TrojanLabel Trojan 2 User manual

User Guide
Version 3.8

TrojanTwo User Guide v3.8
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Copyright statement
© 2017 Trojanlabel, This document, attachments and information contained herein are the
confidential and proprietary property of Trojanlabel and their suppliers. As such, this document,
attached files and information contained herein are subject to all nondisclosure and proprietary
information agreements currently in effect with your organization. Copies of this document, any
portion of this document or attachments may not be transmitted or disclosed to any third party
without the prior written permission of Trojanlabel.
© 2017 Trojanlabel All content is the confidential property of, or licensed to, Trojanlabel
(“Trojanlabel,” “we,” or “us”) and is protected under Danish and Foreign copyright, trademark and
other intellectual property laws.
Trojanlabel.com
Marielundvej 46A 2 sal
2730 Herlev
Denmark
Email: [email protected]
Phone [phone]

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Contents
1 Certificate of compliance and Safety Information ................................................................................... 4
1.1 Introduction ..................................................................................................................................... 5
1.2 General information......................................................................................................................... 5
1.3 Overview and application................................................................................................................. 6
2 Setting up the TrojanTwo......................................................................................................................... 8
2.1 Moving and physical setup............................................................................................................... 8
2.2 Cabling (network and power)........................................................................................................... 8
3 Power on.................................................................................................................................................. 9
3.1 Visible safety check .......................................................................................................................... 9
3.2 Power on process............................................................................................................................. 9
3.3 Installing ink tanks and printhead .................................................................................................... 9
3.3.1 Installing ink tanks.................................................................................................................... 9
3.3.2 Installing the printhead .......................................................................................................... 11
4 Threading the machine .......................................................................................................................... 15
4.1 Unwinder and rewinder roll direction............................................................................................ 15
4.1.1 Rolling direction unwinder - Ink jet coating on the inside or outside..................................... 15
4.1.2 Rolling direction rewinder...................................................................................................... 16
4.2 Threading from scratch .................................................................................................................. 16
4.3 Threading using the currently threaded material .......................................................................... 19
4.4 Adjusting Label Edge Sensor........................................................................................................... 21
5 Calibrate the web path (paper) .............................................................................................................. 26
6 Select and queue print/start job ............................................................................................................ 27
7 Pause, resume or stop print job ............................................................................................................. 28
8 Moving the web ..................................................................................................................................... 30
9 Changing label material.......................................................................................................................... 31
10 Printing modes ................................................................................................................................... 31
10.1 Continuous printing mode ............................................................................................................. 31
10.2 Diecut printing mode ..................................................................................................................... 32
10.3 Blackmark printing mode ............................................................................................................... 35
10.4 Gap size and speeds ....................................................................................................................... 38
11 Shutting down the TrojanTwo press .................................................................................................. 38
12 Driver installation/features................................................................................................................ 39
12.1 Driver installation........................................................................................................................... 39
12.2 Driver features and functions......................................................................................................... 42
13 Software features............................................................................................................................... 45
13.1 Right status bar .............................................................................................................................. 45

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13.2 General settings (HOME menu)...................................................................................................... 46
13.2.1 Overview ................................................................................................................................ 46
13.2.2 Settings................................................................................................................................... 46
13.2.3 Statistics ................................................................................................................................. 53
13.2.4 Shutdown ............................................................................................................................... 55
13.2.5 Exporting statistics data to a CSV file ..................................................................................... 55
13.3 TrojanTwo handling (TrojanTwo tab) ............................................................................................. 57
13.3.1 Overview ................................................................................................................................ 57
13.3.2 Handling ................................................................................................................................. 58
13.3.3 Maintenance .......................................................................................................................... 60
13.3.4 Job Library .............................................................................................................................. 62
13.3.5 Print Queue ............................................................................................................................ 64
13.3.6 Diagnostics ............................................................................................................................. 65
13.3.7 Media Settings........................................................................................................................ 66
14 Updating software and firmware on TrojanTwo ................................................................................ 69
14.1 Updating via online updater........................................................................................................... 69
14.2 Updating via offline updater .......................................................................................................... 70
15 Maintenance ...................................................................................................................................... 72
15.1 Regular cleaning/checking tasks..................................................................................................... 72
15.1.1 Wipe down surfaces............................................................................................................... 72
15.1.2 Emptying waste ink bottle...................................................................................................... 75
15.2 Replacing the wiper roller .............................................................................................................. 76
15.3 Manual printhead wiping ............................................................................................................... 79
16 Trouble shooting ................................................................................................................................ 82
16.1 Error States..................................................................................................................................... 82
16.2 Error messages on screen .............................................................................................................. 85
16.3 Firmware update failure................................................................................................................. 87
17 Slitter for the TrojanTwo.................................................................................................................... 88
17.1 Purpose .......................................................................................................................................... 88
17.2 Safety Labels................................................................................................................................... 88
17.3 Replacing Blades............................................................................................................................. 89
17.4 Software settings and usage .......................................................................................................... 93
17.4.1 Enable Slitter in TrojanTwo User Interface............................................................................. 93

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1Certificate of compliance and Safety Information

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1.1 Introduction
Original instructions
These instructions are Trojanlabel’s original instructions for the Trojanlabel press
(henceforth called the machine or TrojanTwo press).
Purpose
The purpose of these instructions is to ensure correct installation, use, handling and
maintenance of the machine.
Accessibility
The instructions are to be kept in a location known to the staff and must be easily
accessible for the operators and maintenance personnel.
Knowledge
It is the duty of the employer (the owner of the machine) to ensure that anyone who is to
operate, service, maintain, or repair the machine have read the instructions. As a
minimum, they should have read the part(s) relevant for their work. In addition, anyone
who is to operate, service, maintain, or repair the machine is under obligation to look for
information in the instructions themselves.
1.2 General information
Manufacturer
The machine has been manufactured by:
Company name: Trojanlabel
Address: Marielundvej 46A 2 sal
2730 Herlev
Denmark
The machine’s designation
The machine’s complete designation is Label Press type Trojan②.
Machine plate
The machine plate (picture) is situated on the back side of the machine at the lower left
corner:

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1.3 Overview and application
General description
The machine consists of an unwinder/rewinder, double dancer arm system, winder
tensioner, label sensor, nip roller, automatic web clamps, splice table, service door, slitter
(optional) and 4 ink tanks.
If any changes or alterations are made to the machine, these changes or alterations must
be reflected in these instructions as necessary.
The machine’s purpose and intended use
Application: The machine is only to be used to print labels.
The machine must not be used for any other purpose than the purpose mentioned above.
Warning about foreseeable misuse
The TrojanTwo may not be used with inks not endorsed by Trojanlabel. All inks purchased
from Trojanlabel or from official Trojanlabel distributors worldwide are endorsed by
Trojanlabel.
Technical specifications
Physical dimensions in millimeters:
Weight approx. 350-360 kg including inks.

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Electrical:
Nominal supply voltage: 110-240V
Nominal supply frequency: 50-60hz
Estimated peak consumption: 400W
Machine power supply:
1000 W (48 VDC, 21 A), please see “T2 Meanwell RSP-1000-spec.pdf” for details:
http://www.trojanextranet.com/media/55924/T2%20Meanwell%20RSP-1000-spec.pdf
Operating positions, location and arrangement
The machine is intended to be used in a light industrial / office environment. The operator
operates the machine in a standing or sitting position.
Temperature
Recommend operational temperatures
•Operation: 20° to 30° Celsius at RH 22-80% (non-condensing)
•Storage: -5° to 50° Celsius at RH up to 85%, non-condensing at 65°
If transferring the machine from different temperature conditions, ensure that the
machine has time to acclimatize.
Operating Environment
It is important that the machine is placed in a clean environment as possible, with sufficient
air conditioning/cleaning. Avoid placing it in an environment with dust and paper debris, as
the print head nozzles are sensitive to this.
Label Materials
The machine requires ink jet coated materials for optimal print quality; some non-coated
materials will also work. Please contact Trojanlabel or your distributor for
recommendations of suited materials.
It is imperative to have a local source of material, to ensure a stable production.

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2Setting up the TrojanTwo
2.1 Moving and physical setup
The machine is equipped with four (4) wheels for light movement. Do not attempt to push the machine
over doorsteps or other obstacles regardless of size. Due to the very low clearance, please take care if
there are even small height variations of the surface.
Place the machine on a stable level surface and secured by lowering the built-in the stands, using the red
tooth-wheel, until the wheels move freely without touching the ground.
Confirm the machine is leveled, using a spirit leveler.
2.2 Cabling (network and power)
The machine has two cable inlets:
1. Power Supply
2. Ethernet
Only the power supply cable is necessary for powering up the machine. The network cable is necessary for
sending new print jobs to the TrojanTwo and for remote support/software updates.
NOTE: Some units does not have the cover for the Ethernet port.
NOTE: Ethernet cable is not included in the TrojanTwo package
Power ON/OFF switch
Power supply
Ethernet port

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3Power on
3.1 Visible safety check
Before powering on the TrojanTwo, visibly ensure that no foreign objects are interfering with the print
engine or web-path.
3.2 Power on process
1. Press the physical power switch on the backside of the TrojanTwo, switching it from 0 to 1.
a. Turning the main power switch on starts up TrojanControl touch screen and print engine.
For safety reasons the web-path not powered up yet to prevent any unexpected movement
of the label material.
b. Web state will display ‘Emergency stop’.
2. Press the physical green start button which can be found on the top of the machine (near the
screen) to initialize (power up) the web path system.
a. Web state will display ‘Initializing’during this process.
b. The initializing process works with or without threaded label material.
3. The machine is fully functional, when the TrojanTwo tab is visible on the TrojanControl software
and the ‘Web state’ field at status bar is ‘Not calibrated’.
3.3 Installing ink tanks and printhead
3.3.1 Installing ink tanks
The TrojanTwo press uses CMYK ink tanks, each contain 2 liters of ink when opened. Every TrojanTwo ink
tank is QA chip protected ensuring that only genuine Trojanlabel ink tanks can be used.
1.
2.
3.

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1. Open door on left side to gain access to ink tanks (orange arrow on picture above).
2. Connect QA chip reader cable (green arrow on picture above).
3. Connect tube with connector (red arrow on picture above).
When ink tank is connected the proper ink level and percentage is displayed at status bar on the touch
screen:
NOTE: TrojanTwo ink tanks are not refillable and shall be treated as hazardous waste when empty.
Ink tank levels
Reservoir ink tank levels

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3.3.2 Installing the printhead
Unpacking printhead:
1. Open the end of the printhead package outer box and slide out the foil bag.
Inspect the integrity of the foil vacuum sealing. The foil bag should be formed tightly to the
contours of the printhead cartridge as shown above. If the foil is loose to any degree then the seal
has been compromised.
NOTE: If a poor seal is suspected, DO NOT USE the printhead. Report the issue to your supplier.
2. Carefully rip the foil packaging open at the notch. Use scissors if your foil bag does not have a
notch or you are finding it difficult to tear the bag.
3. Remove the printhead from the foil bag.
4. Remove the orange protective plastic cover from the printhead cartridge. Holding the printhead
cartridge by the handle
a. Release the flaps covering the ink ports
b. Release the clip retaining the cover near the centre of the printhead cartridge
c. Carefully remove the protective cover
5. Remove the protective strip from the electrical contacts. While holding the printhead cartridge by
the handle with one hand, grasp the pull tab with the other hand and, slowly and carefully, peel
back the plastic strip covering the electrical contacts.

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NOTE: Dispose of the removed strip immediately and do not allow the removed strip to contact
the electrical contacts.
6. Remove the protective strip from the printhead nozzles. While holding the printhead cartridge by
the handle with one hand, grasp the pull tab with the other hand and slowly and carefully peel
back the plastic strip covering the printhead nozzles. Maintain an angle of no less than 45° with
the printhead surface when pulling on the strip.
NOTE: Dispose of the removed strip immediately and do not allow the removed strip to contact
the electrical contacts or the printhead nozzles.
IMPORTANT: Do not throw away the printhead packaging. The white box has the serial number,
part number and manufacturing date of the printhead. Also it is recommended to store
printheads which are currently not installed in the original packaging.
CAUTION!
DO NOT touch the printhead cartridge’s ink couplings, nozzle surface or the
electrical contacts when installing the printhead cartridge. Hold the printhead
cartridge ONLY by the handles.
DO NOT unpack the printhead cartridge until the machine is ready for
installation. Once unwrapped, delay in installing the printhead can
compromise print quality due to dehydration.
DO NOT place an unwrapped printhead on any surface before installing.
Protect the printhead at all times from dust, fibers, dirt and other
contaminants.

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Installing printhead:
1. Open top cover on TrojanTwo press to gain access to the print engine.
2. Press Release Printhead button in TrojanTwo -> Maintenance menu to open printhead
latch:
3. Insert printhead by the handle into the cradle.
a. Open printhead latch all the way up.
b. Insert printhead into the cradle by the handles.
c. Pull the printhead backwards until it snaps into the proper place standing upright.
a.
b.
c.
c.
b.

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4. Close printhead latch.
5. Press Install Printhead button in TrojanTwo -> Maintenance menu to start priming up the
printhead with ink.
NOTE: When the system is primed up for the first time (first installation when there has not
been any ink in the ink delivery system and the reservoir ink tanks), printhead priming only
begins when reservoir ink tanks are filled up with ink. This may take up to 20 minutes before
actual priming of the printhead begins.

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4Threading the machine
There are two common methods of threading the machine, threading from scratch, i.e. there is no material
present in the machine or using the currently installed material to thread the machine.
4.1 Unwinder and rewinder roll direction
4.1.1 Rolling direction unwinder - Ink jet coating on the inside or outside
Regardless of the threading procedure, you must insert the label roll on the unwinder core according to the
ink jet coated side (coated side must be up for printing).
1. Outside
If the ink jet coating is on the outside of the material, which is the most common, place the roll
so the end of the material is facing clock wise.
IMPORTANT: Ensure Media Settings -> ‘Unwinder or Rewinder label position’ states: Outside
2. Inside
If the ink jet coating is on the inside of the material, then place the roll so the end of the material
is facing counter clock wise.
IMPORTANT: Ensure Media Settings -> ‘Unwinder or Rewinder label position’ states: Inside
Printing on outside of label roll. Printing on inside of label roll.

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4.1.2 Rolling direction rewinder
The rewinder can place the label material on the outside or inside of the roll. The criteria are the same as
for the unwinder, please refer to the above for placement and direction and update the Media settings to
reflect this.
4.2 Threading from scratch
1Press ‘Reload Web’ button at TrojanTwo -> Handling menu.
2Remove the web cleaner (it is sitting on magnets and can be removed easily).
3Place the chosen material on the unwinder roll according to chapter 4.1.1.
4Press ‘Reset Sidesteer Position’ button at TrojanTwo -> Handling menu to set unwinder core
horizontal position to the default position.
Reset Sidesteer Position button (TrojanTwo\Handling menu)
NOTE: Reset Sidesteer Position button is recommended to use every time after Reload Web button
is pressed.
5Adjust Label roll left edge on unwinder core compared to the wall behind (for label edge sensor
zero point calibration, see section 4.4). Make sure the label roll left edge is 99 mm from the wall.
Use the metric scale on the magnet bar or a ruler for measuring the 99 mm.
Spacer
99 mm

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Metric scale on magnet bar
6Adjust position of label edge sensor to left edge of the label roll (see section 4.4 for adjusting label
edge sensor)
Label edge sensor in proper (default) position
Sensor Beam
99 mm

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7Thread the machine according the picture below, until you reach the rewinder.
NOTE: When leading the label web around the NIP roller, press ‘Home Maintenance Module’
button at TrojanTwo -> Handling menu to gain easier access to the NIP roller. When threading is
completed, use the ‘Install Maintenance Module button’ in the same menu to move the
maintenance module back into position.
8Place an empty roll core on the rewinder. Ensure that it is minimum as wide as the threaded label
material.
9Mount the material in direction according to chapter 4.1.2.
10 Check and make sure that Unwinder and Rewinder spindles are tightly locked and fix label rolls to
the shafts.
NIP Roller

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4.3 Threading using the currently threaded material
1Press ‘Reload Web’ button at TrojanTwo\Handling menu.
2Place the magnet on far side of the splicing table.
Magnet on far side of the spicing station.
3Cut the material on the diagonal, using a knife. Use the carved cutting path on the splicing table to
ensure a clean, straight cut.
4Remove the current label roll core from the unwinder.
5Place the chosen material on the unwinder roll according to chapter 4.1.1.
6Draw the material up to the splicing table.
Label material drawn up to splicing table from unwinder.
Magnet
Carved cutting path
Carved cutting path
Magnets