Weber Markoprint X4JET Owner's manual

Translation of the original operating manual
Manual for Installation, Operation and Maintenance
Markoprint X4JET
Artikelnummer der Dokumentation 72800115
Copyright ©, Weber Marking Systems GmbH
Software Version 2.016
As at: May 07, 2015
Version 13
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
E-Mail: [e-mail]
http://www.webermarking.de

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Table of contents
GENERAL..................................................................................................................................................7
INFORMATION ON THIS OPERATING MANUAL..............................................................................7
EXPLANATION OF SYMBOLS .....................................................................................................8
LIMITATION OF LIABILITY ..........................................................................................................9
COPYRIGHT............................................................................................................................9
WARRANTY ............................................................................................................................9
CUSTOMER SERVICE .............................................................................................................10
DECLARATION OF CONFORMITY..............................................................................................10
DESCRIPTION OF THE USED TECHNICAL TERMS .......................................................................10
SAFETY....................................................................................................................................................13
RESPONSIBILITY OF THE OPERATING COMPANY.......................................................................13
STAFF REQUIREMENTS..........................................................................................................14
Qualifications...................................................................................................................14
Unauthorised persons......................................................................................................14
Instruction........................................................................................................................15
INTENDED USE......................................................................................................................15
PERSONAL PROTECTIVE EQUIPMENT ......................................................................................16
SPECIAL HAZARDS ................................................................................................................17
TECHNICAL DATA..................................................................................................................................19
GENERAL SPECIFICATIONS ....................................................................................................19
CONNECTION PARAMETERS...................................................................................................19
OPERATING CONDITIONS .......................................................................................................20
PERFORMANCE DATA ............................................................................................................21
INKS 23
HP inks23
LX inks 23
Trident inks......................................................................................................................23
NAMEPLATE CONTROLLER .....................................................................................................24
NAMEPLATE PRINT HEAD .......................................................................................................24
SCOPE OF DELIVERY .............................................................................................................25
TRANSPORT, PACKAGING AND STORAGE .......................................................................................26
SAFETY NOTES ON TRANSPORT..............................................................................................26
SYMBOLS ON PACKAGING ......................................................................................................27
TRANSPORT INSPECTION.......................................................................................................27
PACKAGING..........................................................................................................................28
STORAGE.............................................................................................................................29
Storage controller.............................................................................................................29
Storage HP print heads....................................................................................................29
Storage LX print heads....................................................................................................29
Storage Trident print heads..............................................................................................30
Storage HP ink cartridge..................................................................................................31
Storage LX ink cartridge...................................................................................................33
Storage Trident ink bottles...............................................................................................35
ASSEMBLY AND FUNCTION.................................................................................................................36
BRIEF DESCRIPTION ..............................................................................................................36
CONTROLLER .......................................................................................................................37
PRINT HEADS........................................................................................................................39
HP –print heads..............................................................................................................39
SmartCard Functionality...................................................................................................42
SmartCard Functions.......................................................................................................43

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LX print heads..................................................................................................................44
MX print heads.................................................................................................................47
Trident –print head module MX 100 / 50..........................................................................50
MAINTENANCE STATION.........................................................................................................53
INSTALLATION AND INITIAL OPERATION...........................................................................................54
SAFETY NOTES FOR INSTALLATION AND INITIAL OPERATION......................................................54
INSTALLATION .......................................................................................................................55
Controller installation........................................................................................................55
HP print head installation .................................................................................................58
Inserting / remove the HP ink cartridge ............................................................................60
LX print head installation..................................................................................................62
Insert / remove LX ink cartridge........................................................................................64
MX print head...................................................................................................................66
Compact mounting bracket...............................................................................................68
Top mounting bracket.......................................................................................................69
Inserting the Trident ink cartridge.....................................................................................70
Bleed the MX print head...................................................................................................71
Rinsing the MX print head................................................................................................73
CONFIGURATION OF THE PRINT TECHNOLOGY .........................................................................74
OPERATION.............................................................................................................................................76
SWITCH ON /SWITCH OFF......................................................................................................76
ILOGIK................................................................................................................................77
PRINT HEAD MODULE SELECTION............................................................................................78
INDICATOR LIGHTS.................................................................................................................79
USER LANGUAGE...................................................................................................................81
MENU STRUCTURE ................................................................................................................82
LOADING LABEL.....................................................................................................................86
VARIABLE INPUT....................................................................................................................86
INPUT COUNTER START VALUE ...............................................................................................86
PRINT START DELAY ..............................................................................................................87
TO SET CONSTANT PRINT SPEED ............................................................................................89
TO SET THE ENCODER RESOLUTION........................................................................................91
TO SET THE ZOOM.................................................................................................................93
PRINT DIRECTION ..................................................................................................................94
TO SET THE NOZZLE ROWS.....................................................................................................94
UPSIDE DOWN.......................................................................................................................95
HEAD ADJUSTMENT ...............................................................................................................96
RESET INK COUNTER .............................................................................................................97
CALCULATE INK CONTENT HP CARTRIDGE...............................................................................97
CALCULATE INK CONTENT LX CARTRIDGE ...............................................................................98
TO RINSE THE NOZZLES MANUALLY.........................................................................................98
WARMING.............................................................................................................................99
BACKUP AT USB STICK........................................................................................................101
TIME /DATE........................................................................................................................101
SENSOR INPUT....................................................................................................................102
INTERNAL PULSE /ENCODER ...............................................................................................103
IP ADDRESS AND IP MASK....................................................................................................104
GATE-WAY-AND MAC ADDRESS..........................................................................................104
SET INK TYPE......................................................................................................................105
SELECT LANGUAGE .............................................................................................................105
WEB-INTERFACE.................................................................................................................106
CONFIGURABLE INPUTS AND OUTPUTS .................................................................................107
NONSTOPPRINTING ............................................................................................................108
IDESIGN .................................................................................................................................................112

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CREATE A PRINT IMAGE .......................................................................................................112
LOAD PRINT IMAGE..............................................................................................................113
INSTALLATION.....................................................................................................................113
CONNECTION TO THE SYSTEM..............................................................................................113
PARAMETER,PREPARATION ................................................................................................113
TEXT DESIGN......................................................................................................................113
LOAD TEXTS .......................................................................................................................113
FAULTS..................................................................................................................................................114
SAFETY..............................................................................................................................114
TABLE OF FAULTS ...............................................................................................................115
Controller.......................................................................................................................115
HP print head.................................................................................................................115
LX-Print head.................................................................................................................116
MX print head ................................................................................................................117
TROUBLE SHOOTING TASKS .................................................................................................118
Cleaning the ink cartridge ..............................................................................................118
Rinsing and bleeding the HP ink cartridge with the ink activator.....................................119
Air in the HP cartridges..................................................................................................121
Cleaning LX ink cartridges.............................................................................................121
Rinsing and bleeding MX print head...............................................................................122
DISASSEMBLY......................................................................................................................................124
SAFETY..............................................................................................................................124
Staff 124
DISASSEMBLY OF A MX PRINT HEAD.....................................................................................125
DISPOSAL...........................................................................................................................126
LIST OF ACCESSORIES AND SPARE PARTS...................................................................................127
HP INK CARTRIDGES ...........................................................................................................127
LX INK CARTRIDGES............................................................................................................129
MOUNTING BRACKETS.........................................................................................................130
OTHER...............................................................................................................................131
APPENDIX .............................................................................................................................................134
SAVE PARAMETER TO A LABEL .............................................................................................134
INK CHART..........................................................................................................................136
SOFTWARE UPDATE ............................................................................................................138
CONFIG-UPDATE.................................................................................................................138
SOFTWARE UPGRADE..........................................................................................................139
HMI-UPDATE......................................................................................................................139
BOOT LOADER-UPDATE.......................................................................................................140
DVD CONTENT ...................................................................................................................141
BOOT ERROR MESSAGES.....................................................................................................142
BOOT LED MESSAGES ........................................................................................................143
PLUGS AND SOCKETS..........................................................................................................144
Sensor 144
Encoder.........................................................................................................................145
Alarm light......................................................................................................................147
External Output..............................................................................................................148
Print Head Cable............................................................................................................155
Serial Interface RS232...................................................................................................156
USB A / B ......................................................................................................................157
Ethernet.........................................................................................................................157
Mac addresses ..............................................................................................................157
TECHNICAL DRAWINGS ........................................................................................................158
Controller.......................................................................................................................158

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Print head HP MK2 Version 1 Single..............................................................................159
Print head HP MK2 Version 2 Single..............................................................................160
Print head HP MK2 Version 1 Twin................................................................................161
Print head HP MK2 Version 2 Twin................................................................................162
Print head LX MK2 Version 1.........................................................................................163
Print head LX MK2 Version 2.........................................................................................164
Druckkopf LX MK2 Version 1 Twin.................................................................................165
Druckkopf LX MK2 Version 2 Twin.................................................................................166
Print head MX 50 ...........................................................................................................167
Print head MX 100 .........................................................................................................168
Mounting bracket Compact.............................................................................................169
Mounting bracket Top.....................................................................................................170
Universal mounting bracket for controller .......................................................................171
INSTRUCTION SHEET............................................................................................................172
PARAMETER LIST.................................................................................................................173
DECLARATION OF CONFORMITY ...........................................................................................176

General 72800115 Markoprint X4JET
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General
Information on this operating manual
This manual enables safe and effective use of the Markoprint X4JET.
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.

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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
… 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.
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.

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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.
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.
Warranty
The warranty terms are specified in the General Terms and Conditions of the
manufacturer.

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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.
Declaration of conformity
The design and Construction of the X4JET, as well as the model distributed by us,
comply with the basic safety requirements for low voltage apparatus and EMC
guidelines, in their latest versions.
Description of the used technical terms
Technical terms
Description
A
B
C
CartClip
HP/LX 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
HP print head
HP 2.5 print head
Print head with HP cartridge from the CompactLine family, which
can be connected to the X4JET.
I
Ink cartridge
Original HP cartridge TIJ 2.5 , model type 45
Ink system
System for the ink bottle and ink supply of the MX print heads

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Technical terms
Description
J
K
L
LED
Light emitting diode
LX
Lexmark –Manufacturer for ink cartridges
LX Cartridge
Ink Cartridge from Lexmark
M
Maintenance station
Includes power supply, vacuum pump and catch tank for the MX
print head
Multiline MX
Print system with MX print heads 50 and 100mm
MX print head
Multiline MX print
head
Print head with Trident print head module Multiline MX family,
which can be connected to the X4JET
MX 50
Print head with Trident print head module Multiline MX family
with 50mm print height
MX 100
Print head with Trident print head module Multiline MX family
with 100mm print height
N
Nozzle plate
O
P
Piezo
A Piezo crystal changes its length with voltage
Piezo print head
A print head, which ejects ink by a piezo crystal.
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 head
Exist of one or more print head modules, combined to one unit
Print head module
Consist of holding fixture for the ink cartridge, electronics and
connection socket and the connection to the controller
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

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Technical terms
Description
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
Trident
Manufacturer of the MX Piezo print heads
U
V
W

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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.
Responsibility of the operating company
The X4JET 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

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Staff requirements
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.
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.

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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 Instruction sheet, Page 172
Intended use
The Markoprint X4JET has been designed, built and must be used exclusively for the
intended purpose described.
The Markoprint X4JET 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.
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.
Any claims arising from damages due to undesignated use are rejected.

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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.

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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
specialized company.
Primary batteries
WARNING!
Risk of injury through incorrect handling of batteries!
Batteries must be handled with particular care.
Therefore:
–Never throw batteries into a fire or subject batteries to high
temperatures. Explosion hazard.
–Do not charge batteries. Explosion hazard.
–Fluid escaping through incorrect use may cause skin irritations. Avoid
contact with the fluid. In case of contact with the fluid, rinse with ample
water. If the fluid comes into contact with the eyes, rinse immediately
with water for 10 minutes and consult a doctor without delay.

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Sharp edges and pointed corners
CAUTION!
Edges and corners pose risk of injury!
Sharp edges and pointed corners may cause abrasions and cuts to the
skin.
Therefore:
–Be cautious when working near sharp edges and pointed corners.
–If in doubt, wear protective gloves.
Dirt and objects lying about
CAUTION!
Risk of stumbling posed by dirt and objects lying about!
Dirt and objects lying about may cause slipping and stumbling resulting in
severe injuries.
Therefore:
–Always keep working area clean.
–Remove objects no longer required.
–Mark stumbling areas with yellow-black marking tape.

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Technical data
General specifications
Specification*
Value
Unit
Weight
3400
g
Length
230
mm
Width
220
mm
Height ahead
42
mm
Height behind
140
mm
*all specifications excl. bracket and connections
Connection parameters
Electrical
Specification
Value
Unit
Voltage (Device)
90 to 240
V AC
Frequency (Power pack)
50 to 60
Hz
Current consumption,
maximum
0,5
A
Power consumption,
maximum
100
W
Protection class
IP 40
-
Standby power input
<18
W
Data interfaces
Specification
Description
USB
USB A
USB
USB B
Ethernet
RJ45
RS 232
Sub-D 9-Pol male
Connection
Voltage
Max. flow
Sensor
24V ±10%
< 100mA
Encoder
24V ±10%
< 100mA
USB
5V ±10%
< 100mA

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Supply voltage
The switching threshold of the inputs is 12V ± 2V.
The sensors / encoders must be designed for 24V operating voltage. E.g. 24V + - 10%
or 10V –30V
The inputs are NPN as standard, but can be rejumpered to PNP with the iDesign
software.
Operating conditions
Environment
Specification
Value
Unit
Temperature range
5 to 45
°C
Relative humidity, maximum
(non-condensing)
10 to 90
%
Duration
Specification
Value
Maximum operating time
The device is designed for
continuous operating.