Squid Ink CoPilot 500 User manual

2005482 Rev G –210505 - BETA
CoPilot 500
Industrial Inkjet Printing System
User Guide

2Abbreviations & Terminology
2005995 Rev O – 210712

2005995 Rev O – 210712
CoPilot 500
Industrial Inkjet Printing System
User Guide
For use with:
•CoPilot 500 Controller,
CoPilot 500 Turbo Controller, or
CoPilot 500 High Speed Turbo Controller
•CoPilot 500 Oil Printhead or
CoPilot 500 Solvent Printhead
Revised 7/12/2021
P/N 2005995 – RevO
Copyright and Trademarks
Copyright ©2021 Squid Ink Manufacturing.
All rights reserved. All trademarks and brand names
are the property of their respective owners.
Alfamaq
1a. Cda. Jacarandas #14 Col. El Vergel, Iztapalapa. Ciudad de
México C.P. 09880
(55) 5426-4137 800 253-2627
[email protected] www.alfamaq.mx

4Abbreviations & Terminology
2005995 Rev O – 210712

2005995 Rev O – 210712
Contents
Abbreviations & Terminology ..................................................................9
Safety .....................................................................................................11
Understanding Safety Notifications ............................................................................. 12
General Precautions ................................................................................................... 12
Introduction............................................................................................13
General System Description ....................................................................................... 13
System Components................................................................................................... 15
Printhead Overview..................................................................................................... 16
Controller Overview..................................................................................................... 17
System Specifications ................................................................................................. 18
Software Specifications............................................................................................... 20
Component Dimensions.............................................................................................. 21
Printhead...............................................................................................................................21
Controller...............................................................................................................................22
Options........................................................................................................................ 23
Mounting Hardware...............................................................................................................24
Installation and Setup............................................................................25
General Recommendations ........................................................................................ 25
Material Handling ..................................................................................................................25
Grounding .............................................................................................................................25
AC Power ..............................................................................................................................25
Work Area .............................................................................................................................26
Vibration................................................................................................................................26
Maintenance Access.............................................................................................................26
Mounting ..................................................................................................................... 27
Mounting the Controller.........................................................................................................28
Mounting Printhead(s)...........................................................................................................29
Mounting the Ink System.......................................................................................................31
Mounting a Photocell.............................................................................................................34
Distance from Substrate........................................................................................................35
Rotating or Tilting the Printhead............................................................................................38
Connecting the Ink Supply .......................................................................................... 39

6Abbreviations & Terminology
2005995 Rev O – 210712
Cartridge Ink System Setup ..................................................................................................39
Bag Ink System Setup...........................................................................................................44
Printhead Height Relative to Ink Reservoir or Ink Pan..........................................................47
Cable Connections...................................................................................................... 51
Connecting Photocell Trigger to Controller ...........................................................................51
Connecting an Optional Encoder to Controller......................................................................52
Custom Triggering Device.....................................................................................................53
Printhead Data Cable............................................................................................................54
Connecting a Second Printhead ...........................................................................................55
Connecting a Second CoPilot 500 Printing System ..............................................................56
Connecting an Optional Low Ink Warning Beacon................................................................57
Connecting to a Desktop PC.................................................................................................58
Connecting to a Local Area Network.....................................................................................59
USB Port ..................................................................................................................... 60
Optional Four Port USB Hub.................................................................................................61
Power Supply .............................................................................................................. 62
Commissioning the Printhead ..................................................................................... 63
Commissioning an Ink Cartridge System ..............................................................................63
Commissioning a Bag Ink System ........................................................................................66
Software Interface .................................................................................69
Interface Button Overview........................................................................................... 69
Home Screen .............................................................................................................. 74
Zoom Screen............................................................................................................... 75
Message Screen ......................................................................................................... 76
Delete....................................................................................................................................76
Message Screen Remote Server ................................................................................ 77
Settings Screen........................................................................................................... 78
Line Speed............................................................................................................................79
Distance to Trigger................................................................................................................81
Print Direction........................................................................................................................82
Encoder.................................................................................................................................83
Repeat and Squid Connect Trigger Settings.........................................................................84
Counters................................................................................................................................86
Spit Settings..........................................................................................................................87
Barcode Validation................................................................................................................89
USB Load..............................................................................................................................90

2005995 Rev O – 210712
Reset.....................................................................................................................................92
Printhead Temperature .........................................................................................................93
Calibrating the Touchscreen .................................................................................................94
Remote Database Server......................................................................................................95
Set Date ................................................................................................................................97
Set Time................................................................................................................................98
Peak Encoder Speed ............................................................................................................99
Custom Keyboard ...............................................................................................................100
Language ............................................................................................................................102
Static IP Address.................................................................................................................104
User Data............................................................................................................................105
Wireless Interface ...............................................................................................................106
Temperature Warning Screens ...........................................................................................110
GUI Refresh ........................................................................................................................112
Software Setup ....................................................................................113
Entering the Proper Settings ..................................................................................... 113
Operation..............................................................................................115
Powering On ............................................................................................................. 115
Creating a Print Message.......................................................................................... 116
Transferring a Print Message .................................................................................... 116
Loading a Print Message .......................................................................................... 117
Printing a Message ................................................................................................... 118
Powering Off ............................................................................................................. 118
Maintenance.........................................................................................119
Checking Mounting Hardware and Connections ....................................................... 119
Cleaning the Nozzle Faceplate ................................................................................. 119
Flushing the Printhead .............................................................................................. 120
Purging the Printhead of Air Bubbles ........................................................................ 123
External Cleaning...................................................................................................... 123
Preparing a CoPilot 500 for Shipping or Storage ...................................................... 123
Troubleshooting ...................................................................................127
Parts List ..............................................................................................129
Replaceable Parts..................................................................................................... 129
Complete Systems ..............................................................................................................129

8Abbreviations & Terminology
2005995 Rev O – 210712
Other Replaceable Parts.....................................................................................................130
Floor Stand Assemblies ......................................................................................................131
Conveyor Mount Assemblies ..............................................................................................132
Inks and Fluids .......................................................................................................... 133
Exploded Views......................................................................................................... 134
Cartridge Ink System...........................................................................................................134
Bag Ink System...................................................................................................................137
Printhead.............................................................................................................................139
CoPilot 500 Controller*/CoPilot 500 HiSpeed Controller**..................................................140
CoPilot 500 Turbo/CoPilot 500 HiSpeed Turbo Controller..................................................141
System Updates ...................................................................................145
Applying Updates from USB ..................................................................................... 145
Product Warranty .................................................................................147
Warranty Statement .................................................................................................. 147
Warranty Period ........................................................................................................ 147
Printheads................................................................................................................. 147
Repairs...................................................................................................................... 147
Print Quality .............................................................................................................. 147
Shipping Policy.......................................................................................................... 147
Exclusions................................................................................................................. 147
Warranty Procedures ................................................................................................ 148
Warranty within 60 days of invoice............................................................................ 148
Warranty 60 days to 1 year from invoice (6 months for Printheads).......................... 148
Warranty Eligibility..................................................................................................... 148
Limited Warranty ....................................................................................................... 148
Disclaimer of Damages ............................................................................................. 149
Technical Support................................................................................151

Abbreviations & Terminology 9
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Abbreviations & Terminology
The following abbreviations are used throughout this User Guide:
Abbreviation Meaning Abbreviation Meaning
C Celsius NTFS A USB format
CE Meets safety, health, and
environmental requirements of
the European Union
P/N Part Number
cm Centimeters PDF417 A barcode format
CP500 CoPilot 500 PNP Positive-Negative-Positive
dpi Dots per inch QR A barcode format
EAN-8 A barcode format RJ12 Registered Jack 12
EAN-15 A barcode format SCC-14 28 A barcode format
F Fahrenheit SCC-14 ITF A barcode format
FAT32 A USB format SSCC-18 A barcode format
fpm Feet per minute SSID Service Set Identifier
ft Feet TUV Meets the requirements of the
German Equipment and Product
Safety Act
GB Gigabytes UCC-128 A barcode format
GND Ground UDP User Datagram Protocol
GUI Graphic User Interface UPC-A A barcode format
Hz Hertz USB Universal Serial Bus
IP Internet Protocol VAC Volts Alternating Current
IT Information Technology W Watts
LED Light-Emitting Diode WiFi Wireless networking technology
ml Milliliters °Degrees
m Meters ‘ Feet
MicroQR A barcode format “ Inches
min Minutes < Less than
mm Millimeters > Greater than
MSI A barcode format # Number
NPN Negative-Positive-Negative % Percent

10 Abbreviations & Terminology
2005995 Rev O – 210712

Safety 11
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Safety
Please follow these simple safety steps to ensure smooth and safe operation:
•While unpacking and setting up the unit, always take care to use proper lifting techniques.
Avoid overreaching and leaning over while handling the printer and accessories.
•While installing, maintaining, and operating the printing system, always wear safety glasses,
gloves, and protective clothing.
•Make sure the electrical power source is properly wired and grounded. The power source
should comply with all safety regulations and codes applicable to the installation location.
•Turn off and unplug the printing system while servicing and performing maintenance.
NOTE: Some service and maintenance procedures require the power to be left on. During
such procedures, carefully follow the safety instructions.
•Use only Squid Ink Manufacturing ink and Squid Ink Manufacturing approved fluids.
•The Squid Ink CoPilot 500 printer systems use a Cartridge Ink or Bag Ink system. Do not
open or puncture the Ink Cartridge or Ink Bag in any way other than normal installation.
•Keep all fluids away from open flame and excessive heat, as they may be combustible.
•Avoid prolonged contact with skin. Fluids can be washed with soap and water.
•Do not look directly into the Printhead. If fluids make eye contact, flush immediately with
water and receive appropriate medical attention.
•Never pour fluids into sink, sewer, or drain. Dispose of fluids in accordance with all
ordinances and regulations pertaining to fluid disposal.

12 Safety
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Understanding Safety Notifications
WARNING:
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION:
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
ATTENTION:
Indicates a hazardous situation which, if not avoided, could result in property
damage only.
General Precautions
When installing, operating, and maintaining the CoPilot 500, observe the following precautions.
WARNING: Health Hazard
Some inks and solvents may be a health hazard if exposed for too long.
Ensure that the area has adequate ventilation.
WARNING: Electrical Hazard
Do not open cover. No user-serviceable parts inside.
WARNING: Electrical Ground Hazard
Ensure that unit is properly grounded.
WARNING: Keep Dry
Keep the equipment dry and indoors.
CAUTION: Fire Hazard
Inks, cleaners, and flush fluids may be flammable. Use caution and keep away
from flame.
CAUTION: Environmental Hazard
Inks, cleaners, and flush fluids may be harmful to the environment. Dispose of
properly.

Introduction 13
2005995 Rev O – 210712
Introduction
General System Description
The CoPilot 500 printing systems consist of a Controller with integrated Touchscreen user
interface and up to two Printheads that can use either Cartridge Ink or Bag Ink systems. The
CoPilot 500 printing systems are designed to print superior quality high-resolution characters on
a variety of porous surfaces.
NOTE: For the purposes of this document, unless a specific differentiation is made:
•“CoPilot 500” can refer to a:
oCoPilot 500 system
oCoPilot 500 Turbo system
•“Controller” can refer to a:
oCoPilot 500 Controller
oCoPilot 500 HiSpeed Controller
oCoPilot 500 Turbo Controller
oCoPilot 500 High Speed Turbo Controller
•“Printhead” can refer to a:
oCoPilot 500 Oil Printhead
oCoPilot 500 Solvent Printhead
oCoPilot 500 HiSpeed Printhead
NOTE: 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 may also cause harmful interference in which case the user will be required to correct
the interference at his or her own expense.
Messages for the CoPilot 500 printing systems are created and edited using PC-based Orion™
software. Messages are then loaded onto the Controller through an Ethernet connection or from
a USB device. Refer to the Orion™ Software User Guide that came with the printer for
information on how to create and print messages.
The Controller sends the print messages to the Printhead. If using a Cartridge Ink system, ink
flows from the Ink Cartridge down into the Ink Reservoir and through an Ink Line to the
Printhead. If using a Bag Ink system, ink comes from an Ink Bag installed in an Ink Pan and

14 Introduction
2005995 Rev O – 210712
flows through the Ink Line to the Printhead. The ink is then ejected onto the substrate through
the Ink Nozzles on the front of the Printhead. Because the system uses capillary action (rather
than a motor) to help supply the ink to the Printhead, the CoPilot 500 is referred to as a “passive
ink system.”

Introduction 15
2005995 Rev O – 210712
System Components
•Controller
•Printhead(s)
•Printhead Data Cable(s)
•Photocell (Trigger)
•Encoder (Optional)
•Ink System (Bag or Cartridge)
•Mounting Hardware
IMPORTANT: If you purchased an optional level of Orion™ that allows connecting to multiple
Printers, a Download Instructions card is included in the shipping carton. Do not throw this
card away. The card contains the Orion license number required for downloading Orion and
connecting the CoPilot 500 printing system. If there is no card, you can still download Orion
and connect to a single printer. If there are problems, call Customer Service at 800-877-5658.

16 Introduction
2005995 Rev O – 210712
Printhead Overview
Nozzle
Face
Ink Level Signal Port
(Cartridge Only)
Data Cable
Port
Photocell Mounting
Bracket Holes
Ink Line
Fitting
Purge Tube
(Capped)
Check
Valve
Hose
Clamp
Power &
Communication
Indicator LED
Front View
Rear View

Introduction 17
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Controller Overview
Printhead 1
Data Cable Port
Printhead 2
Data Cable Port
Power Cord
Receptacle
Power
Switch
USB
Port
Ethernet
Port
Photocell/Encoder OUT
to Second CoPilot
System
Photocell/Encoder IN
Fuse
Label with
Serial Number
Touchscreen
Display
Front View
Rear View

18 Introduction
2005995 Rev O – 210712
System Specifications
Print Technology Piezo impulse Printhead technology
Maximum Print Height 2.8” (7.1 cm) per Printhead
Maximum Throw Distance 0.19” (48.3 mm)
Message Length 180” (457.2 cm)
Vertical Print Resolution 185 dpi
Horizontal Print Resolution 205 dpi
Time and Date Internal real-time clock with battery backup
Product Sensor External Photocell trigger or optional Encoder
Communication Interface One USB host and one Ethernet input
Electrical Requirements 100–240 VAC, 50/60 Hz, 65 W maximum
Storage Environment 34 °F (1 °C) - 122 °F (50 °C)
Substrate Capabilities Porous and non-porous applications
Ink Capabilities Oil-based or solvent-based, depending on Printhead
Ink System Passive Ink Control System:
Squid Ink Manufacturing 500 ml cartridge or 500 ml Bag Ink
systems.
Low Ink Indicator Message alert on Touchscreen
Optional Low Ink Alarm Beacon
Agency Certifications TUV and CE certified

Introduction 19
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Specifications That Vary by Model:
Metric CoPilot 500
Oil Printhead
CoPilot 500
Solvent Printhead
CoPilot 500
HiSpeed Printhead
Controller Compatibility
CP500*
CP500 Turbo
CP500 HiSpeed Turbo
CP500*
CP500 Turbo
CP500 HiSpeed**
CP500 HiSpeed Turbo
Ink Compatibility Oil Solvent Oil
Print Speed Up to 205 fpm
(62 m/min) @ 205 dpi
Up to 150 fpm
(45 m/min) @ 205
dpi
Up to 300 fpm
(91 m/min) @ 205 dpi
for static messages.
Contact Squid Ink
Technical Services at
1-800-877-5658 for
dynamic message
speed assistance.
Drop Size 60 pL 60 pL 30 pL
Operating Environment 34° F (1° C) to
104° F (40° C)
62° F (17° C) to
100° F (37° C)
34° F (1° C) to
104° F (40° C)
* The CoPilot 500 Controller has been replaced by the CoPilot 500 Turbo Controller.
** The CoPilot 500 HiSpeed Controller has been replaced by the CoPilot 500 HiSpeed Turbo Controller.

20 Introduction
2005995 Rev O – 210712
Software Specifications
Time and Date
Multiple formats including: 1,2,4, -digit year, 1,2-digit month, 3 letter
month, custom month string, 1 letter day of month (Korean), 2-digit
day of month, 1-digit day of week, 1,3 letter day of week, 2-digit week
of year, 3 digit Julian year, 1 letter hour, (a-x), 2-digit hour 12 or 24,
2-digit minute, 2 digit second, 1,2 letter meridians (A/P, AM/PM),
custom week string.
Counters Supports 16 Counters, one of which can be a daily counter.
Shift Codes Four programmable shift codes with automated rollover.
Barcodes
Code 39, Interleaved 2 of 5, UPC-A, EAN-8, EAN-13, Code 128,
UCC-128, SCC-14 ITF, SCC-14 28, SSCC-18, MSI, DataMatrix, QR,
MicroQR and PDF417 bar codes standard.
Fonts
Arial (regular and bold), Courier, Tahoma (regular and bold), and
Lucida resident fonts for use in variable data elements. Static
elements in any Windows®font.
Printing Features Reverse, Rotate, Repeat, Invert
Message Storage Capacity 1024 Messages. There is capacity to store more than 1024
messages based on the message complexity up to 1 GB free space.
Message Length Limited by substrate length up to 180”
Logos and Graphics Orion™ Graphical Interface Software supports almost any type of
image file.
Languages English, Spanish, German, Chinese, Japanese, Korean, Russian,
and Polish.