Weber Markoprint iJET User manual

Translation of the original operating manual
Inkjet coder
®
iJET Art. No.: 72801001
Software Version 2.016
As at May 05, 2015
Version 12
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.webermarking.de
Read the operating manual before starting any work!

Art. No.: 72801001
Table of Contents
Page 2of 127
INFORMATION!
Weber Marking Systems GmbH has undertaken all strains to guarantee the completeness, actuality and
correctness of the information of this manual. Nevertheless possible mistakes of the documentation cannot
be completely still excluded; hence Weber Marking Systems GmbH rejects any guarantee in relation on
this information. Changes of the information contained in this documentation are left and can be carried out
any time without announcement.
This documentation or parts of the document may be photo-copied only for the personal use copied, be
reproduced or be translated into other languages. Without previous written approval on the part of
Weber Marking Systems GmbH a reproduction is not admissible to the passing on into three parts.

Art. No.: 72801001
Table of Contents
Page 3of 127
1 Table of Contents
1Table of Contents...................................................................3
2General....................................................................................7
2.1 Information on this operating manual ............................7
2.2 Explanation of symbols..................................................8
2.3 Limitation of liability......................................................10
2.4 Copyright......................................................................10
2.5 Warranty ......................................................................10
2.6 Customer service.........................................................11
2.7 Description of the used technical terms.......................12
3Safety ....................................................................................15
3.1 Responsibility of the operating company.....................15
3.2 Staff requirements .......................................................16
3.2.1 Qualifications................................................16
3.2.2 Unauthorised persons..................................17
3.2.3 Instruction.....................................................17
3.3 Intended use................................................................18
3.4 Personal protective equipment....................................19
3.5 Special hazards ...........................................................20
4Technical data ......................................................................22
4.1 General Specifications.................................................22
4.2 Connection parameters ...............................................22
4.3 Operating conditions....................................................23
4.4 Performance data ........................................................24
4.5 Inks ..............................................................................26
4.6 Nameplate....................................................................27
5Construction and function..................................................28
5.1 Brief description...........................................................28
5.2 Controller .....................................................................29
5.3 Ink cartridge.................................................................30
5.4 SmartCard Functionality..............................................31
5.5 SmartCard Functions...................................................32
5.6 System versions...........................................................33
5.7 Flexible Bracket (Flexbracket) .....................................35
5.8 Cover ...........................................................................36
5.9 Scope of delivery .........................................................38
6Transport, packaging and storage.....................................38
6.1 Safety notes on transport.............................................38
6.2 Symbols on packaging.................................................39

Art. No.: 72801001
Table of Contents
Page 4of 127
6.3 Transport inspection.....................................................39
6.4 Packaging ....................................................................40
6.5 Storage.........................................................................41
6.5.1 Store ink cartridge.........................................42
7Installation and commissioning .........................................43
7.1 Safety notes for installation and commissioning..........43
7.2 Installation....................................................................45
7.2.1 Controller installing.......................................45
7.2.2 Inserting / removing the ink cartridge ...........48
7.3 Commissioning.............................................................50
8Operation ..............................................................................51
8.1 iLOGIK .........................................................................51
8.2 Indicator lights..............................................................52
8.3 Switching on.................................................................53
8.4 Switching off.................................................................53
8.5 User language..............................................................53
8.6 Menu Structure.............................................................54
8.7 Loading print image......................................................58
8.8 Variable input ...............................................................58
8.9 Printing start delay .......................................................58
8.10 To set constant print speed..........................................60
8.11 To set the rotary encoder resolution............................62
8.12 Setting zoom................................................................64
8.13 Print direction...............................................................65
8.14 To set the nozzle rows.................................................66
8.15 Print heading................................................................67
8.16 Resetting ink counter ...................................................68
8.17 Calculate ink content....................................................68
8.18 To rinse the nozzles manually .....................................69
8.19Head temperature........................................................69
8.20 Backup at USB-Stick....................................................70
8.21 Date / Time...................................................................71
8.22 Sensor Internal / External ............................................71
8.23 Internal Pulse / Encoder...............................................72
8.24 IP address und IP mask...............................................73
8.25 Gate-Way- and MAC address......................................74
8.26 Set ink type ..................................................................75
8.27 Select language ...........................................................75
8.28 Web-Interface...............................................................76
8.29 Configurable in- and outputs........................................77
9iDesign...................................................................................78
9.1 Create a print image.....................................................78

Art. No.: 72801001
Table of Contents
Page 5of 127
9.2 Load print image to the iJET memory..........................79
10 Faults.....................................................................................80
10.1 Safety...........................................................................80
10.2 Table of faults ..............................................................81
10.3 Trouble shooting tasks.................................................82
10.3.1 Cleaning the ink cartridge.............................82
10.3.2 Rinsing and bleeding the ink cartridge with
the ink activator ............................................83
10.3.3 Air in the cartridge ........................................84
11 Disassembly .........................................................................85
11.1 Safety...........................................................................85
11.2 Disposal.......................................................................86
12 List of accessories and spare parts...................................87
12.1 Ink cartridges ...............................................................87
12.2 Mounting brackets .......................................................91
12.3 Other............................................................................91
13 Appendix...............................................................................94
13.1 Save parameter to a label............................................94
13.2 Flexbracket installation ................................................96
13.3 Cover installation .........................................................99
13.4 Ink chart.....................................................................101
13.5 Software update.........................................................102
13.6 Software upgrade ......................................................103
13.7 HMI-Update................................................................104
13.8 Boot loader update ....................................................105
13.9 Software versions ......................................................106
13.10 USB stick files............................................................106
13.11 Boot loader USB stick files ........................................106
13.12 Boot error messages .................................................107
13.13 Boot-LED messages..................................................108
13.14 Plugs and sockets......................................................109
13.14.1 Sensor........................................................109
13.14.2 Encoder......................................................110
13.14.3 Plug connection for active switched
outputs........................................................111
13.15 Interfaces...................................................................113
13.15.1 Ethernet......................................................113
13.15.2 USB A.........................................................114
13.15.3 Jumper sensor............................................114
13.15.4 Jumper inputs.............................................115
13.16 Mac addresses...........................................................117
13.17 Technical drawings....................................................118

Art. No.: 72801001
Table of Contents
Page 6of 127
13.17.1 System unit iJET.........................................118
13.17.2 iJET with mounting bracket ........................119
13.17.3 Control system with Flexbracket and
mounting bracket........................................120
13.18 Operation of ink cartridges.........................................121
13.19 Instruction sheet.........................................................122
13.20 Parameter list.............................................................123
13.21 Declaration of conformity ...........................................125

Art. No.: 72801001
General
Page 7of 127
2 General
2.1 Information on this operating manual
This manual enables safe and effective use of the iJET.
The Operating manual is a component of the device and must be
stored close to the device to be accessible to the staff at all times.
The staff must have read this manual thoroughly and understand
the content before starting any work. Compliance with all safety
notes and instructions given in this manual is a basic prerequisite
to safe operation.
Furthermore, the local accident prevention regulations and general
safety provisions for the area of application of the device are
applicable.
Images in this manual serve to provide a basic understanding and
may differ from the actual device version.
In addition to this manual, the instructions in the annexure on the
components included are also applicable.

Art. No.: 72801001
General
Page 8of 127
2.2 Explanation of symbols
Safety notes
Safety notes are identified by symbols in this manual. The safety
notes are preceded by mnemonics signifying the severity of the
hazard.
It is imperative to observe the safety notes and to act with
awareness to avoid accidents, injury to persons and material
damage.
DANGER!
… points out an imminent dangerous situation
leading to death or severe injuries unless avoided.
WARNING!
… points out a potentially dangerous situation
which may lead to death or severe injuries unless
avoided.
CAUTION!
… points out a possibly dangerous situation which
may lead to slight or minor injuries unless avoided.
CAUTION!
… points out a possibly dangerous situation which
may lead to material damage unless avoided.
Tips and recommendations
NOTE!
… points out useful tips and recommendations as
well as information to ensure effective and trouble-
free operation
Result

… refers to a result, following an action by the
operator.
Reference

… refers to a chapter or document.

Art. No.: 72801001
General
Page 9of 127
Special safety notes
The following symbols are used in safety notes to draw attention to
a specific danger.
… indicates hazards due to electrical power. Non-
observance of the safety notes poses a danger of
severe or fatal injuries.

Art. No.: 72801001
General
Page 10 of 127
2.3 Limitation of liability
All the information and instructions in this manual were compiled in
consideration of the current standards and provisions, latest
technology and our many years of know-how and experience.
The manufacturer is not liable for damages resulting from:
ignoring the manual
improper use
use of untrained staff
arbitrary modifications
technical alterations
use of unapproved spare parts
The actual scope of delivery may differ from the explanations and
illustrations provided herein in the case of special designs,
additional order options or after recent technical changes.
The obligations agreed upon in the supply agreement, the general
terms and conditions, the manufacturer’s delivery terms and the
statutory provisions applicable at the time of conclusion of the
contract are applicable.
We reserve the right to make technical updates in the course of
improvements to the performance characteristics and on-going
development.
2.4 Copyright
This manual is copyright protected and intended for internal use
only.
Access to the manual by third parties, any form of duplication –
fully or in part –as well as utilisation and/or submission of the
content is not permitted without the written consent of the
manufacturer, except for internal use.
Offenders will be liable for damages. Rights to further claims are
reserved.
2.5 Warranty
The warranty terms are specified in the General Terms and
Conditions of the manufacturer.

Art. No.: 72801001
General
Page 11 of 127
2.6 Customer service
Our customer service is available to provide technical information.
Please contact your local distributor.
Furthermore, our staffs are always interested in new information
and experiences with the use of the product and which may be
valuable for improvements to our products.

Art. No.: 72801001
General
Page 12 of 127
2.7 Description of the used technical terms
Technical terms
Description
A
B
C
CartClip
HP cartridge holder for storage of already opened cartridges to protect them
against leaking or drying out of nozzle plate
Cartridge
See ink cartridge
Conveyor
The conveyor transports the products, which should be printed and pass
them by the print head
D
DPI
Dots Per Inch
1 Inch = 25,4mm
E
Encoder
See shaft encoder
F
G
H
HP
Hewlett Packard - Manufacturer for ink cartridges
I
Ink cartridge
Original HP cartridge TIJ 2.5 , model type 45
J
K
L
LED
Light emitting diode
M

Art. No.: 72801001
General
Page 13 of 127
Technical terms
Description
N
Nozzle plate
O
P
ppi
Pulse per inch
Print direction
Print direction indicates the direction of movement of the product on the
conveyor belt viewed from the controller in the print direction
Print intensity
Contrast of the print image. If necessary this parameter must be changed to
optimize the print image. A higher intensity gives greater blackening and longer
ink drying time
Print speed
Print speed = Speed of the conveyor. The speed of the conveyor must be
keep constant
Print start delay
Offset print, i.e. by how much is printing delayed in millimetres after the
product is detected by the light barrier.
Print width
The number of pixel can be increased or decreased using this parameter.
The print image becomes narrower or wider.
Product sensor
A sensor for the detection of the product. Mostly used are optical sensors
(photo sensor, light barrier, reflex sensor)
Q
R
S
Sensor
See product sensor
Shaft encoder
If a shaft encoder is connected to the controller, the print speed is
automatically matched to the conveyor belt speed through the impulses of
the rotary encoder
T
TIJ
Thermal Ink JET print function of the HP cartridges
U

Art. No.: 72801001
General
Page 14 of 127
Technical terms
Description
V
W
X
Y
Z
ZTV
Bulk Ink System

Art. No.: 72801001
Safety
Page 15 of 127
3 Safety
This section provides an overview of all significant safety aspects
for optimal staff protection and for safe and trouble-free operation.
Non-observance of the operating instructions and safety notes
specified in this manual may pose severe danger.
3.1 Responsibility of the operating company
The iJET is used in the commercial sector. The company operating
the device must therefore comply with the statutory occupational
safety regulations.
In addition to the safety notes in this manual, instructions
pertaining to safety, accident prevention and environmental
protection must be adhered to. In this context, the following is
applicable in particular:
The operating company must familiarise itself with the applicable
occupational safety regulations and perform risk assessments
to determine additional hazards arising from particular working
conditions where the device is operated. The company must
implement these by compiling operating instructions for the
device.
During the entire period of usage of the device, the operating
company must ensure that its compiled operating instructions
comply with the latest rules and standards and amend the
instructions as required.
The operating company must clearly regulate and define the
responsibilities with respect to installation, operation, trouble-
shooting and cleaning.
The operating company shall ensure that all staff handling the
device have read and understood the operating manual.
The operating company shall furthermore train the staff at
regular intervals and keep them informed of all risks.
The operating company must provide the staff with the
necessary protective equipment.
The operating company is also responsible for ensuring that the
device is maintained in technically perfect condition

Art. No.: 72801001
Safety
Page 16 of 127
3.2 Staff requirements
3.2.1 Qualifications
WARNING!
Inadequate qualification poses danger of injury!
Improper use may lead to severe personal injury
and to material damage.
Therefore:
–all tasks to be performed only by staff qualified for
the task.
The operating manual specifies the following qualifications for
different areas of operation:
Instructed person
has been instructed by the operating company on the work with
which he/she has been tasked and on possible risks arising
from improper actions.
Specialist staff
are, based on their technical training, knowledge and
experience as well as their knowledge of relevant provisions,
capable of executing the tasks assigned to them and to
independently recognise and avoid possible risks.
Electrician
is, based on his/her technical training, knowledge and
experience as well as knowledge of relevant standards and
provisions, capable of executing tasks on electrical equipment
and independently recognising and avoiding possible risks.
The electrician is trained for the specific area of application and
is familiar with the relevant standards and provisions.
Only staffs capable of executing their work reliably are authorised.
Persons whose reaction capability is affected by drugs, alcohol or
medication, for instance, are barred.
Observe the age- and occupation-specific regulations in this
workplace when selecting staff.

Art. No.: 72801001
Safety
Page 17 of 127
3.2.2 Unauthorised persons
WARNING!
Risk to unauthorised persons!
Unauthorised persons who do not comply with the
requirements as described, are not familiar with the
dangers in the working area.
Therefore:
–Keep unauthorised persons away from the
working area.
–In case of doubt, address persons and remove
them from the working area.
–Interrupt all activities whilst unauthorised persons
are in the working area.
3.2.3 Instruction
The staff must be regularly instructed by the operating company.
Records of the instruction sessions should be kept to enable follow
up.
An example of an instruction form is attached.
 Chapter 13.19, Page 122

Art. No.: 72801001
Safety
Page 18 of 127
3.3 Intended use
The iJET has been designed, built and must be used exclusively
for the intended purpose described.
The iJET serves to create print images and to print these from
the top or side onto smooth and absorbent product surfaces,
positioned on a conveyor belt.
Intended use also includes adherence to all the specifications in
this manual.
Any use beyond the intended use or any alternative use of the
equipment is regarded as misuse and may lead to hazardous
situations.
WARNING!
Danger following misuse!
Misuse of the device may lead to hazardous
situations.
Refrain, in particular, from subjecting the apparatus
to the following:
–modification, retrofitting or alteration of the
apparatus or individual sub-assemblies.
–mounting the sub-assemblies for printing on
products from underneath.
–printing on unsuitable product surfaces.
Any claims arising from damages due to undesignated use are
rejected.

Art. No.: 72801001
Safety
Page 19 of 127
3.4 Personal protective equipment
Personal protective equipment must be worn whilst working in
order to minimise the risk of impairment to health.
Wear the protective equipment required for the work at all times,
whilst working.
Observe the instructions on personal protective equipment
displayed in the working area.
Wear when performing special
tasks
Always wear when performing installation tasks:
Protective clothing
is close-fitting work clothing with low tear-resistance, tight sleeves
and no projecting parts. It serves especially as protection against
being snagged by moving machine parts.
Do not wear rings, necklaces or other jewellery.
Safety shoes
for protection against heavy falling parts and slipping on slippery
surfaces.
Safety gloves
to protect the hands against friction, abrasions, cuts or deeper
injuries and contact with hot surfaces.

Art. No.: 72801001
Safety
Page 20 of 127
3.5 Special hazards
The following section identifies the remaining risks, determined
following a risk analysis.
Observe the safety notes listed here and the warnings in other
chapters of the manual to minimise health hazards and avert
hazardous situations.
Electrical power
DANGER!
Danger to life through electric shock!
Contact with live parts poses imminent danger to
life. Damaged insulation or individual components
can be lethal.
Therefore:
–Immediately switch off the power supply and
initiate repairs if the insulation is damaged.
–Work on the electrical system may only be
performed by electricians.
–Before working on the electrical system,
disconnect from the mains (remove mains plug)
and check that power is off.
–Always disconnect mains before performing
cleaning and repair tasks.
–Keep moisture from live parts. Moisture may
cause a short-circuit.
Primary or secondary batteries
Rechargeable and primary batteries contain toxic heavy metals.
They must be treated as special refuse and deposited at municipal
collection points or be disposed of by a specialised company.