1280, 1240 Technical Training

Guide
Videojet Technician Training
Revision: AA 4/3/2020
1280, 1240 Technical Training Guide

Copyright 2020, Videojet Technologies Inc. (herein referred to as Videojet). All rights reserved.This document is the property of
Videojet Technologies Inc. and contains confidential and proprietary information owned by Videojet. Any unauthorized copying,
use, or disclosure of it without the prior written permission of Videojet is strictly prohibited.

Revision Date Changes

AA 4/3/2020 First release.

Videojet Technologies Inc. Phone : 1-800-843-3610 Offices - USA: Atlanta, Chicago, Los Angeles,
1500 Mittel Boulevard Wood Dale, IL Fax: 1-800-582-1343 Philadelphia
60191-1073 USA Int’l Fax : 630-616-3629 Int’l: Canada, France, Germany, Ireland,
www.videojet.com Japan, Spain, Singapore, Netherlands, and
The United Kingdom
Distributors Worldwide
 Contents
Notes & Warnings 7

Safety 9
General Safety Guidelines 9
Electrical Safety Guidelines 10
Fluid Safety Guidelines 12
Compressed Air Safety Guidelines 14
Medical Emergencies 14

Lesson 1: Introduction 15
Message Creation 15
Line Setup 23
Auto PEC 28
Lab 1-1: 7-High Single-line Matrix 32
Lab 1-2: Associated Index Cards 33
Lab 1-3: Grape Soda (16-high plus 7-high twin-line) 34
About Code Height Adjustments 35
Lab 1-4: Rotation 37
Lab 1-5: 5-high Twin-line Matrix 38
Lab 1-6: (7-high quad-line matrix with Timer & Date) 40
Lab 1-7: (9-high twin line matrix with Pull Date) 42
Lab 1-8: 24-high Single Line Matrix with Serializer 43
Lab 1-9: 7 High Tri Line 45
Lab 1-10: 24-High Single-Line Matrix with Code 39 Barcode 46
Lab 1-11: Lab Exercise File Manager 47

Lesson 2: Equipment 53
Ink System Assembly 53
Ink System Tank Top Plate 55
Ink System Valve Base Assembly 57

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Rigid Cavity-type Pump 58

Pump Manifold 59
Venturi System 60
Ink System Manifold 64
Pressure Transducer 68
Service Module 68
Printhead Components 71

Lesson 3: System and Theory 73

1280 Overall System Schematic 74
Ink Supply & Return 1280 75
Clean Start & Stop 1280 76
Nozzle Backflush 1280 78
Vacuum Generation 1280 79
Ink Addition 1280 80
Makeup Addition 1280 82
Prime Mixer Tank 1280 84
Solvent Recovery System 1280 85
Empty & Clean System Routine 1280 86
Instrumentation & Diagnostics System 1280 88
1240 Overall System Schematic 90
Ink Supply & Return 1240 91
Clean Start & Stop 1240 92
Nozzle Backflush 1240 94
Vacuum Generation 1240 95
Ink Addition 1240 96
Makeup Addition 1240 98
Solvent Recovery System 1240 100
Prime Mixer Tank 1240 101
Ink System Drain 1240 102
Instrumentation & Diagnostics System 1240 104
Viscosity Calibration 105
Fluid Cartridge Timeout 109

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Lesson 4: 111
Videojet 1280/1240 Installation & MQT Procedure 111

Lesson 5: Electronics System 123

Overall System Block Diagram 124
Main Control Board Subsystem 125
Main Control Board Test Points 127

Lesson 6: Instrumentation & Diagnostics 133

Ink Compartment Sensors 133
Phasing & Velocity Sensors 134
Phasing & Velocity Amplifier 134
Gutter Detect Sensor 136
Pressure Transducer Circuit 137
Vacuum Transducer Circuit 138

Lesson 7: Smart Chip Supplies & Parts Management System 141

Lesson 8: Advanced I/O 143

wfx.videojet.com & Use of Printer Information Files 143
VideojetConnect Remote Service 153

Appendices 159
Scan2Run Workflow Module 160
Lab 9-1: Scan2Run with a Serial Bar code Scanner 165
Lab Exercise Scan2Run with a USB Bar code Scanner 170
Logging Feature Matrix 175
Program the Main Control Board with Serial Number Information 178
Collect Crash Dump Files via USB 181
SAFE MENU Software Upgrade 182
SIMPLICiTY Elevated Log In 187
LED Status Indicator States (VRS RES) 189
Reset RES to Default IP Address on eth0 191
Training the Customer 193
List of Figures 201
List of Tables 204

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Index 205

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 Notes & Warnings

Notes & Warnings

Pay close attention to these statements because they contain important information on avoiding potential hazards to you or to
the equipment.

General Information
Extra information regarding a task or concept above and beyond the basics.

Care Notes
Care messages provide information on properly maintaining the equipment to keep it functioning in a state
that provides our customers Uptime Peace of Mind.

Cautions Against Unsafe Practices

Indicates hazards or advises against unsafe practices that result in equipment or property damage.

Warnings to Prevent Injury or Death

Indicates danger to you or those around you is possible unless you carry out procedures as directed. Always fol-
low all warnings and wear any PPE called out in warning messages.

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Safety
It is the policy of Videojet Technologies, INC to manufacture non-contact printing/coding systems and ink supplies which must
meet high performance and reliability quality standards. Videojet Technologies, INC enforces strict quality control techniques to
eliminate the potential for defects and hazards in its products.
The intended use of Videojet Technologies, INC Continuous Ink Jet (CIJ) printers is to print information directly onto a product.
Use of this equipment in any other fashion may lead to serious personal injury.
The safety guidelines provided here are intended to educate all attending the presented course on all safety issues such that they
may install, operate, service, and maintain the subject printer(s) in a safe manner.

General Safety Guidelines

l Read and understand the operator manual before installing and operating your Videojet printer in a live production envir-
onment.
l Always refer to the correct service manuals as per the specific printer model for important details.
l Only trained personnel should carry out the installation and maintenance work. Any such work undertaken by unauthorized
personnel can damage the printer and invalidate the warranty.
l To avoid damage to the printer components, use only soft brushes and lint free cloths for cleaning. Do not use high pres-
sure air, cotton waste, or abrasive materials.
l The printhead must be completely dry before attempting to start the printer, otherwise the printhead may get damaged.
l Do not fit or remove any connector on the printer when the power is turned on, otherwise the printer may get damaged.

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Electrical Safety Guidelines

This section explains the safety guidelines related to electrical power supply, electrical cables, fuses, bonding, and grounding.

Electrical Power Supply

Personal Injury
Lethal voltages are present within this equipment when it is connected to the mains electrical supply. Only
trained and authorized personnel must carry out the maintenance work.

Personal Injury
Observe all statutory electrical safety codes and practices. Unless it is necessary to run the printer, disconnect
the printer from the mains electrical supply before removing the covers or attempting any service or repair
activity. Non-adherence to this warning can result in death or personal injury.

Personal Injury
A high AC voltage is present at the inverter and backlight. Extreme caution is required when diagnosing failure
in these areas.

Electrical Cables
Personal Injury
Use only the mains power cable supplied with the printer. This cable must terminate in an approved, three-
pole, mains plug which has a protective ground conductor.

l The electrical power cables, sockets, and plugs must be kept clean and dry.
l For pluggable equipment, the socket-outlet must be installed near the equipment and must be easily access-
ible.

Personal Injury
Always inspect the cables for damage, wear, corrosion, and deterioration. Make all grounding/bonding con-
nections void of areas of paint, ink build-up, and corrosion.

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 Safety

Bonding & Grounding

Personal Injury
The printer must be connected only to an AC power supply that has a protective ground conductor and must
be according to IEC requirements or applicable local regulations.

Personal Injury
Do not use the printer if there is any interruption in the protective ground conductor or if the protective ground
conductor is disconnected. The failure to follow this warning can cause an electrical shock.

Personal Injury
Always ground conductive equipment to an earthing electrode or to the building grounding system with
approved cables as per NEC standards in order to drain all potential static discharge. For example, a metal ser-
vice tray to earth ground.

Personal Injury
A resistance reading from the grounded service tray to the equipment chassis or mounting bracket should be 0
to less than 1 ohm. A resistance check should be made using a safe and reliable ohmmeter and should be
done on a frequent basis.

Personal Injury
The PCBs contain static sensitive devices. A suitably grounded, antistatic wrist strap must be worn when work-
ing on or handling PCBs.

Personal Injury
Always prevent static discharge from occurring. Use proper Grounding and Bonding methods. Only use Video-
jet approved metallic service trays and ground cables.

Personal Injury
Always bond conductive equipment together with approved cables to maintain them at the same potential
and minimize static discharge. For example, printhead to metal service tray.

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Personal Injury
The Optional Wash Station has been solely designed for the cleaning of the printhead. Do not use it for pur-
ging or printing operations or for any other purposes. Always ensure that the jet is stopped and that any haz-
ardous voltages are switched off prior to the commencement of the printhead wash down.

Possible Equipment Damage

Always empty the service trays frequently. Some inks and cleaning solutions are flammable. Make sure that
the waste fluids are disposed according to HAZMAT.

Fuses
Personal Injury
To ensure continued protection against fire hazards, replace fuses only with the specified type and rating.

Fluid Safety Guidelines

This section describes the hazards that may occur while handling ink, make-up fluid, cleaning solutions, and the safety pre-
cautions that a user must take to prevent hazards.

Read the Material Safety Data Sheets

Read and understand the Safety Data Sheet (MSDS) before using any ink, make-up fluid, or cleaning solution. An SDS exists for
each type of ink, make-up fluid, and cleaning solution. For more information, visit www.videojet.com and navigate to Resources
> Safety Data Sheets.

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 Safety

Ink/Make-up/Cleaning Solution
Personal Injury
The ink, make-up fluid and cleaning solution are irritating to the eyes and respiratory system. To prevent per-
sonal injury when handling these substances:

l Always wear protective clothing and rubber gloves.

l Always wear goggles with side-shields or a face mask. It is also advisable to wear safety glasses when car-
rying out maintenance.
l Apply barrier hand cream before handling ink.
l If ink or make-up or cleaning solution contaminates the skin, wash immediately with soap water. DO NOT
use washdown or solvent to clean ink stains from the skin.
l If cleaning solution contaminates the skin, rinse off with running water for at least 15 minutes.

Personal Injury
The ink, make-up fluid and cleaning solution are volatile and highly flammable. They must be stored and
handled in accordance with local regulations.

l Do not smoke or use a naked flame in the vicinity of these substances.

l Immediately after use, remove any tissue or cloth that becomes saturated with these substances. Dispose all
such items in accordance with the local regulations.
l In the event that any ink or make-up or cleaning solution container is not completely empty after use, it
should be resealed. Only full bottles are recommended for use when replenishing ink or make-up or cleaning
solution; partially filled bottles must be disposed in accordance with the local regulations.

Personal Injury
When setting up the nozzle, direct the ink stream into a beaker or suitable container. To avoid the con-
tamination of the ink, do not re-use any ink collected in this way. Dispose all waste ink in accordance with the
local regulations.

Personal Injury
Prolonged breathing of make-up fluid or cleaning fluid vapor may cause drowsiness and/or effects similar to
alcoholic intoxication. Use only in open, well-ventilated areas.

Personal Injury
The cleaning agent is poisonous if taken internally. Do not drink. Seek medical attention immediately if inges-
ted.

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Possible Equipment Damage

Make sure that the cleaning agent is compatible with the ink used before carrying out printhead cleaning oth-
erwise the printhead may get damaged.

Possible Equipment Damage

Any cleaning solutions containing either chloride, including hypochlorite bleaches or hydrochloric acid, can
cause unacceptable surface pitting and staining. These should not be used in contact with stainless steels. If
wire brushes or wire scouring pads are used, these should be made of stainless steel. Make sure that any abras-
ive media used is free from sources of contamination, especially iron and chlorides.

Compressed Air Safety Guidelines

Personal Injury
Airborne particles and substances are a health hazard. Do not use high pressure compressed air for cleaning
purposes.

Medical Emergencies
In the event of a medical emergency, contact a doctor immediately
Emergencies Involving Printer Fluids
All Videojet Technologies, INC inks, make-fluids, and cleaning solutions are also registered with the Rocky
Mountain Poison Control Center, located in the U.S.A. If the bottle or SDS cannot be located, the doctor can
contact the Rocky Mountain Poison Control Center to obtain the information required.
Rocky Mountain Poison Control Center
(303) 623-5716

Medical Care Outside of the U.S.A.

Persons outside the U.S.A. requiring medical attention can have a doctor contact the Rocky Mountain Poison
control Center in the U.S.A. or a poison control center or hospital in their own area.

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Lesson 1: Introduction
Introduction to SIMPLICiTY User Interface, Videojet 1280/1240 Message
Generating Exercises, Level One BASIC

Message Creation
Version Note
Procedure prepared using software version 31890.

1. Enter the Job Editor (log on if necessary) and press New.

2. Press to select Information and enter the job name into the Job Name field. You can also enter into Job Description
(optional) additional information which will be displayed alongside the job name in the job list. Using this feature may
add clarity to the job selection process.

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3. Use settings in the Setup group to optionally associate the job with a specific line setup. If the required line setup is not
yet created, you can return later to edit the job and complete this information.

4. Select the Parameters group.

4.1. Select Print Mode.

Fixed Length shall keep constant the message length as variable inserts are updated.

Fixed Resolution shall keep constant the DPI as variable inserts are updated (length will change).

Use Fixed Length Print Mode if any of the following apply:

l A specific, precise length is required for the message.

l The message must fit into a well-defined window on the packaging.

l The length of the message is known and all information is fixed.

FIGURE 1-1: Fixed Length Print Mode is appropriate for the application pictured above because it is required
to fit the message into a specific area between pre-printed information on the packaging.

Use Fixed Resolution Print Mode under the following circumstances:

l The length of the message will change due to variable inserts or user-prompted fields.

l The length of the message is not known (e.g. due to the number of characters, or an atypical combination of
matrices, bar codes etc.).

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l The message includes a bar code, or the application involves the use of an optical character reader.

FIGURE 1-2: Fixed Resolution Print Mode is appropriate for the application pictured above, since the message
length will change (JULY) but will not interfere with pre-printed information on the packaging.

4.2. Enter into Print Margin the distance between the leading edge of the product and placement of the first stroke of
the message onto the substrate.

FIGURE 1-3: The Print Margin is the desired linear distance between the leading edge of the product and the first prin-
ted stroke of the message.

4.3. At the bottom of the Parameters group, select between automatic and fixed raster selection.

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Auto-Select (preferred) enables the printer to dynamically select the raster with which to print the current job, based
upon code content and current line speed.

Select by Group allows the user to specify the raster group (height) for the current job, but enables the printer to
dynamically select the raster within that group with which to print the job, based upon the current line speed.

If neither Auto-Select nor Select by Group are checked, then the user may specify the specific raster to be used to
print the job regardless of code content or current line speed.

5. Press to select the Instructions group.

5.1. Press New to create a new note.

5.2. Enter into the note information about the message or specific tasks associated with this particular job. These will be
available to the operator whenever the job is subsequently loaded.
6. When finished editing settings in Information, Setup, Parameters, and Instructions, press Done to access the WYSIWYG
message editor.

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 Lesson 1: Introduction

The WYSIWYG message editor will open.

7.
Press to change the zoom level of the view (4 zoom levels are provided).

8.
Press to add the first field to the message and Choose a Field Type from the dropdown selector.

For our example we will select Text.

8.1. Select a Text Type from the dropdown selector.

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Text Type allows you to select between fixed and variable content. If fixed text is required, then enter the required
letters and numbers in place of "Default Text".

8.2. Press to select the Font group.

8.3. The Font tab allows you to select the print height for this particular field (NOT the message as a whole).

8.4. Press to select Layout group and toggle the Bold (multi-stroke), Inverse, Mirror, and Invert as desired for this par-
ticular field.

8.5. Press to select Options and enter a custom Field Name, if desired.

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8.6.
Press . The entered text shall appear in the WYSIWYG message editor.

9.
When finished editing, press . You will be returned to the Jobs screen. The Jobs Screen shows all mes-
sages currently stored in memory along with a preview of the currently-selected job (highlighted in BLUE).

10.
Press to load the currently-selected job.

Any Job Instructions entered for the selected job will display.

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11. Press Complete to acknowledge compliance with the instructions.

12. At the final preview screen, press Load Job to complete job selection and loading. The preview should include any
dynamic user entered fields as they will print.

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 Lesson 1: Introduction

Line Setup
The Videojet 1280/1240 allows for the creation and storage of multiple, distinct Line Setup profiles. You can associate a message
with a particular line setup profile so that all of the line setup parameters are loaded at the time of job selection. Alternatively,
you may load line setup profiles independently of job selection.

Available Line Setup Actions

l Create a new Line Setup.

l Edit an existing Line Setup.
l Activate (load) an existing Line Setup.
l Delete an existing Line Setup.

Create or Edit a Line Setup Profile

1. Select Tools | Line Setup.

2. Select New to create a new Line Setup profile and enter a name for the Line Setup profile when prompted.

Use a Unique Name

Take care in selecting a name for the Line Setup to avoid confusion with job names. Jobs and Line
Setups are distinct entities.

Use of Default Line will result in loss of parameters following

software upgrade
Avoid editing the Default Line profile to enter the customer's Line Setup parameters. Create one or
more new Line Setups instead. A Default Line profile is included within each software upgrade pack-
age; this file will overwrite the existing default file and thereby cause the loss of the customer's para-
meters if the default file happened to be used for production.

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3. Enter a name for the Line Setup profile and press OK. The settings screen for the Line Setup details will open.
4. Select the radio button for the direction in which the product will move.

The Product Direction parameter is the specified direction of product movement relative to the printhead.

Left-to-right product movement Right-to-left product movement

FIGURE 1-4: Illustration of product movement directions.

5. Press Next to continue to Printhead Orientation.

6. Set the Printhead Orientation as appropriate and then press Next to continue.

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 Lesson 1: Introduction

Head Orientation Normal (EHT Up) Head Orientation Inverted (EHT Down)

FIGURE 1-5: Normal and inverted head orientation illustrations.

7. Select the radio button for the desired Print Mode (single print per print trigger, multiple prints per print trigger, or con-
tinuous) and press Next to continue.

8. Enter into the Print Trigger group details related to the product detector. The available options will vary based on the
selected Print Mode.

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Measuring Product Detector to Printhead Distance

The Print Trigger screen requires the user to enter the linear distance from the product detector to the
printhead. Fine tuning of the placement of the code on the product shall be accomplished by utilizing
the margins option within the job file. Since the printhead slot is not located on the centerline of the
printhead cover, take care in measuring the PD to Head Distance since it will be affected by the print-
head orientation.

9. Press Next to continue to Line Speed.

10. In the Line Speed group, select the radio button for the encoding solution in use (internal, external, or auto) and press
Next for page two of encoder settings.

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 Lesson 1: Introduction

11. Enter all settings for the selected encoding solution and press Done when complete.

The Line Setup is now available for activation.

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Auto PEC
The product detector circuit on the Main Control Board of the Videojet 1280/1240 automatically configures itself based upon the
type of detector in use (NPN or PNP). There are no jumpers. However, it is necessary to program the printer with the correct
detector type in order for proper internal circuit configuration to occur.

FIGURE 1-6: Proper selection of the sensor type enables the internal circuit to automatically configure itself without the use of
jumpers.

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 Lesson 1: Introduction

PNP Detecting, Proximity Mode

A Light State setup is assumed (photo-eye turns ON when the product blocks the eye).

1. The user selects the correct sensor type (PNP) for the Line Setup.
2. Through a MOSFET switching circuit on the Main Control Board, the FPGA sets the SEL_PNP signal to GROUND.
3. When the photo-eye is blocked by the product, the PNP transistor in the detector turns ON. Voltage is sourced back into the
printer cabinet via pin 2.
4. The input LED of the opto-coupler chip at location U761 turns ON.
5. With a HIGH input, the output of U761 goes low (Schmitt Trigger). Visible red LED D619 turns OFF.
6. To trigger off of the leading edge of the product, set PD Signal Invert to YES.

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You can check your setup by going to Tools | Diagnostics | Diagnostics Data. PD State (for detector 1) should illuminate when
the photo-cell is blocked.

NPN Detecting, Proximity Mode

A Light State setup is assumed (photo-eye turns ON when the product blocks the eye).

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 Lesson 1: Introduction

1. The user selects the correct sensor type (NPN) for the Line Setup.
2. Through a MOSFET switching circuit on the Main Control Board, the FPGA sets the SEL_NPN signal to +15 VDC.
3. When the photo-eye is blocked by the product, the NPN transistor in the detector turns ON. Ground is supplied to the printer
cabinet on pin 2.
4. The input LED of the opto-coupler chip at location U761 turns ON.
5. With a HIGH input, the output of U761 goes low (Schmitt Trigger). Visible red LED D619 turns OFF.
6. To trigger off of the leading edge of the product, the user sets PD Signal Invert to YES.

You can check your setup by going to Tools | Diagnostics | Diagnostics Data. PD State (for detector 1) should illuminate when
the photo-cell is blocked.

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Lab 1-1: 7-High Single-line Matrix

1. Using the SIMPLICiTY Interface, create and save the following message:

(7-high single-line matrix)

2. Perform Line Setup so that the message is printed 1 inch from the leading edge of the substrate, at a horizontal res-
olution of 60 DPI (10 characters / inch). Use internal encoding.

3. Adjust the set-up so that the code moves by 0.5-inches (12 mm) toward the trailing edge of the substrate.
4. Adjust the set-up so that the code moves by 0.5 inches (12 mm) toward the leading edge of the substrate.

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 Lesson 1: Introduction

Lab 1-2: Associated Index Cards

1. Using the SIMPLICiTY Interface, create and save the following message:

(7-high twin-line matrix)

2. Perform Line Setup so that the message is printed 1 inch from the leading edge of the substrate and at a horizontal res-
olution of 60 DPI (10 characters / inch). Use internal encoding.

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Lab 1-3: Grape Soda (16-high plus 7-

high twin-line)
1. Using the SIMPLICiTY Interface, create and save the following message:

(16-high plus 7-high twin-line)

2. Perform Line Setup so that the message is printed 1 inch from the leading edge of the substrate and at a horizontal res-
olution of 60 DPI. Use internal encoding.

3. Adjust the printer setup so that the code height is 5 mm.

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 Lesson 1: Introduction

About Code Height Adjustments

EHT Voltage is factory preset such that a 16-high message printed with a throw distance of 12 mm shall measure approximately
5 mm from the bottom printed drop to the top printed drop.

EHT Voltage is deliberately hidden within the SIMPLICiTY user interface (Print Height Adjustment) to discourage routine adjust-
ments.

Train Customers to perform routine adjustments to the code height by changing the physical throw distance.

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FIGURE 1-7: Changing the throw distance to adjust message height.

Why Change Throw Distance instead of EHT Voltage?

Leaving the EHT voltage at the factory preset value ensures adequate gutter clearance for the least deflected drops while min-
imizing the flight trajectories of the most deflected drops.

Modification of the EHT voltage from the factory preset value is possible, but be mindful that reducing the factory preset value
shall reduce the gutter clearance of the lower drops (potentially compromising uptime), while increasing the factory preset value
shall increase the drop trajectories (potentially compromising print quality).

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Lab 1-4: Rotation

1. Using the SIMPLICiTY Interface, create and save the following message:

2. Perform Line Setup so that the message is printed 1 inch from the leading edge of the substrate, at a horizontal res-
olution of 60 DPI. Use internal encoding.

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Lab 1-5: 5-high Twin-line Matrix

1. Using the SIMPLICiTY Interface, create and save the following message:

(5-high twin-line matrix; "07/27/16" is the CURRENT DATE)

2. Perform Line Setup so that the message is printed:

l 1 inch from the leading edge of the substrate.

l At a horizontal resolution of 60 DPI.
l Using internal encoding

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 Lesson 1: Introduction

Hint - Custom Reference Builder

In addition to creating the date insert within the Job Editor, you may also use the Custom Reference
Builder tool.

The tool allows you to create customized inserts (fixed or variable) which may subsequently be utilized
across multiple messages (instead of creating the insert each time from scratch).

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Lab 1-6: (7-high quad-line matrix with

Timer & Date)
1. Using the SIMPLICiTY Interface, create and save the following message:

l 7-high quad-line matrix.

l “GH” is a TIMER insert counting the number of 15-minute intervals elapsed since midnight.
l “Day Z” is the date insert. The customer wishes for the days of the month to be represented as follows:

1st of month = Day A 28th of month = Day AB

2nd of month = Day B 29th of month = Day AC
3rd of month = Day C 30th of month = Day AD
26th of month = Day Z 31st of month = Day AE
27th of month = Day AA

2. Perform Line Setup so that the message is printed 1 inch from the leading edge of the substrate, at a horizontal res-
olution of 60 DPI. Use external encoding.

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How shall the printer be set up if the customer requires that the TIMER insert represent the TIME OF THE
DAY (updating every 15 minutes) instead of the number of elapsed 15-minute intervals in the day?

Example:

1500 = BFAA

1501 = BFAA

1502 = BFAA

1515 = BFBF

1516 = BFBF

Etc.

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Lab 1-7: (9-high twin line matrix with

Pull Date)
1. Using the SIMPLICiTY Interface, create and save the following message:

(9-high twin line matrix)

(“OCT-25-16” is a PULL DATE insert – 90 days into the future, rolling over every Tuesday morning at midnight)

2. Perform Line Setup so that the message is printed 1 inch from the leading edge of the substrate, at a horizontal res-
olution of 60 DPI. Use external encoding.

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Lab 1-8: 24-high Single Line Matrix

with Serializer
1. Using the SIMPLICiTY Interface, create and save the following message:

(24-high single line matrix)

"00" is a serializer with the following attributes:

l Increment by 1
l Maximum count 09
l Always print two digits
l Repeat each value one time
l Do not wrap – stop printing once "09" is reached
2. Perform Line Setup so that the message is printed 1 inch from the leading edge of the substrate, at a horizontal resolution
of 60 DPI. Use external encoding.
3. Test system response once the maximum value is reached.

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Does the serializer reset when the job is reloaded?

Does the serializer reset when the printer is taken out of the print mode and then placed back into the print mode?

Does the serializer reset when the product count / print count is reset to zero?

Does the serializer reset when the power is cycled?

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Lab 1-9: 7 High Tri Line

1. Using the SIMPLICiTY Interface, create and save the following message:

(7-high tri-line matrix)

l "OCT1016" is an expiration date insert with a 75-day offset.

l "VV0" is a serializer counting from 000 to 999, with a pad character of "V".
l By customer request, the counting shall begin at "V53" for the first batch.
2. Perform Line Setup so that the message is printed 1 inch from the leading edge of the substrate, at a horizontal res-
olution of 60 DPI. Use external encoding.

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Lab 1-10: 24-High Single-Line Matrix

with Code 39 Barcode
1. Using the SIMPLICiTY Interface, create and save the following message:

(24-high single-line matrix)

l Code 39 bar code.

l “J” actually represents a shift code insert, set up as follows:

0000 – 0035“J”

0036 – 0830“q”

0831 – 1600“123”

1601 – 2359“BRISKTEA”

l The bar code is to be LEFT-JUSTIFIED on an 8.5-inch substrate.

l The shift code is to be RIGHT-JUSTIFIED on an 8.5-inch substrate.
2. Perform Line Setup so that the message is printed 1 inch from the leading edge of the substrate, at a horizontal res-
olution of 60 DPI. Use external encoding.

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Lab 1-11: Lab Exercise File Manager

Name: Date:

Objective
Upon completion of this lab exercise trainee will have demonstrated the ability to Back Up and Restore printer and customer files
using the File Manager system tool. The trainee will demonstrate their understanding by completing the lab exercise at the end of
this lesson and having it reviewed by their instructor for accuracy. 100% accuracy is required.

Instructions
Follow the instruction outlined in this exercise . Upon completion, have the instructor review for accuracy.

References
l Lecture notes
l Training Guide

Exercise Steps
1. With the ink off, select Tools | File Manager and press Printer Backup.

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2. Insert a USB flash drive

3. Press USB Device 1 and then press Next.

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4. Specify a name for the back up and then press Next.

5. Select Options.
6. Toggle Mark as Known Good configuration to ON and then press Backup. The File Manager Backup is complete.

7. Press the Jobs button and delete the jobs created from the message creation exercises.

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8. Go to Tools and access the File Manager system tool.

9. Press Internal and then press Continue.

10. Select the .lsf and .crf files created from the message creation exercises.

11. Go to Tools and access the File Manager system tool.

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12. Press Restore Backup.

13. Insert the USB flash drive.

14. Select Location | USB Device 1 and then press Next.

15. Select Options and toggle both Restore System Settings and Restore Security Settings to ON.

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16. Press Next.

17. Select File.

18. Select the desired Archive then press Restore.

Once the restoration is complete, the printer will reboot.

19. Log in as Admin and go to Jobs to verify the deleted files are restored.

The File Manager Lab Exercise is complete.

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Equipment Description & Component Identification
The ink system within the Videojet Videojet 1280/1240 ink compartment is of a single tank design which includes several ser-
viceable or replaceable components.

Ink System Assembly

FIGURE 2-1: Videojet 1240 Ink System.

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FIGURE 2-2: Videojet 1280 Ink System.

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Ink System Tank Top Plate

Many of the supporting ink system components are mounted upon the Ink System Tank’s top plate.

FIGURE 2-3: Videojet 1280 Ink System Top Plate.

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FIGURE 2-4: Videojet 1240 Ink System Top Plate.

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Ink System Valve Base Assembly

The Ink System Valve Base Assembly is located on the ink system top plate. It is available as a replacement part in the event of
an ink system valve failure.

FIGURE 2-5: Videojet 1280 Valve Base Assembly.

FIGURE 2-6: Videojet 1240 Valve Base Assembly.

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Rigid Cavity-type Pump

The Videojet 1280/1240 printer utilizes a rigid cavity gear-type ink pump – the same type utilized with the 1000 Series printers.

FIGURE 2-7: The Videojet 1280/1240 pump.

FIGURE 2-8: The drive gear and the driven gear rotate within a rigid cavity.

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Rigid Cavity Pump Pros & Cons

There are advantages and disadvantages to using a rigid cavity ink pump within an industrial ink jet printer.

Pros
l It is well-suited for bidirectional flow (i.e. pigmented applications).
l Long-lasting with predictable end-of-life.
l It requires less torque to attain the same discharge pressure when compared to other pump types. Thus, the pump will draw
less current resulting in less unwanted heating of the ink.

Cons
l The pump is less capable of maintaining flow at higher pressures (when compared to other pump types). Due to the fixed
dimensions within the pump cavity, there will be leakage of fluid from the discharge side of the pump back to the suction
side (slip) at higher pressures.

FIGURE 2-9: Graph of flow rate decrease as pressure increases for a cavity-type pump.

l The pump is unable to self-compensate for wear or thermal effects, and thus pump rpm will be variable especially over the
life of the pump.
l Complex design, with multiple moving parts and several critical tolerances.
l Higher cost.

Pump Manifold
The Pump Manifold directs the flow of ink from the Mixer Tank into the suction side of the ink pump and distributes the pump
discharge to the Filter Module and the Dual-Venturi assembly.

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FIGURE 2-10: Pump manifold flow paths, illustrated.

Two O-rings Fitted to Ink Pump

When removing and replacing the ink pump, there are two O-rings to remove and replace.

Venturi System
The Videojet 1240 has a dual Venturi system which creates vacuum for both fluid addition and printhead/gutter return.
The Videojet 1280 has a dual Venturi system in which only one Venturi is used for fluid addition. Printhead/Gutter return occurs
with the use of a Gutter Pump.

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The Venturis are located on the discharge side of the ink pump. The venturis are carefully tuned to reduce overall ink flow to the
lowest practical level while still generating adequate vacuum for printer services. Reducing the flow rate reduces the adverse
effect of pump heat upon the ink.

FIGURE 2-11: Videojet 1240 Venturis.

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FIGURE 2-12: Videojet 1280 Venturis.

Videojet 1280 Gutter Pump

Printhead/ Gutter Vacuum is created by a dedicated Gutter Pump. Vacuum is applied from the suction port of the gutter pump to
the gutter via a valve. In the printhead, valve VG is energized to supply vacuum to the gutter. De-energizing VG also allows the
return line to be sealed following shutdown. The gutter pump draws unused ink back from the printhead and discharges it dir-
ectly into the mixer tank. Gutter pump suction is automatically set using the umbilical length parameter. If necessary, gutter
pump vacuum can be adjusted .

FIGURE 2-13: Videojet 1280 Gutter Pump.

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FIGURE 2-14: Videojet 1280 Gutter Pump Speed Adjustment.

Positive Air Pump

The positive air pump is an optional feature designed to pressurize the printhead so long as the cabinet is powered ON. Positive
air at the printhead prevents any airborne particles from entering the Print Engine and gutter return circuit.

FIGURE 2-15: Positive Air Pump.

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Ink System Manifold

A 7-port manifold on the back of the ink system provides the connections for fluid and air to enter and exit the ink system. The
manifold's internal channels complete the flow paths of all the ports.

FIGURE 2-16: Videojet 1280 Port Description.

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FIGURE 2-17: Videojet 1240 Port Description.

Ink System Manifold Umbilical Connections

FIGURE 2-18: Videojet 1280 Manifold Connections

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FIGURE 2-19: Videojet 1240 Manifold Connections.

FIGURE 2-20: Videojet 1280 Manifold Internal Channels.

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FIGURE 2-21: Videojet 1240 Manifold Internal Channels.

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Pressure Transducer
A traditional 4-wire pressure transducer is utilized to monitor ink pump discharge pressure.

The device is powered by +3 VDC supplied by the Videojet 1280/1240 Valve Connector Board. The use of the Wheatstone
bridge configuration ensures that a change in output voltage is proportional to the change in the applied strain (pressure), since
any change in resistance due to temperature effects will be canceled out by the bridge.
Ink flow (84 cc / min) is supplied to the transducer from the Filter Module via a channel located immediately beneath the ink sys-
tem top plate.

Service Module
The Service Module is a printer-managed consumable within the ink system. It is designed to meet the following commercial
requirements:

l Contribute to a more lower cost maintenance plan than the 1000 Series.
l Ease of replacement
l No mess / no waste
l Improved performance versus 1000 Series Filters.

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A Smart Chip is incorporated into the design of the Service Module that it:

l Stores device run hours, ink type, and number of insertions.

l Enforces the prescribed maintenance interval (3000 Hours or 12 Months).
l Validates other components are manufacturer approved.

FIGURE 2-22: Service Module flow path.

FIGURE 2-23: Service Module Three Stage Filter.

Flow into and out of the Service Module is controlled by two spring-loaded valves. When the Module is installed, the valves are
opened by two metallic inserts in the ink system top plate. This allows for ink to flow through the module when the system is run-
ning, but it also allows for the module to drain when the ink jet is stopped. Thus, when the Service Module replacement is

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necessary, the part shall contain so little ink that it may be disposed of as non-hazardous waste. Additionally, the spring-loaded
valves shall shut as soon as the part is removed from the top plate, preventing any residue from leaking ("no mess").

FIGURE 2-24: Service Module spring-loaded valve assembly.

FIGURE 2-25: Service Module fit location on the top plate.

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Printhead Components
The print quality and reliability of the Videojet 1280/1240 is achieved by using the existing 1000 series printhead assembly.

Printhead Valve Module

FIGURE 2-26: The Printhead Valve Module with the valves removed.

FIGURE 2-27: Printhead Valve Module flow paths.

l GREEN = Gutter/Flush Return

l RED = Flush Supply
l YELLOW = Ink Supply

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FIGURE 2-28: Printhead Valve Module with Valves.

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Theory
Videojet 1280/1240 Ink System Theory of Operation and System Analysis
The design objectives for the Videojet 1280/1240 Ink System were:

l Build on the proven printhead and ink system of the Videojet 1000 Series.
l Provide stable performance and reliability across a broad range of operating conditions, including uneven production sched-
ules where shutdowns can range from 8 hours to multiple weeks.
l Improve ease of maintenance, (Service Module).
l Provide a replaceable ink system valve assembly.

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1280 Overall System Schematic

FIGURE 3-1: Diagram: Videojet 1280 Ink System.

Videojet 1280 Ink System Components

l Single tank system.
l Smart Chip protected ink and make up cartridges.
l Replaceable ink system Service Module.
l Replaceable ink system 5 valve assembly
l Gutter Pump
l Dual Venturi
l Condenser/Trap for solvent recovery

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Ink Supply & Return 1280

This section describes the normal flow path if ink from the Mixer Tank through the Umbilical to the printhead and back.

FIGURE 3-2: Diagram: Videojet 1280 Ink Supply & Return.

1. The ink pump draws ink from the mixer tank.

2. Ink flows into the Service Module and is filtered. Ink exits the Service Module past the pressure damper.
3. Then Gutter Pump turns on, sending vacuum through the umbilical and towards the printhead.
4. Ink flows across the pressure transducer.
5. Ink exits the mixer tank via the red tube and feed filter, through the umbilical, and towards the printhead.
6. Ink flows through VF. Heating occurs.
7. Ink flows through the nozzle, drop formation occurs.
8. Unprinted drops enter the gutter.
9. Gutter pump suction draws the unprinted drops through valve VG and down the length of the umbilical.
10. The gutter pump discharges into the mixer tank.

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Clean Start & Stop 1280

The clean start and stop procedure uses make up to clean the printhead of dry ink and dust before and after the start of the ink-
stream.

Clean Start & Stop 1280 Part 1

Figure 3-3 below represents Part 1, priming the flush pump.

FIGURE 3-3: Diagram: Videojet 1280 Clean Start & Stop, Part 1.

1. The ink pump draws ink from the mixer tank.

2. Ink flows through the Venturi, creating vacuum.
3. Valve VJ opens sending vacuum to valve VV.
4. Valve VV opens sending vacuum to the flush pump.
5. The flush pump diaphragm retracts.
6. The check valve opens allowing make up from the make up cartridge to fill the flush pump.

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Clean Start & Stop 1280 Part 2

Figure 3-4 below represents Part 2, discharging the flush pump.

FIGURE 3-4: Diagram: Videojet 1280 Clean Start & Stop, Part 2.

1. The ink pump draws ink from the Mixer tank and discharges towards valve VR.
2. The Gutter Pump turns on, sending vacuum through the umbilical towards the printhead.
3. Valve VR opens, and pressurized ink flows to the flush pump.
4. The flush pump discharges the make up.
5. Make up flows through the flush filter and the umbilical towards the printhead.
6. Valve VL opens, supplying the pressurized make up to the nozzle.
7. VP and VG open to supply vacuum the nozzle and gutter.
8. Make up is returned to the Gutter Pump and then discharged into the mixer tank.

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Nozzle Backflush 1280

This section describes the sequence of events which occur after the user initiates the Nozzle Backflush routine.

FIGURE 3-5: Diagram: Videojet 1280 Nozzle backflush.

1. The Gutter Pump turns on, sending vacuum through the umbilical towards the printhead.
2. Valve VP opens, sending vacuum to the nozzle.
3. User supplies manual irrigation to the face of the nozzle (using cleaning solution appropriate to the ink type in use).

4. Cleaning solution is returned to the Gutter Pump and is then discharged into the mixer tank.

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Vacuum Generation 1280

The Videojet 1280 utilizes vacuum generated by both a Venturi and a Gutter Pump.

FIGURE 3-6: Diagram: Videojet 1280 Vacuum Generation.

1. The ink pump draws ink from the mixer tank.

2. Ink flows through the Venturi, generating vacuum.
3. The vacuum generated by the Venturi is used for Flush Pump prime, Ink addition, and Make up addition.
4. The Gutter Pump turns on, sending vacuum through the umbilical towards the printhead.
5. The vacuum generated by the Gutter Pump is used for Purge/Gutter return, solvent recovery, and mixer tank prime.

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Ink Addition 1280

This section describes the steps used to replenish the mixer tank with fresh ink from the Ink Cartridge.

FIGURE 3-7: Videojet 1280 Ink Addition diagram.

1. Ink is consumed due to printing.

2. The mixer tank level drops, the Medium probe is uncovered, and the Mixer Tank Low warning is displayed.
3. Ink flowing through the Venturi generates vacuum.
4. Valve VJ opens, sending vacuum to valve VI.
5. Valve VI opens, sending vacuum to the ink cartridge and drawing ink into the ink system until the Medium Probe is
covered.

When the Mixer Tank level drops below middle, the valves used for ink addition cycle open and shut in a series of one second
pulses until the core level is restored to middle. On the printer’s main screen, the amount of fluid remaining in each cartridge is dis-
played only in coarse percentage increments: 100%, 80%, 60%, 40%, 20%, 5%, and 0%.

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Table 3-1: Ink Volume Displayed by Percent

Displayed Level (%) Volume (mL)

100% 750 - 676

80% 675 - 526

60% 525 - 376

40% 375 - 226

20% 225 - 76

5% <75

0% Empty

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Makeup Addition 1280

Viscosity control and make up additions occur as long as the ink is running.

FIGURE 3-8: Videojet 1280 Makeup Addition diagram.

1. Makeup addition is triggered when the target pressure rises to .03 bar above the temperature-compensated target pressure.
2. Ink flowing through the Venturi generates vacuum.
3. Valve VJ opens, sending vacuum to Valve VM.
4. Valve VM opens, sending vacuum to the Make Up cartridge and drawing Make Up into the ink system.

Once this occurs, the makeup add valve cycles open and shut in a series of one-second pulses. The printer determines the number
of pulses based upon the printhead temperature. At a typical printhead temperature of 35° C, the number of pulses is seven.

Table 3-2: Makeup Volume Displayed by Percent

Displayed Level Volume

100% 750 - 676

80% 675 - 526

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Displayed Level Volume

60% 525 - 376

40% 375 - 226

20% 225 - 76

5% <75

0% Empty

Empty Makeup Cartridge Detection

The Mixer Tank is equipped with a vacuum transducer. This vacuum transducer is a sensor that measures the amount of vacuum
on the makeup addition line. Normally, if any fluid is present in the cartridge, the measured vacuum will be very low (close to
zero). However, once the cartridge begins to run dry and the plastic fluid container begins to collapse, the amount of vacuum will
increase rapidly. If the makeup cartridge is already past low and the vacuum measured on the makeup addition line is >400
mbar, the printer deems that the makeup cartridge is empty.

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Prime Mixer Tank 1280

This section describes the sequence of events when priming the mixer tank using the on board Installation Wizard.

FIGURE 3-9: Diagram: Videojet 1280 Prime Mixer Tank.

1. Gutter Pump turns on, generating vacuum and sending it to valve VC.
2. Valve VC opens, sending vacuum to valve VI.
3. Valve VI opens, sending vacuum to the ink cartridge.
4. Ink flows from the ink cartridge into the mixer tank through valve VI and then leaves the mixer tank through valve VC.
5. Ink enters the Gutter Pump and is then discharged back to the mixer tank.

Once the Medium probe is covered, the printer terminates the Prime Core procedure.

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Solvent Recovery System 1280

This section describes the operation of the Videojet 1280 Solvent Recovery System.

FIGURE 3-10: Diagram: Videojet 1280 Solvent Recovery System.

1. Solvent-laden vapors from the mixer tank enter the condenser trap.
2. The vapors from the mixer tank are warmer than the air in the condenser trap. Solvent condenses and collects in the trap.
3. The remaining dry air vents to the atmosphere via a blue breather tube at the bottom of the cabinet.
4. The Gutter Pump turns on and sends vacuum to valve VC.
5. Valve VC opens, sending vacuum to valve VS.
6. Valve VS opens, sending vacuum to the condenser trap.
7. The collected solvent is drawn out.
8. The solvent is returned to the Gutter Pump and is then discharged to the mixer tank.

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Empty & Clean System Routine 1280

Empty and Clean System is an automated routine included with the Videojet 1280 software program. It is appropriate to perform
this procedure in the following circumstances:

l When preparing the printer for shipping.

l When preparing the printer for long-term shutdown/storage.
l When recovering from suspected ink contamination.

Required Tools & Parts

l Up to 4 ink system drain cartridges (dependent upon the initial level of fluid in the system. PN. 611207
l Up to 4 full or nearly full make-up cartridge

Theory of Operation Part 1

During Part 1 of the routine, the ink pump is used to empty the mixer tank into empty cartridges.

FIGURE 3-11: Diagram: Videojet 1280 Empty & Clean Part 1.

1. The user inserts an empty core drain cartridge into the right hand slot, or both slots if prompted.
2. The ink pump energizes, drawing ink from the mixer tank.
3. Pressurized ink is sent to valve VR. VR opens, sending ink to valve VV.

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4. VV opens, sending ink to valve VI and VM.

5. VI and VM opens, allowing the ink to flow from the mixer tank into the empty cartridges.

The printer will continuously monitor Ink Pump RPMs to determine when the mixer tank drain is complete.

Theory of Operation Part 2

During Part 2 of the procedure, the Gutter Pump is used to prime the mixer tank with makeup from the cartridge. Makeup is then
circulated throughout the entire ink system and then drained into an empty cartridge.

FIGURE 3-12: Diagram: Videojet 1280 Empty & Clean Part 2.

1. The Gutter Pump energizes, followed by the opening of valves VC and VM to draw 1/2 the makeup cartridge volume from
the cartridge into the mixer tank.
2. The Ink Pump energizes, drawing makeup from the mixer tank.
3. Makeup is sent to the printhead through the umbilical, via the Service Module.
4. Makeup is returned to the mixer tank via valve VG and the Gutter Pump.
5. The makeup is then drained from the mixer tank into the empty cartridge.
6. The remaining 1/2 of makeup in the makeup cartridge is drawn into the mixer tank,
7. Events 2 - 5 repeat.

Part 2 of the Empty & Clean System routine will be repeated. This ensures that the printer is completely flushed and ready for stor-
age, shipping, or recommissioning.

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Instrumentation & Diagnostics System

1280
The Videojet 1280 is equipped with numerous instruments and sensors located in the ink compartment, electronics compartment,
and printhead. Some of the sensors are depicted in Figure 3-13 below.

FIGURE 3-13: Diagram: Videojet 1280 Instrumentation & Diagnostic System.

Table 3-3: Diagnostic Instrumentation Legend (1280)

Diagnostic Device Description and Location

1 Cover Detect Switch Located in the PH chassis, disables HV if printhead cover is not fitted.

2 Gutter Detect Sensor Detects the presence or absence of ink in the gutter.

3 Phasing/Velocity Sensors Fly-by detectors embedded in the Print Module ground plate.

4 Printhead Temperature Sensor Transistor type temperature sensor located beneath the Valve Module.

5 Pressure Transducer Monitors ink pump discharge pressure.

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Diagnostic Device Description and Location

6 Mixer Tank Level Rods Monitors mixer tank level. (High, Medium, Low, Empty)

7 Vacuum Transducer Measures vacuum on the makeup addition line to verify the makeup cartridge is
0%.

8 Mixer Tank Temperature Located on the mixer tank.

Sensor

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1240 Overall System Schematic

FIGURE 3-14: Diagram: Videojet 1240 Ink System.

Videojet 1240 Ink System Components

l Single tank system.
l Smart Chip protected ink and make up cartridges.
l Replaceable ink system Service Module.
l Replaceable ink system 4 valve assembly.
l Dual Venturi.
l Solvent recovery

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Ink Supply & Return 1240

This section describes the normal flow path of ink from the Mixer Tank through the Umbilical to the Printhead and back.

FIGURE 3-15: Diagram: Videojet 1240 Ink Supply & Return.

1. The ink pump draws ink from the mixer tank.

2. Ink flows into the Service Module and is filtered. Ink exits the Service Module, past the pressure damper.
3. Pressurized ink flows through the transducer, generating vacuum which is then sent to the printhead.
4. Ink flows across the pressure transducer.
5. Ink exits the mixer tank via the red tube and feed filter, through the umbilical, and towards the printhead.
6. Ink flows through valve VF. Heating occurs.
7. Ink flows through the nozzle. Drop formation occurs.
8. Unprinted drops enter the gutter.
9. Venturi suction draws the unprinted drops through valve VG and down the length of the umbilical.
10. The returned ink flows through the Venturi and then discharges into the mixer tank.

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Clean Start & Stop 1240

The clean start and stop procedure uses makeup to clean the printhead from dry ink and dust before and after the start of the ink
stream.

Clean Start & Stop 1240 Part 1

Figure 3-16 below represents Part 1, priming the flush pump.

FIGURE 3-16: Diagram: Videojet 1240 Clean Start & Stop Part 1.

1. The ink pump draws ink from the mixer tank.

2. Ink flows through the Venturi, creating vacuum and sending it to valve VV.
3. VV opens, sending vacuum to the flush pump.
4. The flush pump diaphragm retracts.
5. The check valve opens, allowing makeup from the makeup cartridge to fill the flush pump.

Clean Start & Stop 1240 Part 2

Figure 3-17 on the facing page represents Part 2, discharging the flush pump.

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FIGURE 3-17: Diagram: Videojet 1240 Clean Start & Stop Part 2.

1. The ink pump draws ink from the Mixer tank.

2. Ink flows through the Venturi, creating vacuum and sending it to the printhead.
3. Valve VR opens, and pressurized ink flows to the flush pump.
4. The flush pump discharges the makeup.
5. Makeup flows through the flush filter and the umbilical towards the printhead.
6. Valve VL opens, supplying the pressurized makeup to the nozzle.
7. Valves VP and VG open to supply vacuum the nozzle and gutter.
8. The returned makeup flows through the Venturi then discharges into the mixer tank.

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Nozzle Backflush 1240

This section describes the sequence of events which occurs after the user initiates the Nozzle Backflush routine.

FIGURE 3-18: Diagram: Videojet 1240 Nozzle Backflush.

1. The ink pump draws ink from the Mixer tank.

2. Ink flows through the Venturi, creating vacuum and sends it to Valve VP.
3. VP opens, sending vacuum to the nozzle.
4. User supplies manual irrigation to the face of the nozzle (using cleaning solution appropriate to the ink type in use).
5. The returned cleaning solution flows through the Venturi then discharges into the mixer tank.

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Vacuum Generation 1240

The Videojet 1240 utilizes vacuum generated by two Venturis.

FIGURE 3-19: Diagram: Videojet 1240 Vacuum Generation.

1. The ink pump draws ink from the mixer tank.

2. Ink flows through the Forward Venturi, generating vacuum.
3. The vacuum generated by the Forward Venturi is used for Flush Pump prime, Ink addition, and Make up addition.
4. Ink flows through the Return Venturi, generating vacuum.
5. The vacuum generated by the Return Venturi is used for Purge/Gutter return.

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Ink Addition 1240

This section describes the steps used to replenish the Mixer Tank with fresh ink from the cartridge.

FIGURE 3-20: Diagram: Videojet 1240 Ink Addition.

1. Ink is consumed due to printing.

2. The mixer tank level drops, the Medium probe is uncovered, and the Mixer Tank Low warning is displayed.
3. Ink flowing through the Venturi generates vacuum.
4. Valve VI opens, sending Venturi vacuum to the ink cartridge and drawing ink into the ink system until the Medium Probe is
covered.

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When the Mixer Tank level drops below middle, the valves used for ink addition cycle open and shut in a series of one second
pulses until the core level is restored to middle. On the printer’s main screen, the amount of fluid remaining in each cartridge is dis-
played only in coarse percentage increments: 100%, 80%, 60%, 40%, 20%, 5%, and 0%.

Table 3-4: Ink Volume Displayed by Percent

Displayed Level (%) Volume (mL)

100% 750 - 676

80% 675 - 526

60% 525 - 376

40% 375 - 226

20% 225 - 76

5% <75

0% Empty

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Makeup Addition 1240

Viscosity control and make up additions occur as long as the ink is running.

FIGURE 3-21: Videojet1240 Makeup Addition diagram.

1. Makeup addition is triggered when the target pressure rises to 0.03 bar above the temperature-compensated target pres-
sure.

2. Ink flowing through the Venturi generates vacuum.

3. Valve VM opens, sending Venturi vacuum to the Makeup cartridge and drawing Makeup into the ink system.

Once this occurs, the makeup add valve cycles open and shut in a series of one-second pulses. The printer determines the number
of pulses based upon the printhead temperature. At a typical printhead temperature of 35° C, the number of pulses is seven.

Table 3-5: Makeup Volume Displayed by Percent

Displayed Level Volume

100% 750 - 676

80% 675 - 526

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 Lesson 3: System and Theory

Displayed Level Volume

60% 525 - 376

40% 375 - 226

20% 225 - 76

5% <75

0% Empty

The Mixer Tank is equipped with a vacuum transducer. This vacuum transducer is a sensor that measures the amount of vacuum
on the makeup addition line. Normally, if any fluid is present in the cartridge, the measured vacuum will be very low (close to
zero). However, once the cartridge begins to run dry and the plastic fluid container begins to collapse, the amount of vacuum will
increase rapidly. If the makeup cartridge is already past low and the vacuum measured on the makeup addition line is >400
mbar, the printer deems that the makeup cartridge is empty.

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Solvent Recovery System 1240

This section describes of the Videojet 1240 Solvent Recovery System.

FIGURE 3-22: Diagram: Videojet 1240 Solvent Recovery System.

1. Solvent-laden vapors exit the mixer tank.

2. The vapors from the mixer tank are warmer than the air in the loop. Solvent condenses.
3. Solvent is separated from the air and returns to the mixer tank.
4. The dry air that remains is vented to the atmosphere via a blue breather tube at the bottom of the cabinet.

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 Lesson 3: System and Theory

Prime Mixer Tank 1240

This section describes the sequence of events when priming the mixer tank using the on board Installation Wizard.
The Videojet 1240 utilizes the Ink Pump to draw the ink directly from the ink cartridge. This is achieved with the use of the Prim-
ing block that must be installed between the Ink Pump and the Mixer Tank, as well as connecting the Priming Block tube to the fit-
ting located on the Ink Add line.

FIGURE 3-23: Diagram: Videojet 1240 Prime Mixer Tank.

1. Priming Block is installed.

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2. Tubing from the Priming Block is connected to the Ink Addition tubing from the ink cartridge.
3. The ink pump energizes and draws ink from the ink cartridge.
4. Ink flows from the ink cartridge into the mixer tank.
5. The ink flows through both venturis filling the mixer tank.

The printer terminates the Prime Core procedure once the Medium probe is covered.

Ink System Drain 1240

This section describes the sequence of events performed during the Ink System Drain.

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 Lesson 3: System and Theory
FIGURE 3-24: Diagram: Videojet 1240 Ink System Drain.

1. The user inserts an empty core drain cartridge into the right hand slot, or both slots if prompted.
2. The ink pump energizes, drawing ink from the mixer tank.
3. Pressurized ink is sent to valve VR. VR opens, sending ink to valve VV.
4. VV opens, sending ink to valve VI and VM.
5. VI and VM opens, allowing the ink to flow from the mixer tank into the empty cartridges.

The printer will continuously monitor Ink Pump RPMs to determine when the mixer tank drain is complete.

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Instrumentation & Diagnostics System

1240
The Videojet 1240 is equipped with numerous instruments and sensors located in the ink compartment, electronics compartment,
and printhead. Some of the sensors are depicted in Figure 3-25 below.

FIGURE 3-25: Diagram: Videojet 1240 Instrumentation & Diagnostics.

Table 3-6: Instrumentation Legend (1240)

Diagnostic Device Description and Location

1 Cover Detect Switch Located in the PH chassis, disables HV if printhead cover is not fitted.

2 Gutter Detect Sensor Detects the presence or absence of ink in the gutter.

3 Phasing / Velocity Sensors Fly-by detectors embedded in the Print Module ground plate.

4 Printhead Temperature Sensor Transistor type temperature sensor located beneath the Valve Module.

5 Pressure Transducer Monitors ink pump discharge pressure.

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 Lesson 3: System and Theory

Diagnostic Device Description and Location

6 Mixer Tank Level Rods Monitors mixer tank level (High, Medium, Low, Empty).

7 Vacuum Transducer Measures vacuum on the makeup addition line to verify the makeup cartridge is
0%.

8 Mixer Tank Temperature Located on the mixer tank.

Sensor

Viscosity Calibration
The Videojet 1280/1240 controls ink viscosity by comparing its target pressure to the Temperature-compensated Target Pressure
(TCTP). This Temperature-compensated Target Pressure is a theoretical value which represents the pressure required to attain the
Velocity Set Point under ideal viscosity conditions. These pressures are located in the Diagnostics | Diagnostics | Ink System
screen in the SIMPLICiTY user interface.

FIGURE 3-26: Ink system Pressures display.

The printer begins its determination of the Temperature-compensated Target Pressure by reading three coefficients off of the ink
cartridge Smart Chip.

FIGURE 3-27: Coefficients shown in the Diagnostics | Ink System | Ink screen.

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For the ink in use, these three coefficients establish the temperature – viscosity curve. As temperature increases, viscosity
decreases, and the relationship is parabolic. The equation for a parabola is:

...where y = viscosity, x = printhead temperature, and a, b, and c are the three viscosity coefficients. The printer is able to
establish the following curve within its memory:

FIGURE 3-28: Viscosity / PH Temperature Curve.

Thus, by measuring the printhead temperature, the printer is able to determine what the ink viscosity should be.

FIGURE 3-29: Determined Viscosity.

Once the viscosity has been determined from this first curve, the printer is able to pinpoint the temperature-compensated target
pressure by utilizing a second curve – the curve of viscosity versus pressure. As viscosity increases, pressure increases, and this rela-
tionship is linear. This curve is affected by the size of the nozzle orifice (hence the need to program this correctly during install-
ation).

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 Lesson 3: System and Theory

FIGURE 3-30: Viscosity / Pressure Curve.

Knowing the viscosity, the temperature-compensated target pressure is determined.

FIGURE 3-31: Determining TCTP.

Why is Viscosity Calibration needed?
The curve of viscosity-versus-pressure is “universal” and is not affected by the ink in use. However, this curve is also theoretical in
nature. It is appropriate to use this curve to determine the temperature-compensated target pressure for the theoretically-perfect
printer. But in reality, each printer deviates by some unique amount from the theoretically-perfect printer. This is due to the sum
total of all the deviations and tolerances within an individual printer’s hydraulic system – caused by slight deviations with the ink
pump, Core, pressure transducer, tubing, umbilical, and (especially) the nozzle. Therefore, this method of determining the Tem-
perature-Compensated Target Pressure may only be utilized after a viscosity calibration is performed.

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FIGURE 3-32: Determining TCTP, continued.

The viscosity calibration is performed during the installation procedure. The critical fact which allows the calibration to be per-
formed is that the ink viscosity is known to be perfect (since the Core is freshly primed and no opportunity for thickening or dilu-
tion is yet present). Using this known (perfect) viscosity, the viscosity-pressure curve yields the temperature-compensated target
pressure for the theoretically-perfect printer. This pressure should establish an actual velocity equal to the velocity set point (+ / -
.1 m / sec). If a different pressure is required, this difference must be due to the hydraulic differences between the printer in ques-
tion and the theoretically-perfect printer. When the viscosity calibration is performed, these differences are saved in the form of
an offset. From that moment forward, the printer is able to make the correct conclusions about its own viscosity because the
unique printer attributes are accounted for via the viscosity calibration.

FIGURE 3-33: Viscosity Calibration.

Before viscosity calibration in the scenario depicted in Figure 3-34 on the facing page, theory states that 3.12 bar is required to
match the velocity set point. The reality is that 3.18 is required. Since the viscosity is known to be perfect, the deviation is due to
unique attributes of the particular printer in use.

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 Lesson 3: System and Theory

FIGURE 3-34: Before Viscosity Calibration.

FIGURE 3-35: After Viscosity Calibration.

Fluid Cartridge Timeout

The Fluid Cartridge Timeout feature allows an operator to set a limit for how long the printer will run with an empty cartridge.
The intent of this is to prevent the printer from faulting out due to the following:

l Unable To Control Viscosity Fault: Due to the printer no longer adding makeup.
l Mixer Tank Empty Fault: Due to the printer no longer adding ink.

This Timeout can be set from 0 to 12 Hours, where 0 disables the feature. The printhead will shutdown when the timeout expires.
It is good to note that if this feature is enabled, the operator cannot start the jet with empty cartridges in the printer.

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FIGURE 3-36: Fluid Timeout located in Tools | Printer Settings | Printer Control.

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 Lesson 4:
Videojet 1280/1240 Installation & MQT
Procedure
Personal Injury
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The ink and make-up fluid are irritating to the eyes and respiratory system. To prevent personal injury when handling these substances:
Always wear protective clothing and rubber gloves. Always wear goggles with side-shields or a face mask. It is also advisable to wear safety
glasses when carrying out maintenance. Apply barrier hand cream before handling ink. If ink or make-up fluid contaminates the skin, wash
immediately with soap water. DO NOT use washdown or solvent to clean ink stains from the skin.
111

This procedure was prepared using software version 31690.

Printer ID:

Previous Ink, if any:

Ink/Makeup type to be used:

Technician and Date:

Lesson 4:
 1280, 1240 Technical Training Guide
Item Issues
Item Name Multimedia Assistant
# Noted
Inspect the packaging. Does the external packaging look damaged?

1
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2 Remove the printer from the packaging and place it on a stand or table top.
112
 Item Issues
Item Name Multimedia Assistant
# Noted
Inspect printer exterior for any damage.
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3
113

Lesson 4:
 1280, 1240 Technical Training Guide
Item Issues
Item Name Multimedia Assistant
# Noted
Open the hydraulics compartment and inspect for any disconnected tubes or cables, Videojet 1240
etc. Verify that the hydraulic manifold is connected securely to the back of the ink sys-
tem. Also, ensure that all tubes on the manifold are connected correctly as well as the
vent tube.
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4 Videojet 1280
114
 Item Issues
Item Name Multimedia Assistant
# Noted
Open the electronics compartment and ensure all electrical cables are fitted and
routed properly. Record the MCB Rev #:

MCB Rev #

1. Remove the printhead cover and inspect for damage.

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2. Check the distance between the nozzle and charge electrode.

l 60µ C/E Distance = 1mm

6 70µ C/E Distance = 2.3mm

115

3. Visually check the charge electrode gap.

l Gap = 0.575 - 0.675

4. Replace the printhead cover.

1. Plug the printer in to power.

2. Power the printer ON.
3. Check that the Videojet logo displays on the splash screen.
7
4. After boot up is complete, press and hold the Log In button for 10 seconds.
5. Enter the Advanced Personnel Password. Printer should display ink sys-
tem/cartridge warnings.

Lesson 4:
 1280, 1240 Technical Training Guide
Item Issues
Item Name Multimedia Assistant
# Noted
(Field Installation only) IF Workflow Modules are to be installed, then proceed as fol-
lows:

1. Install the Workflow Modules using the USB stick provided with the printer.
2. Export the .pri (Printer Information File).
3. Upload the .pri to wfx.videojet.com.

8 4. Perform any additional software upgrades as directed by the portal.

IF no workflow modules are to be installed (no USB stick with Workflow Modules
provided), then proceed as follows:
Company Confidential Rev AA

1. Export the .pri (Printer Information File)

2. Upload the .pri to wfx.videojet.com.
3. Perform any additional software upgrades as directed by the portal.
116
 Item Issues
Item Name Multimedia Assistant
# Noted
Go to Tools | Printer Settings | System Information and record the following:
Product Name

Product Version

XP Version

XP Build System

OS Version
9
Qt Version
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Boot Loader

Serial Number
117

FPGA(MCB)

Ink Core

Service Module

Go to Tools | Printer Settings | Printhead Control and record the following:

Print Height Adjust

10 Charge Scale

Phase Charge

Lesson 4:
 1280, 1240 Technical Training Guide
Item Issues
Item Name Multimedia Assistant
# Noted
Go to Tools | Diagnostics | Ink System | Ink and verify that the mixer tank is empty.

11

Install one fresh cartridge of ink and one fresh cartridge of makeup. Go to Tools | Dia-
gnostics | Ink System | Ink and then press Update. This will program the Service Mod-
ule and the VCB smart chip with the ink type.
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118

Return to the Home Screen, press the Ink Cartridge %, and record the following.

Ink Type

Expiration Date

Ensure that the data matches the information on the cartridge label.
13

Go to Tools | Engineering | Production Setup and verify the following:

l Serial Number is entered correctly.

14
l Print Module (Nozzle Type) is set correctly. (60µ or 70µ).
l Conduit Length is set correctly (2m or 3m).
 Item Issues
Item Name Multimedia Assistant
# Noted

15 Go to Tools | Maintenance | EHT Calibration and perform an EHT Calibration.

You may skip this step if it was performed after the initial start up.

1. Go to Tools | Printer Settings | Printhead Control | Printhead Elevation.

2. Check that the current value is 0.
3. Place the printhead at the same physical elevation as the point where the
umbilical exits the cabinet.

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119

1. Go to Tools | Installation.
2. Launch the Installation Wizard and then perform it to its entirety.
17

Lesson 4:
 1280, 1240 Technical Training Guide
Item Issues
Item Name Multimedia Assistant
# Noted
l Check ink stream alignment and fine-tune if necessary.
l The stream should be horizontally centered and vertically no more than 1.5-
2.5 stream widths from the flat side of the gutter.
l The flat side is opposite of “arc” side of the gutter.
l The flat side shall be closer to the EHT plate (angled plate).

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120

1. Use an eye loupe to check that the jet stream is centered in the Charge Tunnel.
2. Check for good drop break off.
19
3. If break-off is marginal, go to Tools | Printer Settings | Print Head Control
and confirm that Automatic Modulation is enabled.
 Item Issues
Item Name Multimedia Assistant
# Noted
Go to Tools | Diagnostics | Diagnostics Data | Printhead and Nozzle and record the
following:
Velocity Set Point

Actual Velocity

Head Temperature
(Both Values)

Nozzle Frequency

Nozzle Voltage (V)

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20 (Both Values)

Selected Phase

Phase Profile
121

(PASS/FAIL)

Go to Tools | Diagnostics | Diagnostics Data | Ink System and record the following:

Pressure (Both Values)

Compensated Pressure

Pump RPM

21 Verify that all warning/fault conditions have been cleared.

With the printhead cover on, use the positive air flow meter and cap to verify and
record the flow rate out of the printhead. 4 to 5 SCFH is expected.

Positive Air Flow Rate

22
1. Positive Air Flow Rate:

Lesson 4:
 1280, 1240 Technical Training Guide
Item Issues
Item Name Multimedia Assistant
# Noted
Prior to placing the printer into production:

1. Measure (in cm) the vertical distance between the umbilical exit point on the
side of the cabinet and the bottom of the printhead when it is fitted to the con-
veyor. This is the Printhead Elevation.
2. Select Tools | Printer Settings | Print Head Control | Print Head Elevation.
23
3. Once the printhead is in position, ensure to enter the measured Printhead Elev-
ation value (in cm) prior to initiating Ink On.

4. Record new pressures (both numbers).

Pressure (Both Values)

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MQT Only

1. Ensure that the electronics compartment is closed.

122

2. Ensure that the printhead is properly grounded to a service tray.

3. Create a 24 high message.
24
4. Create an Continuous line set up file.
5. Print continuously for 24 hours, taking a print sample every 1 hour (when pos-
sible).
6. Prior to terminating the print test, check for printhead build up. Then return to
step 20 and re-record the values for the listed parameters.
Lesson 5: Electronics
System
The Videojet 1280/1240 Electronics system is comprised of six main components:

l Mains Power Supply

l EHT module
l Main Control Board (MCB)
l Touchscreen
l Smart Chip Reader
l Valve Connector Board (VCB)

The Main Control Board (MCB), is the heart of the electronics system. Key attributes of the MCB are:

l Charge amplifier control

l Valve control
l Heater control
l Fan and air pump control
l Photocell, encoder, lampstack, and relay control
l Level detection
l Gutter detect
l Modulation control
l Ink pump control

The VCB provides the connection point for ribbon cables originating at the MCB. The VCB distributes electronic signals to the fol-
lowing components within the Ink System:

l Valves
l Level detectors
l Instrumentation
l Ink Pump (this connection is accessible, to allow for pump replacement)
l Ink System Smart Chip

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Overall System Block Diagram

FIGURE 5-1: Diagram: Electronics system block.

1. The mains power supply provides the following voltages to the Main Control Board: +24VDC.
2. The Main Control Board supplies the following voltages : +24VDC, +5VDC, +3.3VDC, and +12VDC.
3. These voltages are supplied to FIB, Valve Connector Board, and Smart Chip Board.

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 Lesson 5: Electronics System

Main Control Board Subsystem

FIGURE 5-2: Diagram: Main Control Board Subsystem.

1. Printhead
2. Shaft Encoder
3. EHT Power Supply
4. Modulation
5. Charge
6. Positive Air Pump ( If available)
7. Alert Light
8. Product Detector
9. FIB

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10. Ink Pump

11. Ink System Smart Chip
12. Ink System Temperature Sensor
13. Ink System Valves
14. Level Rods
15. Pressure Transducer
16. Vacuum Transducer
17. Gutter Pump (1280)
18. Ink Cartridge Smart Chip
19. Makeup Cartridge Smart Chip
20. MCB Fan

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 Main Control Board Test Points
Use the information here to perform basic diagnostics of the printer Main Control Board.
This procedure is intended to be performed only by Videojet service personnel who have completed the proper course of instruction.

Damage to Components
Take care when using test equipment to measure the electronic signals at PCB test points. Board damage may occur if voltage-carrying test
points are inadvertently shorted to ground.

TP Name Description Measurement

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TP41 Charge Amplifier Output

l Ink stream must be ON.

l Check for the same signal at the charge tunnel shell to
127

verify the integrity of the umbilical.

Lesson 5: Electronics System

 1280, 1240 Technical Training Guide
TP Name Description Measurement

TP42 Modulation Transformer Output

l Ink stream must be ON.

l Check for the same signal at the nozzle pin connection
to verify the integrity of the umbilical.
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TP45 Velocity signal from printhead TAPD

l 16-spike pattern
l Ink stream must be ON
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 TP Name Description Measurement

TP46 Phasing signal from printhead TAPD

l 16-spike pattern
l Ink stream must be ON
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TPV17 Head Cover Switch Cover On: 0VDC

Cover Off: 3.3VDC

TPV48 Gutter Detect Ink On: .003VDC

Ink Off: .359VDC
129

TPV49 Pressure Transducer As pressure increases, voltage measurement increases. Approx-

imate readings are:

l 1 Bar = 1.03VDC
l 2 Bar = 1.72VDC
l 3 Bar = 2.42VDC

Lesson 5: Electronics System

TPV51 Vacuum Transducer 100mbar = .4VDC

TPV15 Head Heater l Min = 0VDC

l Max = 24VDC

TPV16 Head Temperature 1° C = .055 VDC

TP_31V EHT Power Supply l Min = 0VDC

l Max = 32VDC
 1280, 1240 Technical Training Guide
TP Name Description Measurement

TPV13 EHT Drive Power l Min = 0VDC

l Max = 31VDC

TP_-15V PSU -15V l Min =-14.2VDC

l Max = -15.8VDC

TP_15V PSU 15V l Min = 14.2VDC

l Max = 15.8VDC

TP_R5V PSU 5V l Min = 4.7VDC

l Max = 5.3VDC
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TP_24V PSU 24V l Min = 22.8VDC

l Max = 25.2VDC
130
 Lesson 5: Electronics System
FIGURE 5-3: Diagram: MCB Test Points.
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Lesson 6:
Instrumentation &
Diagnostics
The Instrumentation and Diagnostics System is comprised of an array of sensors located in the printhead, ink compartment, and
electronics compartment.

Ink Compartment Sensors

FIGURE 6-1: Ink System Valve Connector Board Sensors.

1. Level Rods: Ground, Low, Medium, High. Monitors the level in the mixer tank for fluid additions, and mixer tank related
faults and warnings.
2. Temperature Sensor: Monitors the ink system temperature.

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3. Pressure Transducer: 4 wire strain gauge, its amplified analog output signal is supplied directly to the Main Control Board.
It measures Actual Pressure. This pressure is compared to the Target Pressure. The difference between the two is used to
increase or decrease the pump speed.
4. Vacuum Transducer: Once the Makeup cartridge begins to run dry and the plastic fluid container begins to collapse, the
amount of vacuum will increase rapidly. If the makeup cartridge is already past low and the vacuum measured on the
makeup addition line is > 400 mbar, the printer deems that the make-up cartridge is empty.

Phasing & Velocity Sensors

The Phasing & Velocity Sensors are physically embedded within the printer's ground plate. The fly-by sensors are a part of a larger
sub-assembly called the Twin-Amplifier Phase Detector (TAPD) board. Direct electrical connection is established via 5 pins.

FIGURE 6-2: Videojet 1280/1240 TAPD Board (Rear View).

Table 6-1: TAPD Board Pins

Pin Carries

1 Ground

2 -15 VDC

3 +15 VDC

4 Phasing

5 Velocity

Phasing & Velocity Amplifier

All circuitry is part of the TAPD board, which is embedded within the Printhead Engine's ground plate. From pins 4 and 5, the
phasing and velocity signals are transferred to the Main Control Board via the umbilical. All processing of the Phasing / Velocity
signal is performed by the Main Control Board.

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 Lesson 6: Instrumentation & Diagnostics

FIGURE 6-3: Schematic: Phasing & Velocity Amplifying Circuit.

Because the phasing and velocity signals are sent upstream of the first-stage amplifier on the Main Control Board, BOTH signals
shall be viewable when the test points TPV46 and TPV47 on the Main Control Board are monitored using an oscilloscope.

Phasing & Velocity: Signal Processing on the Main Control

Board
The Phasing Signal is supplied to the Main Control Board from the Printhead via the 10-way connector at the MCB location
PHEAD1; the Velocity Signal is supplied to the Main Control Board via the 12-way connector at the MCB location PHEAD2 .

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FIGURE 6-4: Schematic of phasing/velocity signal amplification on its way to the FPGA.

Gutter Detect Sensor

The circuitry for the Gutter Detect Sensor resides on the Main Control Board. A dedicated wire carries the square-wave drive signal
via the umbilical to the printhead chassis.

FIGURE 6-5: The Gutter Detect Chamber.

The presence of the ink in the gutter detect chamber causes the output of the amplifier on the Main Control Board to drop from
High (0.359VDC) to Low (.003VDC).

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 Lesson 6: Instrumentation & Diagnostics

FIGURE 6-6: Schematic: Gutter Detect Circuit.

Pressure Transducer Circuit

The Pressure Transducer amplifier circuit resides on the Main Control Board. The output of the transducer bridge is supplied to a
series of amplifiers on the Main Control Board. As the pressure applied to the transducer INCREASES, the voltage output also
INCREASES. The amplified analog output of the circuit is supplied to the Main Control Board Micro-controller.
The output can be measured at test point TPV49, with the following approximate measurements:

l 1 Bar = 1.03VDC
l 2 Bar = 1.72VDC
l 3 Bar = 2.4VDC

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FIGURE 6-7: Schematic: Pressure management via Pressure Transducer and Main Control Board.

Vacuum Transducer Circuit

The Vacuum Transducer amplifier circuit resides on the Main Control Board. The output of the transducer bridge is supplied to a
series of amplifiers on the Main Control Board. As the vacuum applied to the transducer INCREASES, the voltage output also
INCREASES. The amplified analog output of the circuit is supplied to the Main Control Board Micro-controller.
The output can be measured at test point TPV51, As vacuum increases, the measured voltage increases.

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 Lesson 6: Instrumentation & Diagnostics

FIGURE 6-8: Schematic: Vacuum Management via Vacuum Transducer to Main Control Board.

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Lesson 7: Smart Chip
Supplies & Parts
Management System
5 components within the Videojet Videojet 1280/1240 printer are fitted with smart chips.

FIGURE 7-1: Diagram: Components fitted with Smart Chips.

1. Ink System Valve Connector Board

2. Service Module
3. Main Control Board
4. Ink Cartridge
5. Make Up Cartridge

The advantages of fitting these printer components with smart chip are as follows:

l It prevents inadvertent use of incompatible or expired fluids, thereby enhancing uptime and performance.
l It enables the printer to manage its preventative maintenance program to benefit the customer.
l It allows for instant verification of part revision number, assembly number, build version, and manufacturing date in sup-
port of escalation resolution.

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Table 7-1: Summary of Smart Chip Data

Data Written During Data Written During
Smart Chip
Manufacturing Printer Operation
Main Control Board Board assembly number, revision number, Printer Serial Number
build version, board serial number, man-
ufacturing date.

Ink System Valve Con- l Printer model number l Ink Parameters

nector Board l Fluid reference numbers
l Run Hours

Service Module l Micron Size l Number of insertions

l Service Module assembly number, revi- l Ink Type
sion number, serial number, and man-
l Run Hours
ufacturing date.

Ink Cartridge l Ink type l Number of Insertions

l Cartridge size l Level
l Associated makeup
l Ink density
l Viscosity coefficients
l Lot code
l Expiry
l Slope
l Type of shaking required
l Makeup type (MEK, etc.)
l Modulation routine type
l Head temperature
l Qualified nozzle size
l 1 or 2 part
l Ink Conductivity
l Phase Offset

Make Up Cartridge l Makeup type l Number of insertions

l Cartridge size l Level
l Lot Code
l Expiry

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Lesson 8: Advanced I/O
wfx.videojet.com & Use of Printer
Information Files
Use the self service portal at wfx.videojet.com to manage SIMPLICiTY software updates and to acquire workflow modules for
the printer as necessary.

Process Description - Printer Manufacturing & Installation

1. At our Zhuhai manufacturing facility, a unique 2D bar code is printed and affixed to the exterior of the box for each
SIMPLICiTY printer to be shipped.

The 2D bar code contains the coder's Printer Information File (.pri). The .pri includes the following data:

l MAC address of Main Control Board Network Interface Card.

l Printer Serial Number
l Current Software Version Information
l Current Software Configuration (installed Workflow Modules, if any)
2. The printer arrives at a Videojet distribution center (Zhuhai, Wood Dale, Sao Paolo, etc.). The Videojet Administrator
updates wfx.videojet.com to indicate the new location of the printer (under VJ Global).

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3. If the printer is sold and workflow modules are included in the order, then the 2D bar code is scanned by a licensing sta-
tion at the distribution center. The licensing station interfaces with Oracle and the software portal (wfx.videojet.com) in
order to generate a USB stick containing the purchased Workflow Modules for that particular printer.

The USB stick is included within the packaging as the printer is shipped to the customer site.

If no workflow modules are sold, then this initial interaction with the software portal does not occur.

4. Whenever a printer using the SIMPLICiTY interface is sold to a new customer, an account shall be created for that cus-
tomer within wfx.videojet.com. The printer is assigned to the customer and to the specific plant location where the printer is

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 Lesson 8: Advanced I/O

to be installed. The customer shall receive a Welcome email with log-in information so that he may create his own Super
Admin account within the portal. This enables the customer to manage future software updates and configuration changes
(addition of Workflow Modules) if he so desires.
5. The printer arrives at the customer site. In conjunction with the printer installation, the Videojet service engineer shall
install the purchased Workflow Modules (if any) from the supplied USB stick.

6. Having installed the Workflow Modules, the service engineer shall generate a new Printer Information File (.pri) via the
printer's Software Download System Tool (export to USB).

This new Printer Information File shall be uploaded to wfx.videojet.com at the earliest opportunity. It is likely that a soft-
ware update shall be called for by the portal.

7. If no Workflow Modules have been sold with the printer, then the service engineer should upgrade the printer software
to the latest version prior to installing the printer.

7.1. Export a Printer Information File at the printer.

7.2. Upload the Printer Information File to wfx.videojet.com. The software portal shall immediately advise as to whether a
software upgrade is available.
7.3. Download the upgrade package and install it at the printer.

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7.4. Export a second Printer Information File and upload this to wfx.videojet.com. This action ensures that the printer
and the portal remain synchronized.

FIGURE 8-1: A printer as it will appear in wfx.videojet.com at installation if no Workflow Modules have been sold.

In Figure 8-1 above, Upload PRI is RED because there have been no prior interactions between the printer and the
portal and therefore the software configuration of the printer is unknown.

Software Management via wfx.videojet.com

FIGURE 8-2: Status of a single printer as displayed via the workflow portal using a Videojet Service log-in.
In Figure 8-2 above, the customer view is identical save for the addition of a Buy Now option (for Workflow Modules).

Table 8-1: wfx.videojet.com UI Element Descriptions

UI Element Description

Indicates the status of the connectivity between the printer and the portal. For printers with a live
connection, it will be green

Indicates this printer was downgraded to an older software version. This is not normally displayed.
Sometimes, in conjunction with this icon you might see the red triangle requiring a software
upgrade.
Further interaction with the portal will be allowed only after approval by Videojet Admin or equi-
valent.

Friendly Name of the Printer

Printer Type/ Model

Serial number of the printer

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UI Element Description

Indicates that a software update is available for this printer. RED = mandatory upgrade. YELLOW =
optional upgrade. GRAY = upgrade package was downloaded via the portal, but the PRI file, indic-
ating that the package was installed on the printer, has not yet been uploaded to the portal.

Button used to manually upload a PRI file to the portal. RED = an upload is required prior to any fur-
ther interaction.

Escalation Release Software

DOWNLOAD button used to generate the printer-specific .zip file including available software
upgrades and/ or updates to Workflow Modules.

Provides the option to DECOMMISSION a printer (uninstall workflow modules for redeployment). It
also allows access to PRINTER CONFIGURATIONS, where available restoration points are
found.

Workflow Modules deployed to this particular printer. GREEN = the latest version is installed;
YELLOW = an optional upgrade is available. If these or similar icons are shown in the Available
row, then licenses have been purchased but modules have not yet been deployed.

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Advantages of Software Management via wfx.videojet.com

l wfx.videojet.com retains current information regarding software configuration and software version information for this
printer. The customer (or the Videojet service engineer) may determine at any time whether updates are available and may
deploy these when it is convenient to do so.
l A restoration point is established within the system following each download from the portal; this will allow for more effi-
cient recovery in the event of an anomaly (board replacement, SD card failure, or the update of software or workflow mod-
ules causing unforeseen negative consequences).

FIGURE 8-3: Restore points in the Printer Configuration section of the workflow portal.
The blue buttons at the bottom of the screen represent available restoration points for this printer; these are auto-
matically created following each download interaction with the portal.

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Process Description - Normal Software Update

If the printer is connected directly to the portal via LAN1 or LAN2, then the user shall be alerted to the availability of a software
update via an icon at the top of the printer's user interface. This network update may be performed at the user's convenience.
Otherwise, the user (or Videojet service engineer) may check for available software updates via wfx.videojet.com.

Optional upgrades shall be indicated via YELLOW; mandatory upgrades shall be indicated in RED.
If the user presses either the triangular button or the DOWNLOAD button, then the software portal shall generate the required
software upgrade package for the printer in question (including all licensed workflow modules). Upgrade the printer software via
USB using the Software Download System Tool.

Remember to export a new Printer Information File from printer to USB stick upon completion of upgrade and to upload this new
.pri file to the portal. (Upload PRI shall turn RED as soon as the .zip file has been downloaded).

Process Description - System Recovery after Main Control

Board Replacement
If the Main Control Board is replaced, then licensed Workflow Modules will temporarily be unavailable due to the change in the
MAC address of the Network Interface Controller. However, the desired software configuration may be recovered via wfx.video-
jet.com as follows:

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1. Power the printer ON. If the printer is already running, switch the ink jet OFF.
2. Go to Tools | Printer Settings | System Information and view the Serial Number.

If the Serial Number is blank, or if the Serial Number differs from the one on the printer's ID tag (adhered to the back of
the printer cabinet), then continue with this procedure.

3. Locate the serial number on the back of the printer cabinet.

4. Log on using the Manufacturer's Password. See "SIMPLICiTY Elevated Log In" on page 187.

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5. Go to Tools | Engineering | Production Setup. The Serial Number field will be editable.

6. Enter the correct serial number acquired from the printer ID tag on the back of the cabinet.

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7. Confirm that the serial number was programmed correctly by going to Tools | Software Download. Press OK when
prompted to insert a USB drive.

8. Remember to Log out upon completion of the procedure.

9. Export a new Printer Information File to USB and upload this file to wfx.videojet.com. The following message is expec-
ted:

Previously-installed workflow modules shall be moved to the Available row and may be re-licensed through the normal
download procedure.

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VideojetConnect Remote Service

VideojetConnect™ Remote Service allows for the real-time transfer of printer data from a connected Videojet coder to a
remote computer server and the Videojet Cloud. The printer data may be utilized to provide early warning to plant personnel or
Videojet technical staff, to allow for remote monitoring via customizable dashboards, and to enable and initiate corrective
actions via remote diagnostics and/or Virtual Network Computing (VNC).

Theory of Operation

1. The connected printer communicates with a local server via a special remote service protocol. The printer supplies sensor
information to the server every 30 seconds; the server is informed of events (faults, warnings, user interactions) as they hap-
pen. Although the communication is technically two-way, the server does not respond except upon initial connection (i.e.
handshake).
2. The server runs proprietary Videojet software which converts the printer-supplied information to .XML format and com-
municates it via HTTPS (encrypted) to the Videojet Cloud; these communications are one-way.
3. The following services are supplied by the Videojet Cloud:
l Configurable alerts (email) to local plant personnel.
l Alerts directly to Videojet Technical Support (where supported).

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l Remote monitoring via customizable dashboards.

l If enabled, temporary remote control of the printer via VNC for diagnostic and repair purposes.

The VideojetConnect™ Remote Service application is a System Tool, available out-of-box on all SIMPLICiTY printers. Licensing,
however, shall be controlled via the Videojet Cloud. Since the protocol is proprietary, all value-added features will be available
only if the proper license is legitimately acquired and maintained.

Printer Implementation with Remote Edge Server (RES)

The preferred implementation of VideojetConnect™ Remote Service will utilize a Remote Edge Server (RES) in lieu of a traditional
computer server or laptop.

FIGURE 8-4: Remote Edge Server board, out of its case.

Remote Edge Server Advantages

l Integrates a dedicated machine for the purpose of running Videojet Plant Server software.
l The Videojet software running on the connected RES device will check for updates every 7 days (manual update are not gen-
erally required).
l Small footprint for ease of integration.
l The device is capable of acting as a physical bridge between two networks (e.g. internal plant network and Cloud).

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FIGURE 8-5: Sample integration with RES, Ethernet connectivity, PHYSICAL BRIDGE.
In this configuration, the Remote Edge Server acts as a physical bridge, separating the Videojet equipment from the
external network (only the RES is visible to the LAN / WAN). The laptop is required only for initial setup of the
Remote Edge Server, and to diagnose connectivity problems. (Eth0 = static; Eth1 = DHCP).

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FIGURE 8-6: Alternate integration with RES, Ethernet connectivity, VIRTUAL BRIDGE.
In this configuration, the Remote Edge Server acts as a virtual bridge with both Videojet equipment and customer
LAN devices physically connected to the same network but operating on different subnets. The laptop is required
only for initial setup of the Remote Edge Server and to diagnose connectivity problems. (Eth0 = static; Eth1 =
DHCP). This configuration may be preferred if it is desirable to network devices with minimal hardware (switches,
etc.).

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FIGURE 8-7: Alternate integration with RES, Ethernet connectivity, COMMON NETWORK.
In this configuration, all devices reside within the same subnet. The RES acquires printer data and supplies con-
verted XML files using Eth0. Each Videojet printer may itself be set to DHCP (if supported), or they may be pro-
grammed with static IP addresses within the subnet via Static Exclusion set-up at the DHCP server. RES eth0's IP
address must remain fixed via either Static Exclusion or Reserved IP (since each printer must be programmed with
the RES's IP address).

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Appendices
Scan2Run Workflow Module 160
Lab 9-1: Scan2Run with a Serial Bar code Scanner 165
Lab Exercise Scan2Run with a USB Bar code Scanner 170
Logging Feature Matrix 175
Program the Main Control Board with Serial Number Information 178
Collect Crash Dump Files via USB 181
SAFE MENU Software Upgrade 182
SIMPLICiTY Elevated Log In 187
LED Status Indicator States (VRS RES) 189
Reset RES to Default IP Address on eth0 191
Training the Customer 193
List of Figures 201
List of Tables 204

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Scan2Run Workflow Module

The Scan2Run Workflow Module enables a customer to utilize a bar code scanner with a 1860, 1580, 1280 and 1240 printer for
either of two purposes:

l Message Selection
l Dynamic update of prompted fields within messages

Both serial and USB bar code scanners shall be supported, although the type of scanner to be utilized may be limited by the
printer in use. The 1580, 1280, 1240 have no serial port. The 1860 serial port is available only as an add-on.

Acquiring the Scanner

Order the part number from Table 9-1 below to acquire a scanner with the appropriate connection type.

Table 9-1: Scanner Part Numbers

Type Part Numbers Comments

RS-232 MS-0965-17 (scanner) + MS1371 Recommended for 1860 only. Expansion Board not required if 611197
(adapter cable) + 611197 (RS-232 is ordered separately. No RS-232 connectivity on 1580, 1280, 1240
Cable Connector) without USB-to-RS-232 adapter.

USB MS-0695-USB Recommended for all SIMPLICiTY printers.

Installing the Scan2Run Workflow Module

Scan2Run shall be acquired and installed using normal wfx.videojet.com software management procedures. See "wfx.video-
jet.com & Use of Printer Information Files" on page 143.

Configuring the Printer for Scan2Run

Once the Scan2Run Workflow Module is installed, perform these steps to complete printer configuration.

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1. Log on using the Manufacturer's Password. See "SIMPLICiTY Elevated Log In" on page 187.
2. Go to Tools | Scan2Run.

3. Toggle ON Scan2Run.

4. Select the appropriate scanner type.

5. If a serial bar code scanner is selected, perform these additional steps in order to properly configure the com-
munications port.

5.1. Select Tools | Communications.

5.2. Select COM5 and set COM5 Protocol to Scan2Run.

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5.3. Ensure that the protocol parameters are entered correctly for the scanner in use.

For Videojet-supplied scanners, the protocol shall be:

Baud Rate 9600

Data Bits 8

Stop Bits 1

Flow Control None

Parity Bit None

5.4. Select Tools | Scan2Run and set Connection to COM5.

Set up Message Selection & Dynamic Field Update

The Scan2Run Workflow Module allows for the use of Job and Data Markers. A job / data marker is a unique identifier to be
included at the beginning of each string of scanned bar code data which enables the printer to identify whether the subsequent
data is a message name (in which case, the printer will perform message selection functions) or prompted field data (in which
case, the printer will dynamically update the field(s) of the current message). The use of job and data markers allows the same
scanner to be employed for both message selection and prompted field update purposes.

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Job and Data Markers Are an Optional Feature

The use of job and data markers is optional. If these fields are left blank, then the printer will assume that
each inbound data string represents a message name. In this manner, the retail bar codes off of actual
products may be used as the bar codes for message select purposes (as long as corresponding messages exist
in the printer's memory).

To set up Job and Data Markers, proceed as follows:

1. Go to Tools | Scan2Run.
2. Select Markers.

3. Enter the unique character to be utilized as the job marker as well as the unique characters to utilize as data markers for
up to four user prompted fields. To avoid conflicts with data within the bar code strings, use special characters as job
and data markers.

The scanner is now ready for message select and/or dynamic field update purposes. Observe the following guidelines:

l The scanner itself must be programmed to append Start of Text (hexadecimal [02]) to the beginning of each scanned data
string and to append End of Text (hexadecimal [03]) to the end. If a scanner other than the standard Videojet accessory is
used, refer to the scanner's programming guide for instructions on how to achieve this.
l The scanner itself must provide data in ASCII format.

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l The message selection function is case-sensitive, so the characters encoded in any bar codes to be used for message selec-
tion must match exactly with the job names.
l Data markers will correlate to user prompted fields in the order in which the prompted fields were added to the message
(Data Marker 1 = first User Prompted Field that was added, etc.).

Functional Test
Use the Test tab of the Scan2Run Workflow Module to validate system operation prior to placing the equipment into production.

Once all parameters are configured correctly, scan a bar code with the connected device to test the system.

l If no data appears in the Scanned Data field, then either the scanner protocol is incorrect (RS-232 variation) OR the scan-
ner is not appending [02] and [03] to the start and end of the scanned data string, respectively.
l If Scanned Data is populated but Detected Data Type remains blank, then either the scanned data string does not include
the correct marker OR the scanned data string does not match the name of a job stored within the printer's memory.
l If Scanned Data is populated and the Detected Data Type displays as expected (Job Name or User Prompted Data), then
the bar code scanner and printer have been configured correctly and the system is ready to be put into production.

Table 9-2: Scanner-related Error Codes

Error Reason Solution

(E2010) Failed The scanned message name does not exist within the printer's Check message names vs. bar
to download job memory. code data. They must agree
exactly (case sensitive).

(E2360) Data Scanned data does not include a marker and the printer is con- Check bar code data; perform
read from scan- figured to use markers. functional test if necessary.
ner is invalid

... Data type Invalid marker Don't use " as a marker.

unknown

(E2364) Failed Data contains an unknown marker OR the printer is unable to

to update update the load the new message or update scanned data prior to
scanned data" the receipt of the next print trigger.

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Lab 9-1: Scan2Run with a Serial Bar

code Scanner
Name: Date:

Objective
Upon completion of this lab exercise trainee will have demonstrated the ability to install and configure a serial Bar code scanner,
as well as creating and loading a job with specific markers for both the job and user fields. The trainee will demonstrate their
understanding by completing the lab exercise at the end of this lesson and having it reviewed by their instructor for accuracy.
100% accuracy is required.

Instructions
Follow the instruction outlined in this exercise . Upon completion, have the instructor review for accuracy.

References
l Lecture notes
l Training Guide

Exercise Steps
1. Once the Scan2Run workflow module has been installed, go to Tools and access the Communications system tool.

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2. Select the appropriate COM and then press Protocol

3. Set protocol to Scan2Run and then press OK.

4. Go to Tools and access the Scan2Run workflow module.

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5. Under Settings, enable Scan2run and then set the Scanner Type to Serial.

6. Under Markers, set the following,

l Job Marker = !
l Data Marker 1 = #
l Data Marker 2 = $

7. Create a new job and name it CS1.

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8. Insert the first text field, then under Text Setup, set the Text Type to User Prompted.

9. Insert a second text field. Under Text Setup, set the Text Type to User Prompted.
10. Save the job and return to the home screen.
11. Scan the bar code below to load the job CS1. Verify on the home screen.

12. Scan the bar code below to populate the first user prompted field. Verify on the home screen.

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13. Scan the bar code below to populate the second user prompted field. Verify on the home screen.

14. Lab exercise is complete. Have the instructor verify the operation of loading a job and populating the user prompted
fields.

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Lab Exercise Scan2Run with a USB Bar

code Scanner
Name: Date:

Objective
Upon completion of this lab exercise trainee will have demonstrated the ability to install and configure a USB Bar code scanner,
as well as creating and loading a job with specific markers for both the job and user fields. The trainee will demonstrate their
understanding by completing the lab exercise at the end of this lesson and having it reviewed by their instructor for accuracy.
100% accuracy is required.

Instructions
Follow the instruction outlined in this exercise . Upon completion, have the instructor review for accuracy.

References
l Lecture notes
l Training Guide

Exercise Steps
1. Once the Scan2Run workflow module has been installed, go to Tools, and access the Communications system tool.

2. Under settings, enable Scan2Run, and set the Scanner Type to USB.

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3. Under Markers, set the following

l Job Marker = !
l Data Marker 1 = #
l Data Marker 2 = $

4. Create a new job and name it CS1.

5. Insert the first field, then under Text Setup, set the Text Type to User Prompted.

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6. Insert the second field, then under Text Setup, set the Text Type to User Prompted.
7. Save the job and return to the home screen.
8. Scan the bar code below to load the job CS1. Verify on the homescreen.

9. Scan the bar code below to populate the first User Prompted field. Verify on the home screen.

10. Scan the bar code below to populate the second User Prompted field. Verify on the home screen.

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11. Lab exercise is complete. Have the instructor verify the operation of loading a job and populating the user prompted
fields.

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 Logging Feature Matrix
The SIMPLICiTY user interface provides eight different methods of capturing and exporting printer-related parameters and events for external analysis. The
table below provides details related to each of these logging methods.

How
Log Where to Reported Data Elements Storage long is Memory Export to
Consists of… Clearable?
Name access? in VRS? and periodicity location the data Allocated USB?
stored?

Event Log Tools | Yes Warnings, faults, Event + time + SD card 18 months Up to 3 GB Safe menu Yes (manually)
Performance | generic user actions duration, as they occur available; upgrade and
Printer Logs (e.g., job selected, jet normal use normal
start) <1 MB software
upgrade will
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clear it

OEE Log Tools| | No OEE metrics over time Month + printer Not stored; 18 months None Same as Yes (manually)
Performance | OEE availability + rather, the event log
Availability operational availability, numbers
175

on demand are re-

calculated
each time
the app is
accessed

Service Log Tools | File Yes. 280 sensor points + Sensors: every 30 SD card 2 days 6 30 MB Same as Yes (manually).
Manager | Export Basically, other VRS-specified seconds (SD card) and Cloud (if months Infinite event log The data is only
Files. Choose the log is data (e.g., VNC on/off, 1 min (Cloud). VRS is accessible with
option “SL ….” comprised print count) Other data: when the enabled) USB, unless VRS
of all the value changes is enabled.
data points
reported in
VRS.

Appendices
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How
Log Where to Reported Data Elements Storage long is Memory Export to
Consists of… Clearable?
Name access? in VRS? and periodicity location the data Allocated USB?
stored?

USB Tools | Diagnostics | No It will log whatever the .csv file is automatically USB stick Depends Depends on N/A Automatically once
Logging USB Logging. It is logging.xml file tells it to created within only on size of size of USB enabled. Be sure
only available if an log. EclipseLogs on the USB drive drive to turn OFF
inserted USB stick USB stick. The 8 GB = logging prior to
contains an periodicity is specified approx. 10 extracting the
EclipseLogs folder within logging.xml – it is days (at 1 stick; otherwise,
which itself contains displayed on the UI sec interval the last few
logging.xml. (not editable) once & all minutes of data
logging is enabled. parameters may not be written
logged) to the stick.
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Crash Option to export to No Windows EC diagnostic Computer and OS SD card Until N/A No longer Yes (manually)
Dump USB is asserted at information suitable for diagnostics and other exported to available once
every boot-up until programmer analysis MCB USB exported to
actually exported locations USB
(also available via
176

Safe Menu)

Installation North America only No ‘IM Nodes’ (IM = 275 IM Nodes Supplied N/A Entire USB N/A Automatically if
Log – USB stick P/N Information Manager – recorded every 2 USB stick drive (4 GB) enabled. Be sure
392929 is included basically, every seconds. It will start to turn OFF
with each printer measured or automatically IF the logging prior to
shipment programmed stick is inserted prior to extracting the
parameter within the power on. Otherwise, stick; otherwise,
UI) it must be enabled in the last few
the same manner as minutes of data
USB Logging. may not be written
to the stick.

Hardware Tools | Diagnostics | No Self Test results in a .txt Approx. 130 line items USB Stick Until N/A N/A Yes (manually)
Self Test Self Test format of PASS/FAIL results replaced by
w/ related parameters the results
of the ‘next’
Self Test
 How
Log Where to Reported Data Elements Storage long is Memory Export to
Consists of… Clearable?
Name access? in VRS? and periodicity location the data Allocated USB?
stored?

Engineering Tools | Engineering No Service Log (above) + See individual entries USB stick See 8 MB Safe menu Yes (manual)
Log | Debug Logging Event Log (above) + above only individual upgrade and
(Manufacturer’s additional engineering entries normal
Password logs (‘modulation’) + above software
required!) printer settings + upgrade will
customer data (jobs, clear it
security) + .pri +
WorkFlow Modules &
license information
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Program the Main Control Board with

Serial Number Information
The Main Control Board Smart Chip is the ‘host’ Smart Chip; it performs authentication of the other seven Smart Chips within the
system. The Main Control Board Smart Chip also stores the printer (system) serial number, which is initially programmed during
the manufacturing process. This serial number is the key identifier used by Videojet Remote Service as well as in the licensing of
software Workflow Modules. Because the Main Control Board may be changed during the lifetime of the printer, provision has
been made to allow the Smart Chip to be programmed with the printer serial number outside of the manufacturing process. The
procedure below lists the necessary steps.

Enter the Serial Number Correctly!

Take care when manually entering the printer serial number in order to program the Main Control Board Smart
Chip. Inaccurate entry of the serial number will disable all licensed Workflow Modules and will prevent con-
nectivity via VideojetConnect Remote Service.

Procedure
1. Power the printer ON. If the printer is already running, switch the ink jet OFF.
2. Go to Tools | Printer Settings | System Information and view the Serial Number.

If the Serial Number is blank, or if the Serial Number differs from the one on the printer's ID tag (adhered to the back of
the printer cabinet), then continue with this procedure.

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3. Locate the serial number on the back of the printer cabinet.

4. Log on using the Manufacturer's Password. See "SIMPLICiTY Elevated Log In" on page 187.
5. Go to Tools | Engineering | Production Setup. The Serial Number field will be editable.

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6. Enter the correct serial number acquired from the printer ID tag on the back of the cabinet.

7. Confirm that the serial number was programmed correctly by going to Tools | Software Download. Press OK when
prompted to insert a USB drive.

8. Remember to Log out upon completion of the procedure.

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Collect Crash Dump Files via USB

Perform this procedure when the printer asserts the following warning during boot-up: The printer has recently crashed. Would
you like to copy crash information to USB stick?

Warnings Will Persist

The printer will continue to assert the same warning at every boot-up until the crash dump files are saved to a
USB stick. Therefore, assertion of the warning does not necessarily indicate that the problem is recent. Con-
versely, assertion of this warning may also indicate that multiple crashes have occurred since the last back-up.

1. Prepare a USB stick with a folder EclipseReports in the root directory.

2. Cycle power. When the warning is received (The Printer has recently crashed. Would you like to copy crash information
to USB?), select Yes and insert the prepared USB stick.

The printer will automatically and immediately write the crash information to the USB stick.

3. Once the normal printer boot-up resumes, remove the USB stick.

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4. Supply the files as directed to aid in debugging.

FIGURE 9-1: The copy crash files procedure writes to EclipseReports\Crashes on the prepared USB stick.
Supplying the file(s) within this folder to Videojet R&D will aid in debugging.

SAFE MENU Software Upgrade

Data Loss
Software upgrades are normally performed using the Software Download System Tool. The Safe Menu pro-
cedure could result in the loss of customer data (jobs, line setups), installation history, etc.

l Prepare a USB Stick

l Access Safe Menu
l Install Application Software

Prepare a USB Stick

1. Download the required .swu file from wfx.videojet.com if you do not yet have it.
2. Plug a USB memory stick into a PC.
3. Delete any files currently on the USB memory stick.

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4. Place the .swu file to the root of the USB Flash Drive.

Access Safe Menu

1. Power the printer OFF.
2. Press and hold in the upper left corner of the screen while powering the printer ON to enter the safe menu. This will take
between 10 and 15 seconds.

3. When prompted, enter today's password (same as Level 3 password for 1000-series printers) and press OK.

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Install Application Software

1. Insert the prepared USB stick.
2. Press to select Manage Printer Software.

3. Press to select Install From USB.

4. Press to select the Available USB Device then press Continue.

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5. Press to select the Available Update File.

6. If desired, press to select Migrate OS configuration and Migrate Application files. Migrate OS configuration retains Com-
munication Parameters, IP Address, Server IP, etc. Migrate Application Files retains customer jobs, printer settings, vis-
cosity calibration, etc.

7. Press to select Start Installation.

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8. Software Update will begin.

9. Once software update is successful, press OK. The printer will apply changes and reboot. Safe Menu software update is
complete.

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SIMPLICiTY Elevated Log In

Logging in with the Elevated login grants access to higher-level functions via the user interface. It is also useful if the user has
inadvertently locked himself out of the system.

1. Press and hold the Log in (or Log out) button.

2. After approximately 5 seconds, the Elevate Login Status screen will appear.

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3. Enter the 6-digit password for the day. Once the password has been successfully entered, the superuser icon will be dis-
played at the top of the touchscreen:

4. Remember to log out once you complete your work (in case the user has Auto logout turned OFF).

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 Appendices

LED Status Indicator States (VRS RES)

The PCB inside the RES has both a red and a green status indicator LED. Both the red PWR LED and the green ACT LED should illu-
minate when you connect the power supply to the RES.

FIGURE 9-2: The PWR LED illustrated in a non-Videojet case.

The red LED indicates that the RES has an active power supply. If it fails to light or flashes it indicates that there is a problem with
the power supply. The red power LED will flash if the voltage drops below 4.63V.

FIGURE 9-3: The green LED illustrated in a non-Videojet case.

The green LED will flash to indicate software activity. If the green LED does not flash or stays on, then it is likely that there is a
problem with your RES board’s MicroSD card.

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Table 9-3: RES LED States

LED State Meaning

PWR Off No power to the PCB

(Red)
On PCB is powered.

Flashing PCB is powered but there is a fault/error.

ACT Flashing Normal operation, data is reading/writing to the MicroSD card.

(Green)
Off/Solid There is a problem reading/writing data to the MicroSD card. There may be a problem with the
On MicroSD card.

No Pattern to LED Activity

There is no fixed pattern for the green LED flashes like on some Videojet products. The green LED simply
flashes every time it needs to read information from its MicroSD card.

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 Appendices

Reset RES to Default IP Address on

eth0
In the event that you lose track of the RES IP address (such as leaving it to DHCP and having no idea what the subnet or address
are) then you can jumper two pins to reset the IP address to default. The reset will not revert any software or remove any files,
only the IP address is reset.

Procedure
1. Unplug the power from the RES.
2. Insert a jumper pin on PIN3 and PIN5 on the J8 connector.

3. Plug the power on the RES.

4. Wait until the ACT LED light is solid green.
5. Wait another 30 seconds and double check that the LED is solid green.
6. Unplug the power from the RES.
7. Remove the jumper.
8. Plug the power on the RES and wait a few seconds for it to reboot.
9. Type 192.168.13.51 default eth0 IP address on the browser address bar.
10. Edit and submit the previous eth0 IP address.

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 Training the Customer
Use these guidelines during all operator-level training to be conducted in conjunction with equipment installation. Allow two hours and forty-five minutes for
training to cover all topics up to troubleshooting. Cover troubleshooting as time allows.

Table 9-4: Safety (20 Minutes)

Topic Facilitator’s Points of Emphasis Learner’s Activities

PPE Discuss personal protective equipment required for inkjet printer operation Ask trainees to describe local PPE requirements in
(safety glasses, gloves). order that you may gauge any risk related to safety
glasses (availability, etc.).

Disposal Discuss fluid disposal - waste fluid shall be disposed of as Hazmat. NOTE: Ask trainees to describe local procedures for HAZMAT
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if possible, attempt to learn local policies related to the recycling of empty disposal, in order that you may gauge any risk related to
cartridges / Smart Chips. ink or makeup handling.

Ink Discuss ink storage (FLAM locker, and ideally in a climate-controlled

Storage environment).
193

Ink Discuss general ink safety (the need for adequate ventilation, how to remove
Safety it from your skin, no smoking).

Electrical Discuss general electrical safety (it is necessary to ground while test
Safety printing, do not use the Videojet wash station for test printing purposes,
since a reliable ground path does not exist).

Table 9-5: Adding Fluids (10 Minutes)

Topic Facilitator’s Points of Emphasis Learner’s Activities

Fluid Bays Adding fluids - ink on the right, makeup on the left.

Appendices
 1280, 1240 Technical Training Guide
Topic Facilitator’s Points of Emphasis Learner’s Activities

Indicators l Indicators shall be provided when either cartridge nears

empty:

l The printer provides a visual indication of the time until

cartridge replacement for each cartridge on the Home
Screen. This is a calculated value based upon current
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usage and shall be updated every day.

When to The cartridge shall not be replaced until it is empty (level = 0%).
Replace At this time, the appropriate warning shall be displayed by the
printer.
194

Level Explain cartridge level tracking. This is based on the printer

Tracking counting the number of addition pulses when drawing fluid from
both the Ink and Makeup cartridges.

Insertions Explain that the printer tracks the number of insertions for each If a used (empty) cartridge is available, then give each trainee the
cartridge and that a maximum of fifteen insertions are allowed. opportunity to remove and replace a cartridge. Focus on the
For this reason, avoid unnecessary removal and replacement of physical and display indications which verify that the cartridge is
cartridges. properly fitted.
 Table 9-6: Security (10 Minutes)
Topic Facilitator’s Points of Emphasis Learner’s Activities

Default There are four default security levels: Admin (Password = 3333),
Levels Maintenance (2222), Operator (1111), and Logged Out (no password
entered).

Logging l Explain that the printer always boots up to a Logged Out state and
In that a valid password must be entered before most printer operations
are allowed.

l Demonstrate Login from the Home Screen:

l Verify successful Login by viewing the Tools screen.
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Logging l Demonstrate Logout from the Home Screen and show how the Tools Provide each trainee with the opportunity to log on using
Out menu has changed. one of the default roles and passwords and to log out.
l Explain the Auto Logout feature (Tools | User Access | Security
Mode) and disable this feature, if appropriate.
195

Table 9-7: Normal Startup (20 Minutes)

Topic Facilitator’s Points of Emphasis Learner’s Activities

Starting
the Jet Press the Start Jet button to initiate printer startup.

Appendices
 1280, 1240 Technical Training Guide
Topic Facilitator’s Points of Emphasis Learner’s Activities

Clean vs l As the printer automatically selects the preferred method of startup (clean or quick) based Trainees shall observe all typical
Quick upon current conditions, explain this difference to the trainees. printer indications during a normal
Starts jet startup.
l The start up is complete and the printer is ready to be placed into the print mode when the
status bar reads as follows:

l Set expectations appropriately related to length of startup (it will be variable, due to the
fact that the printer is performing a number of auto-adjust routines, and it will be affected
by environmental factors, etc.).
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Table 9-8: Status Indicators (20 Minutes)

Learner's
Topic Facilitator’s Points of Emphasis
Activities
196

Start
& Stop
l Press to elevate to RUNNING state.
Print

l Press to return to OFFLINE state.

Warnings Most warnings will automatically clear once the condition has cleared. Pressing the warning in the dropdown list
provides additional information and corrective actions.
 Learner's
Topic Facilitator’s Points of Emphasis
Activities
Faults The name of the an asserted fault is shown on the status bar. Pressing the name of the fault in the dropdown list
provides additional information and corrective actions. If logged on, you can manually clear the fault once the
condition is corrected.

Table 9-9: Running Production (5 Minutes)

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Topic Facilitator’s Points of Emphasis Learner's Activities

Selecting Jobs Select previously-created jobs for printing using the Jobs button. Trainees will load existing jobs using the Jobs
button.
197

Home Screen Explain the normal indications observed via the Home Screen during
Data printing.

l Batch Print Count increments

l Batch Product Count increments

Appendices
 1280, 1240 Technical Training Guide
Table 9-10: Message Creation (1 Hour)
Facilitator’s Points of
Topic Learner's Activities
Emphasis
Messages & Message l Create and name a new Ask trainees to explain their current message format in as much detail as is
Parameters job. possible.
l Program the job
parameters.

Text Fields l Add fixed text.

l Edit the text.
l Change the font.
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l Position the text field.

Date Fields l Add a date field.

l Edit the date format.
198

l Create an expiry date.

Time & Shift Codes l Add the current time.

l Edit the time type.
l Create a shift code.
l Create a timer.

Serializers l Explain Serializers. Each trainee will create and save a message which closely replicates that
which shall be used in production.
l Create a serializer.

Advanced Features l User-prompted fields

l Adjustable day rollover
l Inhibited day rollover
 Table 9-11: Normal Shutdown (10 Minutes)
Learner's
Topic Facilitator’s Points of Emphasis
Activities
Shutdown, l Press the Stop Jet button in order to initiate printer shutdown. Identify the
stop types Stop Jet
l The printer shall automatically select the method of shutdown (Clean vs. Quick) based upon current
button.
conditions.

When to l It is appropriate to kill the main power when the status bar changes to Shutdown.
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Shutdown
199

l Do not interrupt the shutdown sequence with a hard kill.

l The printer logic for shutdown is less stringent than the logic for startup, so most stops will end up being
CLEAN. For this reason, excessive starts and stops may still result in high mixer tank level and low ink
viscosity. However, users should be encouraged to stop the jet whenever the printer is not to be used to
avoid excessive idling.

Table 9-12: Basic Printer Maintenance (10 Minutes)

Learner's
Topic Facilitator’s Points of Emphasis
Activities
Printhead Demonstrate printhead cleaning.
Cleaning

Appendices
 1280, 1240 Technical Training Guide
Learner's
Topic Facilitator’s Points of Emphasis
Activities
When to Clean When is it okay to clean the printhead? If the Start Jet button is visible, then both the ink jet and vacuum are Identify the
OFF and it is appropriate to clean the printhead. Start Button.
If no fault has been asserted, then the status bar will also indicate:

Cleaning the l Inspect the printhead cover and clean it if necessary whenever the printhead is cleaned.
Printhead l If the printhead cover is handled during printhead cleaning, take care to ensure that the cover is
Cover restored to service with the printhead screw pointing PARALLEL to the direction of product motion.
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Table 9-13: Operator Level Troubleshooting (Time Permitting)

Symptom Troubleshooting Actions to Demonstrate
200

The printer is not displaying

any faults, but it is not
1. Check if the printer is in the state.
printing.
2. Ensure that the correct message is selected. Use the Preview
window on the Home Screen.
3. Check if the Print Count is incrementing.
4. Go to Tools | Diagnostics | Diagnostics Data to check product
detector operation.

The code is printed at the 1. Check Print Margin and PD to PH Distance.

incorrect location on the
product. 2. Use the button to make small changes to code width and
placement on the fly.

Poor Print Quality 1. Check the physical Throw Distance.

2. Check Head Cleanliness.
 Appendices

List of Figures
Figure 1-1: Fixed Length Print Mode is appropriate for the application pictured above because it is required to fit the message into
a specific area between pre-printed information on the packaging. 16

Figure 1-2: Fixed Resolution Print Mode is appropriate for the application pictured above, since the message length will change
(JULY) but will not interfere with pre-printed information on the packaging. 17

Figure 1-3: The Print Margin is the desired linear distance between the leading edge of the product and the first printed stroke of
the message. 17

Figure 1-4: Illustration of product movement directions. 24

Figure 1-5: Normal and inverted head orientation illustrations. 25

Figure 1-6: Proper selection of the sensor type enables the internal circuit to automatically configure itself without the use of jump-
ers. 28

Figure 1-7: Changing the throw distance to adjust message height. 36

Figure 2-1: Videojet 1240 Ink System. 53

Figure 2-2: Videojet 1280 Ink System. 54

Figure 2-3: Videojet 1280 Ink System Top Plate. 55

Figure 2-4: Videojet 1240 Ink System Top Plate. 56

Figure 2-5: Videojet 1280 Valve Base Assembly. 57

Figure 2-6: Videojet 1240 Valve Base Assembly. 57

Figure 2-7: The Videojet 1280/1240 pump. 58

Figure 2-8: The drive gear and the driven gear rotate within a rigid cavity. 58

Figure 2-9: Graph of flow rate decrease as pressure increases for a cavity-type pump. 59

Figure 2-10: Pump manifold flow paths, illustrated. 60

Figure 2-11: Videojet 1240 Venturis. 61

Figure 2-12: Videojet 1280 Venturis. 62

Figure 2-13: Videojet 1280 Gutter Pump. 62

Figure 2-14: Videojet 1280 Gutter Pump Speed Adjustment. 63

Figure 2-15: Positive Air Pump. 63

Figure 2-16: Videojet 1280 Port Description. 64

Figure 2-17: Videojet 1240 Port Description. 65

Figure 2-18: Videojet 1280 Manifold Connections 65

Figure 2-19: Videojet 1240 Manifold Connections. 66

Figure 2-20: Videojet 1280 Manifold Internal Channels. 66

Figure 2-21: Videojet 1240 Manifold Internal Channels. 67

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Figure 2-22: Service Module flow path. 69

Figure 2-23: Service Module Three Stage Filter. 69

Figure 2-24: Service Module spring-loaded valve assembly. 70

Figure 2-25: Service Module fit location on the top plate. 70

Figure 2-26: The Printhead Valve Module with the valves removed. 71

Figure 2-27: Printhead Valve Module flow paths. 71

Figure 2-28: Printhead Valve Module with Valves. 72

Figure 3-1: Diagram: Videojet 1280 Ink System. 74

Figure 3-2: Diagram: Videojet 1280 Ink Supply & Return. 75

Figure 3-3: Diagram: Videojet 1280 Clean Start & Stop, Part 1. 76

Figure 3-4: Diagram: Videojet 1280 Clean Start & Stop, Part 2. 77

Figure 3-5: Diagram: Videojet 1280 Nozzle backflush. 78

Figure 3-6: Diagram: Videojet 1280 Vacuum Generation. 79

Figure 3-7: Videojet 1280 Ink Addition diagram. 80

Figure 3-8: Videojet 1280 Makeup Addition diagram. 82

Figure 3-9: Diagram: Videojet 1280 Prime Mixer Tank. 84

Figure 3-10: Diagram: Videojet 1280 Solvent Recovery System. 85

Figure 3-11: Diagram: Videojet 1280 Empty & Clean Part 1. 86

Figure 3-12: Diagram: Videojet 1280 Empty & Clean Part 2. 87

Figure 3-13: Diagram: Videojet 1280 Instrumentation & Diagnostic System. 88

Figure 3-14: Diagram: Videojet 1240 Ink System. 90

Figure 3-15: Diagram: Videojet 1240 Ink Supply & Return. 91

Figure 3-16: Diagram: Videojet 1240 Clean Start & Stop Part 1. 92

Figure 3-17: Diagram: Videojet 1240 Clean Start & Stop Part 2. 93

Figure 3-18: Diagram: Videojet 1240 Nozzle Backflush. 94

Figure 3-19: Diagram: Videojet 1240 Vacuum Generation. 95

Figure 3-20: Diagram: Videojet 1240 Ink Addition. 96

Figure 3-21: Videojet1240 Makeup Addition diagram. 98

Figure 3-22: Diagram: Videojet 1240 Solvent Recovery System. 100

Figure 3-23: Diagram: Videojet 1240 Prime Mixer Tank. 101

Figure 3-24: Diagram: Videojet 1240 Ink System Drain. 103

Figure 3-25: Diagram: Videojet 1240 Instrumentation & Diagnostics. 104

Figure 3-26: Ink system Pressures display. 105

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 Appendices

Figure 3-27: Coefficients shown in the Diagnostics | Ink System | Ink screen. 105

Figure 3-28: Viscosity / PH Temperature Curve. 106

Figure 3-29: Determined Viscosity. 106

Figure 3-30: Viscosity / Pressure Curve. 107

Figure 3-31: Determining TCTP. 107

Figure 3-32: Determining TCTP, continued. 108

Figure 3-33: Viscosity Calibration. 108

Figure 3-34: Before Viscosity Calibration. 109

Figure 3-35: After Viscosity Calibration. 109

Figure 3-36: Fluid Timeout located in Tools | Printer Settings | Printer Control. 110

Figure 5-1: Diagram: Electronics system block. 124

Figure 5-2: Diagram: Main Control Board Subsystem. 125

Figure 5-3: Diagram: MCB Test Points. 131

Figure 6-1: Ink System Valve Connector Board Sensors. 133

Figure 6-2: Videojet 1280/1240 TAPD Board (Rear View). 134

Figure 6-3: Schematic: Phasing & Velocity Amplifying Circuit. 135

Figure 6-4: Schematic of phasing/velocity signal amplification on its way to the FPGA. 136

Figure 6-5: The Gutter Detect Chamber. 136

Figure 6-6: Schematic: Gutter Detect Circuit. 137

Figure 6-7: Schematic: Pressure management via Pressure Transducer and Main Control Board. 138

Figure 6-8: Schematic: Vacuum Management via Vacuum Transducer to Main Control Board. 139

Figure 7-1: Diagram: Components fitted with Smart Chips. 141

Figure 8-1: A printer as it will appear in wfx.videojet.com at installation if no Workflow Modules have been sold. 146

Figure 8-2: Status of a single printer as displayed via the workflow portal using a Videojet Service log-in. 146

Figure 8-3: Restore points in the Printer Configuration section of the workflow portal. 148

Figure 8-4: Remote Edge Server board, out of its case. 154

Figure 8-5: Sample integration with RES, Ethernet connectivity, PHYSICAL BRIDGE. 155

Figure 8-6: Alternate integration with RES, Ethernet connectivity, VIRTUAL BRIDGE. 156

Figure 8-7: Alternate integration with RES, Ethernet connectivity, COMMON NETWORK. 157

Figure 9-1: The copy crash files procedure writes to EclipseReports\Crashes on the prepared USB stick. 182

Figure 9-2: The PWR LED illustrated in a non-Videojet case. 189

Figure 9-3: The green LED illustrated in a non-Videojet case. 189

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List of Tables
Table 3-1: Ink Volume Displayed by Percent 81

Table 3-2: Makeup Volume Displayed by Percent 82

Table 3-3: Diagnostic Instrumentation Legend (1280) 88

Table 3-4: Ink Volume Displayed by Percent 97

Table 3-5: Makeup Volume Displayed by Percent 98

Table 3-6: Instrumentation Legend (1240) 104

Table 6-1: TAPD Board Pins 134

Table 7-1: Summary of Smart Chip Data 142

Table 8-1: wfx.videojet.com UI Element Descriptions 146

Table 9-1: Scanner Part Numbers 160

Table 9-2: Scanner-related Error Codes 164

Table 9-3: RES LED States 190

Table 9-4: Safety (20 Minutes) 193

Table 9-5: Adding Fluids (10 Minutes) 193

Table 9-6: Security (10 Minutes) 195

Table 9-7: Normal Startup (20 Minutes) 195

Table 9-8: Status Indicators (20 Minutes) 196

Table 9-9: Running Production (5 Minutes) 197

Table 9-10: Message Creation (1 Hour) 198

Table 9-11: Normal Shutdown (10 Minutes) 199

Table 9-12: Basic Printer Maintenance (10 Minutes) 199

Table 9-13: Operator Level Troubleshooting (Time Permitting) 200

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Index
Data Markers 162
A DHCP 154

Actual Pressure 134 Disposal 193

Actual Velocity 108, 121

Air Flow Meter 121
E
Air Pump Control 123
ASCII 163 EHT
Automatic Modulation 120 EHT Voltage 35
EHT Calibration 119
EHT Drive Power 130
B EHT Module 123

Baud Rate 162 EHT Plate 120

Break Off 120 EHT Power Supply 124-125, 129

Electronics Compartment 88, 104, 115, 133
Encoder Control 123
C Encoding 125
External 40, 43, 45-46
Charge 125
Escalation Software 147
Charge Amplifier Control 123
Charge Amplifier Signal 127
Charge Electrode 115 F
Charge Scale 117
Charge Tunnel 127 Fan Control 123

Compensated Pressure 121 FIB 124-125

Condenser 74, 85 Filter Module 59, 68

Contamination 86 Flow Control 162

Cover Detect 88, 104, 129 Fluid

Custom Reference Builder 39 Cartridge Timeout 109

Cartridges 84, 86, 96, 101-102, 141
Fluid Reference Numbers 142
D Fluids 142
Storage 193
Data Bits 162
Flush Pump 76-77, 92

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Fly-by Sensors 134

FPGA 134 L

Friendly Name 146 Lampstack 125

Lampstack Control 123
Level Detection 104, 123, 133
G
Level Rods 88, 125, 133
Ground Plate 134 Line Setups 16, 23
Gutter 75, 77, 91, 95 Line Speed 26
Clearance 36 Print Mode 25
Gutter Detect 88, 104, 123, 129, 136 Print Trigger 25
Gutter Pump 77, 79, 85, 125 Line Speed See also Line Setups, Line Speed

H M

Head Temperature 121, 129, 142 MAC Address 143

Heater Control 123 Main Control Board See MCB
High Voltage 75 Mains Power Supply 123-124
Manifold 114
Flush Pump Out 64-65
I Gutter Pump Return 64-65
Ink Add 64-65
Ink Coefficient 105
Ink Feed Out 64-65
Ink Compartment 53, 88, 104, 114, 133
Ink System Prime 64-65
Ink Conductivity 142
Makeup Out 64-65
Ink Density 142
Vent 64-65
Ink Parameters 142
Matrices
Ink Pump 76, 86, 91, 94, 101, 125
16 High 34
Ink Stream
24-High Single Line 43, 46
Alignment 120
5-High Twin-Line 38
Ink System Valves 125
7-High Quad-Line 40
7-High Single Line 32
7-High Tri Line 45
J
7-High Twin Line 33-34
Job See Messages 9-High Twin Line 42

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 Index

MCB 115, 123-125, 134, 136-138, 141

Fan 125 P

Replacement 149 Parity Bit 162

Message Selection 162 Phase Charge 117
Messages 198 Phase Profile 121
Fields 19 Phasing and Velocity 88, 104, 134
Fonts 19 Amplifier 134
Information 15 Phasing Signal 129, 134
Job Name 15 Photocell Control 123
Print Margin 17 Positive Air Flow 121, 125
Print Mode 16 PPE 193
Raster Select 17 Pressure 121
Rotation 37 Pressure Transducer 75, 88, 91, 104, 125, 129, 134, 137
Serializer 43 PRI Files 116, 143
Mixer Tank 59, 75, 77-80, 84, 87, 91-92, 94-96, 100-102, Priming Block 101
109, 118, 133
Print Mode See also Line Setups, Print Mode; Messages,
Temperature Sensor 104 Print Mode
Modulation 125, 142 Printhead 78, 91, 133
Modulation Control 123 Elevation 122
Modulation Transformer Signal 128 Orientation 24
Printhead Temperature 104
Product
N
Direction 24
Network and TCP/IP 153, 191 Product Detect 125
Nozzle 77, 115 Prompted Field 162
Flush 78, 94 PSU 130
Frequency 121 Pumps 59
Type 118 Ink Pump Discharge Pressure 68
Voltage 121
Number of insertions 142
R

Relay Control 123

O
Remote Service Protocol 153
OEE 175 RES 154, 189, 191
Offset 108, 142 Restoration Point 148

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Run Hours 69, 142

V

Vacuum 60, 76, 79-80, 95-96, 98

S
Vacuum Transducer 83, 88, 99, 104, 125, 129, 134, 138
SD Card 175 Valve Base Assembly 57
Micro SD Card 189 Valve Control 123
Sensors 133 Valve Control Board See VCB
Serial Number 142, 150, 178 Valves
Serial Ports 160 Check 92
Service Module 68, 91, 118, 141 Spring Loaded (Service Module 1) 69
Disposal 68 VC 74, 85, 88
Shipping 86 VF 74-80, 82, 84-86, 88, 90-92, 94-96, 98, 101-102
Smart Chip Board 124, 141 VG 62, 74-80, 82, 84-86, 88, 90-92, 94-96, 98, 101-
102
Smart Chips 69, 90, 118, 123, 125, 141, 149
VI 74, 79-80, 84, 86, 88, 90, 95-96, 102
Software Update 147, 182
VJ 74, 76, 79, 82, 88
Solvent Recovery 79, 90, 100
VL 74-80, 82, 84-86, 88, 90-92, 94-96, 98, 101-102
Startup 196
VM 74, 79, 82, 86, 88
Static IP Addresses 154
VP 74-77, 79-80, 82, 84-86, 88, 90, 92, 95-96, 98, 102
Stop Bits 162
VR 74, 86, 88, 90, 102
Storage 86
VS 74, 88
VV 74, 76, 79, 86, 88, 90, 95, 102

T VCB 118, 123, 141

Velocity See Phasing and Velocity
TAPD Board 134 Velocity Setpoint 108, 121
Target Pressure See TCTP Velocity Signal 128, 134
TCTP 98, 105, 134 Viscosity 109
Temperature-Viscosity Curve 106 Calibration 107
Temperature Sensor 88, 125, 133 Viscosity Coefficients 142
Throw Distance 35 VRS 189
Top Plate 57

W
U
Wheatstone Bridge 68
Umbilical 77-78, 91, 127
USB 160

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 Index

Workflow Modules 116, 143, 160

Licensing 143, 149, 152

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