossary................................................................................................................................iv
▪Table of contents ...................................................................................................................v
1INTRODUCTION
1.1 Qualified personnel............................................................................................................ 1-1
1.2 Elementary personal protection......................................................................................... 1-1
1.3 Intended Use ..................................................................................................................... 1-1
1.4 Specifications..................................................................................................................... 1-2
1.4.1 Coding unit ....................................................................................................... 1-2
1.4.2 Control unit....................................................................................................... 1-3
1.4.3 Ink..................................................................................................................... 1-4
1.4.4 Label features................................................................................................... 1-4
1.4.5 Life span........................................................................................................... 1-5
1.4.6 Electrostatic charge.......................................................................................... 1-5
1.4.7 Shock & vibration ............................................................................................. 1-5
2TECHNICAL DESCRIPTION
2.1 The print system................................................................................................................ 2-1
2.2 Coding unit......................................................................................................................... 2-2
2.3 Control unit......................................................................................................................... 2-3
2.4 Sensors.............................................................................................................................. 2-5
2.4.1 Photocell........................................................................................................... 2-5
2.4.2 Encoder............................................................................................................ 2-5
2.5 Label design ...................................................................................................................... 2-6
2.5.1 Integrated label design program ...................................................................... 2-6
2.5.2 NiceLabel ......................................................................................................... 2-6
3PRINT PROCESS DESCRIPTION
3.1 Print cycle .......................................................................................................................... 3-1
3.2 Printhead............................................................................................................................ 3-1
3.3 Ink system.......................................................................................................................... 3-2
3.4 Spit function....................................................................................................................... 3-2
3.5 User interface .................................................................................................................... 3-3
3.5.1 Menu structure ................................................................................................. 3-3
3.5.2 LED indicators on control unit .......................................................................... 3-3
3.5.3 Keyboard.......................................................................................................... 3-4
3.5.4 System information........................................................................................... 3-8
3.5.5 Menu structure ................................................................................................. 3-9
4SAFETY
4.1 General.............................................................................................................................. 4-1
4.2 Control unit......................................................................................................................... 4-1
4.2.1 General information.......................................................................................... 4-1
4.2.2 Power supply.................................................................................................... 4-2
4.2.3 Precautions before power-up........................................................................... 4-2
4.2.4 Precautions when opening the control unit...................................................... 4-3

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4.3 Anti-static precautions........................................................................................................4-3
4.3.1 Printhead ..........................................................................................................4-3
4.3.2 Printed circuit boards........................................................................................4-3
4.4 Ink and cleaner...................................................................................................................4-4
4.4.1 General safety measures .................................................................................4-4
4.4.2 First aid measures............................................................................................4-4
4.4.3 Warning labels..................................................................................................4-4
4.4.4 Caution labels...................................................................................................4-4
5TRANSPORT & STORAGE
5.1 Printer equipment...............................................................................................................5-1
5.1.1 Shipping and handling......................................................................................5-1
5.1.2 Pre-transport procedure ...................................................................................5-1
5.1.3 Pre-storage procedure......................................................................................5-2
5.2 Ink and cleaner...................................................................................................................5-4
5.2.1 Handling and storage .......................................................................................5-4
5.2.2 Transport information .......................................................................................5-4
6INSTALLATION
6.1 Requirements.....................................................................................................................6-1
6.1.1 Provided by the customer.................................................................................6-1
6.1.2 Equipment.........................................................................................................6-1
6.1.3 Optional parts ...................................................................................................6-1
6.2 Unpacking..........................................................................................................................6-2
6.2.1 Coding unit........................................................................................................6-2
6.2.2 Control unit .......................................................................................................6-3
6.2.3 Encoder (Optional) ...........................................................................................6-3
6.2.4 Ink set...............................................................................................................6-4
6.3 Coding unit mounting options ............................................................................................6-4
6.3.1 Distance between front plate and product........................................................6-4
6.3.2 Ink reservoir......................................................................................................6-5
6.3.3 Ink reservoir orientation....................................................................................6-5
6.3.4 Printhead rotation [X54] [X72] ..........................................................................6-6
6.3.5 Radial printhead rotation ..................................................................................6-6
6.3.6 Axial printhead rotation [X54] [X72]..................................................................6-9
6.3.7 Radial and axial printhead rotation [X54] [X72]..............................................6-11
6.4 Positioning the sensors....................................................................................................6-12
6.4.1 Photocell for print request (X04).....................................................................6-12
6.4.2 Photocell to enter BCD code into the buffer (X08).........................................6-12
6.4.3 Encoder (optional) ..........................................................................................6-13
6.5 Mounting the control unit..................................................................................................6-14
7COMMISSIONING
7.1 Preparing the control unit...................................................................................................7-1
7.2 Filling the ink system..........................................................................................................7-2
7.3 Tuning the speed related parameters................................................................................7-5
7.3.1 Preparing for the first test print.........................................................................7-5
7.3.2 Tuning the test print with the encoder disabled................................................7-7
7.3.3 Tuning the test print with the encoder enabled ................................................7-8
7.4 General print parameter settings .......................................................................................7-8
7.4.1 Changing the print direction..............................................................................7-8
7.4.2 Changing the print direction and mirroring the label.........................................7-9
7.4.3 Setting the print request parameters................................................................7-9
7.5Spit parameter settings....................................................................................................7-10
7.5.1 Setting the spit parameters.............................................................................7-10
7.5.2 Setting the ink low and ink out outputs...........................................................7-12

H550 AE Rev.: 007 kortho KGJ X-series
vii
7.6 User settings.................................................................................................................... 7-12
8OPERATION
8.1 Powering up....................................................................................................................... 8-1
8.2 Operational ........................................................................................................................ 8-2
8.2.1 Start printing..................................................................................................... 8-2
8.3 Operator data input............................................................................................................ 8-2
8.3.1 Text item input menu........................................................................................ 8-3
8.3.2 Date advance input menu ................................................................................ 8-4
8.3.3 Number start value input menu........................................................................ 8-4
8.4 Label management............................................................................................................ 8-5
8.4.1 Selecting a label for printing............................................................................. 8-5
8.4.2 List labels (Local files)...................................................................................... 8-6
8.4.3 Add labels......................................................................................................... 8-6
8.4.4 Moving a label .................................................................................................. 8-8
8.4.5 Deleting a label................................................................................................. 8-9
8.4.6 Editing a label................................................................................................. 8-10
8.4.7 Creating a label .............................................................................................. 8-11
8.4.8 Showing a preview ......................................................................................... 8-15
8.5 Re-filling the ink reservoir................................................................................................ 8-16
8.5.1 Purging the printhead..................................................................................... 8-17
8.5.2 Priming the printhead..................................................................................... 8-18
8.6 Adjusting printer settings ................................................................................................. 8-19
8.6.1 System settings.............................................................................................. 8-20
8.6.2 Printer settings ............................................................................................... 8-25
8.6.3 Signal settings................................................................................................ 8-28
8.6.4 Network settings............................................................................................. 8-32
8.6.5 Label settings ................................................................................................. 8-35
8.6.6 Print settings................................................................................................... 8-37
8.7 Specific settings for the TsC20-Duo................................................................................ 8-39
9DIAGNOSTICS / TROUBLESHOOTING
9.1 Service............................................................................................................................... 9-1
9.1.1 Test labels........................................................................................................ 9-1
9.1.2 Fonts................................................................................................................. 9-2
9.1.3 Test................................................................................................................... 9-6
9.1.4 Printer............................................................................................................... 9-8
9.1.5 Diagnostics..................................................................................................... 9-10
9.1.6 Graphics......................................................................................................... 9-12
9.2 Information....................................................................................................................... 9-15
9.2.1 General........................................................................................................... 9-15
9.2.2 Health............................................................................................................. 9-16
9.2.3 Backup............................................................................................................ 9-16
9.2.4 System Info .................................................................................................... 9-18
9.2.5 Report............................................................................................................. 9-19
9.2.6 Upgrade.......................................................................................................... 9-21
9.3 Fault finding ..................................................................................................................... 9-23
9.3.1 Control unit..................................................................................................... 9-23
9.3.2 Coding unit ..................................................................................................... 9-24
9.3.3 Print request sensor ....................................................................................... 9-26
9.3.4 Encoder.......................................................................................................... 9-26
9.4 Error/warning messages.................................................................................................. 9-27
9.5 Poor print quality.............................................................................................................. 9-27
9.5.1 General issues ............................................................................................... 9-27
9.5.2 Often seen print results.................................................................................. 9-29
10 MAINTENANCE

kortho KGJ X-series H550 AE Rev.: 007
viii
10.1 Quick and regular checks ................................................................................................10-1
10.2 Nozzle maintenance ........................................................................................................10-1
10.3 Yearly maintenance .........................................................................................................10-1
10.4 Replacing parts of the printhead housing ........................................................................10-1
10.4.1 Anti-static precautions ....................................................................................10-1
10.4.2 Open the printhead housing...........................................................................10-2
10.4.3 Close the printhead housing...........................................................................10-3
10.4.4 Replacing the printhead PCB [X18, X18si, X18+]..........................................10-3
10.4.5 Replacing the printhead PCB [X54]................................................................10-4
10.4.6 Replacing the printhead PCB [X72]................................................................10-5
10.4.7 Replacing the piezo printhead [X18, X18si, X18+].........................................10-6
10.4.8 Replacing the piezo printhead [X54] ..............................................................10-6
10.4.9 Replacing the piezo printhead [X72] ..............................................................10-7
10.4.10 Replacing the ink filter....................................................................................10-8
10.5 Updating firmware and software......................................................................................10-8
11 DISMANTLING & DISPOSAL
11.1 Dismantling ......................................................................................................................11-1
11.1.1 System............................................................................................................11-1
11.1.2 Ink reservoir....................................................................................................11-1
11.1.3 Printhead housing...........................................................................................11-1
11.1.4 Control unit .....................................................................................................11-1
11.1.5 Sensor devices...............................................................................................11-1
11.1.6 Ink and cleaner...............................................................................................11-2
11.2 Disposal ...........................................................................................................................11-2
11.2.1 Disposal method.............................................................................................11-2
11.2.2 Waste separation............................................................................................11-2
Index
▪Keywords ............................................................................................................................... I
▪Figures ................................................................................................................................. III
Part 1; selecting a label for printing over Ethernet. .........................................................................M-1
Select Label command standard version (Unicode) .........................................................M-1
Select Label command standard version (ANSI) ..............................................................M-2
Select Label command Escape version..............................................................................M-2
Part 2; updating text fields inside the printed label over TCP/IP....................................................M-3
Update text field command; standard version .................................................................M-3
Update text field command; Escape version.....................................................................M-4
Appendices
Appendix A Specifications....................................................................................................A-1
Appendix B Dimensions.......................................................................................................B-1
Appendix C Part lists & illustrations .....................................................................................C-1
Appendix D Connections......................................................................................................D-1
Appendix E NiceLabel driver tutorials..................................................................................E-1
Appendix F Quick reference menu structure.......................................................................F-1
Appendix G Error list ........................................................................................................... G-1
Appendix H Using the BCD label selection..........................................................................H-1
Appendix I Using variables in labels....................................................................................I-1
Appendix J Setting and using the security option ............................................................... J-1
Appendix K Restore factory settings using dipswitch ..........................................................K-1
Appendix L The automation feature ....................................................................................L-1
Appendix M Selecting and updating a label over TCP/IP....................................................M-1
Appendix N Remapping inputs & outputs ............................................................................N-1
Appendix O EC Declaration of conformity........................................................................... O-1

H550 AE Rev.: 007 kortho KGJ X-series
1-1
1 INTRODUCTION
1.1 Qualified personnel
Operators are qualified when they have read and understand sections 1 to 8 of this manual. A specific
preliminary training is not required.
Technicians that carry out repairs and technical maintenance on the printer equipment should have
secondary technical education or comparable technical level of knowledge through practical experience.
Installation or servicing of the printer must only be performed by qualified personnel of Korthofah BV or a
local distributor, which is designated by Korthofah BV.
For customer installations authorisation must be obtained from Korthofah BV or a local distributor, which is
designated by Korthofah BV.
1.2 Elementary personal protection
▪Use the printer only in a well ventilated area.
▪Do not eat or drink while working with the ink or cleaner.
When at risk for contact with the ink or cleaner:
▪Wear chemical resistant gloves.
▪Use safety goggles or face shield in case of splash risk.
▪Wear suitable protective clothing as protection against splashing of or contamination with ink or
cleaner.
When installing of servicing the equipment:
▪Ensure that the host machine is stopped.
▪Ensure the control unit of the printer is switched off.
Please read the SAFETY section and the SDS of the ink used for more information. The SDS can be
downloaded from the Kortho website (www.kortho.com).
1.3 Intended Use
The GraphicJet X-series are industrial printers and are designed to print directly on substrates e.g.
cardboard, wood and paper. The printers can print labels with fixed and/or dynamic items. Dynamic items
are items like operator input text, number, date and time. Beside text related items, the printer can also print
items such as barcodes, shift-codes and graphics.
The labels can be designed with a PC based design tool or they can de designed on the control unit. The
labels designed with a PC based design tool can be downloaded to the control unit by Ethernet or by USB
thumbdrive. The labels will be stored in the label memory.
Beware:
USB must be formatted as FAT12, FAT16, FAT32, exFAT, TexFAT in order to be supported. The
NTFS file system is not supported in any of the Windows CE versions.

INTRODUCTION
kortho KGJ X-series H550 AE Rev.: 007
1-2
Normal use means use under normal conditions as described in this manual i.e. use inks recommended by
Korthofah BV and use only original spare parts.
The printer may not be used in areas which have a fire or explosion hazard.
Korthofah BV does not accept any liability for damage to the equipment or personal injury resulting from
improper use of the equipment or improper maintenance. Neither does Korthofah BV accept any liability for
the normal wear-and-tear of the equipment.
1.4 Specifications
Only general specifications are described in this section. Refer to Appendix A for more detailed
specifications.
1.4.1 Coding unit
Fig. 1.1 Coding units, global dimensions
A general impression of the coding unit dimensions is given in Fig. 1.1. The dimensions (H x W x D, in mm)
(bracket included) and the typical specifications of coding units are:
Part.nr.
Coding unit
Height
Width
Depth
Print area
Print speed
Ink type
817752
Coding unit X18
322
170
477
17,5x1500
0-40m/min
GJ8
818157
Coding unit X18+
322
170
477
17,5x1500
0-60m/min
GJ8
818227
Coding unit X18si
322
170
477
17,5x1500
0-40m/min
GJ4
817555
Coding unit X54
322
183
480
53,7x2000
0-60m/min
GJ8
819041
Coding unit X72
322
190
480
71,8x2000
0-45m/min
GJ9
The ambient temperature must be between 5 °C and 40 °C, with a relative humidity between 10% and 90%
(non-condensing).
Use only Kortho GJ inks and cleaners for this printer. Make sure the ink and cleaner used match.