WaxJet 6100, Service Reference Manual

Page 1: ...FoxJet Inc 2016 E Randol Mill Rd Suite 409 Arlington TX 76011 SERVICE REFERENCE MANUAL SERIES 6 WAXJET HIGH RESOLUTION PRINTING SYSTEMS Revision 4 15 February 1999...

Page 2: ...nstitutes your aknowledgment and acceptance of and your express agreement to comply with the above state Field of Use Restriction Any other use of the Produce is prohibited and in violation of this Fi...

Page 3: ...uipment Mounting 2 3 Product Detection Photocell 2 4 Proximity 2 4 Reflective 2 4 Inductive 2 5 Print Registration Photocell 2 5 External Alarm 2 6 Line Speed Monitoring Shaft Encoder 2 6 AutoPrint Mo...

Page 4: ...Alternative Input Devices 4 8 Chapter 5 Command Definitions Configuration Commands 5 1 Editing Commands 5 6 Utility Commands 5 13 Rear Port Commands 5 22 Chapter 6 WaxJet Installation Setup System Con...

Page 5: ...6 20 RS 485 Wiring 6 21 Controller Configuration 6 21 Chapter 7 Service Routine Maintenance 7 1 Maintenance Schedule 7 1 Daily Cleanup 7 2 Cleaning Photocell Lens 7 2 Cleaning Interior of Controller 7...

Page 6: ...8 4 Removal 8 4 Installation 8 4 Power Supply Unit 8 5 Removal 8 5 Installation 8 5 Interface PCB 8 6 Removal 8 6 Installation 8 7 Backup Battery Ni Cad 8 8 Removal 8 8 Installation 8 8 Backup Battery...

Page 7: ...ation 8 27 Chapter 9 Parts Bracketry Parts Replacement Kits 9 1 Printhead Replacement Kit 9 1 Heater Assembly Replacement Kit 9 1 Wax Tubing Replacement Kit 9 2 Fuse List 9 2 Bracketry 9 3 Controller...

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Page 9: ...er case a product detect circuit ensures that the desired message will be printed on the correct location on the package or carton Basic Operation Single Phase 110VAC or 220 VAC 50 or 60 Hz powers Ser...

Page 10: ...t products do not come into contact with it High heat from the Printhead may damage product s and the Printhead may be damaged as well Avoid handling the wax system and wax hose while in operation Use...

Page 11: ...high resolution print quality To ensure that system is installed in an application geared for success the following factors must be considered Substrate Type Series 6 wax adheres very well to chipboa...

Page 12: ...o Printhead 8 kHz maximum The formula for converting foot per minutes to inches per seconds is FPM 5 IPS Using Internal Oscillator 35000 W Freq Print DPI s are determined with the following formulas U...

Page 13: ...6 systems will operate in ambient air temperatures ranging from 50 95 Fahrenheit Humidity non condensing can range between 20 and 80 Standard equipment cabinets are not water resistant however NEMA 4...

Page 14: ...ted up line from the Printhead for accurate product detection Most photocell assemblies have some adjustment capabilities for operation in various application designs Proximity The proximity photocell...

Page 15: ...tion in the lines of flux induces a change in the current driving the coil and consequently send a product detect signal Print Registration Photocell The Print Registration Photocell detects a print r...

Page 16: ...printing bar codes The shaft encoder synchronizes Printhead firing to the speed of the production line Shaft encoders generate a number of pulses during shaft rotation that relate to the conveyor lin...

Page 17: ...coder pulses and photocell signals product detection Product detection signals can be actual photocell triggers or AutoPrint Module generated photocell triggers The AutoPrint Module has three modes of...

Page 18: ...2 8 Application Design This page intentionally left blank...

Page 19: ...nland Series 6 Firmware Software Firmware 100 Messages Programmable Counters 100 Char line Automatic Time Date Del Ins Functions Edit Save Functions Programmable Shift Functions Product Batch Counters...

Page 20: ...to 6 mm Max Line Speed at is 80 ft min 24M min Max Line Speed at 1 8 150 ft min 46 M min Max Line Speed at 1 16 260 ft min 80 M min Printhead Orientation Horizontal Vertical Down with 8 angle in eith...

Page 21: ...Dimensions Controller Application Design 2 11...

Page 22: ...Integrated Printhead Wax System 2 12 Application Design...

Page 23: ...models will be the firmware the Printhead used and the electronics that drive the Printhead The WaxJet Driver board is a single Printhead driver The WaxJet system will only have one driver circuit At...

Page 24: ...NOT be adjusted in the field If voltages are incorrect a fault cannot be remedied by adjusting a potentiometer CPU PCB The CPU PCB contains a 32 bit CMOS microprocessor for high performance data mani...

Page 25: ...PCB on this cable as well The Printhead wax tank and wax hose heating circuits are controlled on the Driver PCB Two pico fuses are used to provide overload protection for the 36 VAC heating circuit vo...

Page 26: ...s The Printhead Data Cable supplies heater voltage from the Driver PCB to the Printhead heater circuit The heated wax flows smoothly to the Printhead The Printhead is positioned so that gravity feed f...

Page 27: ...ow long after product detect that a print cycle will occur The DELAY value is in rasters and the print resolution determines how many rasters there are in a given length of conveyor travel If print re...

Page 28: ...head connected to the system Some commands relate to two Printhead Quantum systems and the WaxJet system only have one Printhead Most configuration commands will affect all heads connected to the cont...

Page 29: ...re message SystemMaster Programming FoxJet has developed a Windows base program that will control up to 32 FoxJet Printing Systems through the external serial port Rear Port SystemMaster gives the use...

Page 30: ...etailed in Command Definitions pertain to individual heads When the commands are received the printer applies those changes to the Current Head only The Current Head defaults to Head A and may be chan...

Page 31: ...C Inserts Exp MM DD YY YE Inserts Year EY Inserts Exp Year MO Inserts Month EM Inserts Exp Month DA Inserts Day ED Inserts Exp Day JD Julian Date EJ Inserts Exp Julian date YL Inserts last digit year...

Page 32: ...essage for Numbers V3V2U1 This embedded code will print digit 1 each time digits 2 3 when they are not leading zeros counting up from the LOWER value set with the NUMBERS command The LOWER value and i...

Page 33: ...ns will NOT produce line separation After selecting the font input the desired messages on each line On line 5 enter the font information Example MSG 1 L1 F91 Line 1 contents Line 2 contents Line 3 co...

Page 34: ...be mixed For instance if message 1prints a counter using the embedded code U2U1 and message 2 prints a product code that may change on every print cycle and both messages are in the SELECT string the...

Page 35: ...systems Must be set to match control device The arrow keys select the desired baud rate Keystrokes to enter command are B A Use arrow keys to make desired selection and press R to save CURVE Models A...

Page 36: ...okes are D i 1 VT 100 Emulation Terminal 2 Wyse Terminal 3 FoxJet Terminal 4 Reserved for future use ASCII String To change the display to utilize the Wyse terminal enter DI2 CR ENCODER Y N Models All...

Page 37: ...m s to operate under SystemMaster network and accept SystemMaster commands via the Rear Port connection Avoid input conflicts by returning display screen to main menu This command is set at installati...

Page 38: ...with the numeric values for Hour Minute and Second Use HH MM SS format The arrow keys A and l r can be used for changing only part of the time ASCII String To set the time to 11 20 21 PM TI232021 CR T...

Page 39: ...9 is entered This multiplies the number of rasters for each character Example A 5hx5w raster character is printed at a bold value of 2 The 5x5 raster character would now be a 5x10 raster character AS...

Page 40: ...is terminated with CR or FF Terminating message with CR will print the message in batch mode terminating with FF will print only once one for one mode Changing fonts is accomplished with a CTRL F and...

Page 41: ...ls Selected head This command will allow the user to turn a message upside down At the command prompt the keystrokes are I N ASCII String To set the image to inverted enter INY CR MIRROR Y N Series 6...

Page 42: ...t of the count The REP which starts with 0 being an increment of one is a value that determines how many times a count is repeated The INC is the value at which the counts sequence increments by NUMBE...

Page 43: ...ines for fine tuning position At the command prompt the keystrokes are P O ASCII String To position the image up 5 nozzles or channels from the bottom enter PO5 CR SELECT 0 99 All models Selected head...

Page 44: ...rompt the keystrokes are W I ASCII String To set the WIDTH to 5 enter WI5 CR Utility Commands Utility commands are used for special functions diagnostics and some other printing features BACKUP Y N Al...

Page 45: ...e two passwords that determine the level 1 and level 2 access At the command prompt the keystrokes are C P When change password is enabled the keyboard will allow two passwords to be entered The top l...

Page 46: ...mands to be accessed Baud Rate Delay Label Request Reverse Status Bold Encoder Label Save Select Test Print Call Save Gap Network Sign In Trigger Edge Clear Map ID Numbers Slant Verify Counters Invert...

Page 47: ...tocell triggers during setup or warmup Product counters can only be reset by accessing the PC command A UPPER 99999999 B LOWER 00000000 C REP 000 D INC 001 ASCII String The sequence for rear port prog...

Page 48: ...changing only part of the time ASCII String To cause the date to advance at 11 05 20 PM enter RO230520 CR SAVE GROUP 0 31 All models Certain settings may be saved into 1 of 32 parameter group storage...

Page 49: ...egin 16 00 00 End 23 59 59 Code C With the above settings the A will be printed between midnight and 7 59 AM when using the embedded code SH SS for Series 8 systems ASCII String The sequence for exter...

Page 50: ...been enabled Cycling power on the FoxJet controller will not sign out the user At the command prompt the keystrokes are S O TEST PATTERN All models Selected head This command generates a test pattern...

Page 51: ...nter ASCII String To verify if a logo has been downloaded enter VE CR ZAP All models This command will reset all parameters and messages to factory default settings At the command prompt the keystroke...

Page 52: ...nable ACN CR to disable via Host PC LABEL REQUEST Label Request is programmed through the Front Port and when SystemMaster receives a Label Request a search and download process is initiated in System...

Page 53: ...next page Then you encode the logo information into hexadecimal code so that the FoxJet printer can decode it properly Now you re ready to write an ASCII command string The command string has many co...

Page 54: ...e status Wax level Printhead temperature status Printhead heater status 0 AVAIL 1 NOT AVAIL 0 HV OK 1 HV NOT OK 0 WAX LOW 1 WAX OK 0 AT TEMP 1 BELOW TEMP 0 NOT HEATING 1 HEATING For example a Printhea...

Page 55: ...Command Definitions 5 21...

Page 56: ...5 22 Command Definitions This page intentionally left blank...

Page 57: ...t abnormal A Low battery condition though can cause the CPU not to boot After system is powered up the battery will recharge Configuring the system to operate consists of setting a few switches on the...

Page 58: ...igured for 9600 baud SW1 is normally set for 9600 baud on both the Front and Rear Ports See Table 6 1 for configuration SW2 is a bank of six individual switches that are used to configure peripherals...

Page 59: ...4 38 4K 38 4K 5 38 4K 38 4K 6 38 4K 38 4K 7 38 4K 38 4K 8 9600 38 4K 9 9600 38 4K A 9600 9600 B 9600 19 2K C 19 2K 9600 D 19 2K 19 2K E 19 2K 19 2K F 19 2K 19 2K Table 6 1 Switch SW1 CPU SWITCH NUMBER...

Page 60: ...ver PCB doesn t require any particular settings however a visual inspection should be performed to ensure that all components are properly seated and that no damaged has occurred during shipping 6 4 I...

Page 61: ...le can be set to operate on 220 VAC or 110 VAC The fuse module s orientation will determine voltage configuration When inserting fuse module ensure that voltage being used can be read when latch is cl...

Page 62: ...ual pieces Special bracketry has been designed for more complicated application situations For more detailed information concerning the different bracketry kits see Parts Production Line The following...

Page 63: ...n setting the throw distance The Printhead Wax System must be mounted so that nothing strikes it in order to avoid depriming and possible damage 1 Place the Printhead Wax System on a stable platform n...

Page 64: ...n the housing Then secure sheath retaining nut to sheath 7 Secure Printhead PCB to housing and re install the Housing Cover 8 Reassemble integration hardware The hardware can be mounted on either side...

Page 65: ...Ensure that system has been turned off for at least one 1 hour prior to changing the orientation of the Printhead 2 Remove integration hardware 3 Remove the cap on the unconnected fitting 4 Loosen ho...

Page 66: ...g W WIDTH setting of FoxJet controller LS Line Speed in inches second IPS Freq Firing pulses generated by belt movement in cycles per second Hz to Printhead 8 kHz maximum 3 Mount the appropriate wheel...

Page 67: ...C Supply 2 Route encoder cable to Controller and connect to Encoder 1 jack on Connector Panel PIN SIGNAL NAME TYPE 7 Shaft Encoder Signal Input 5 DC Ground Ground 6 12 VDC Supply 3 Connect Alarm Beaco...

Page 68: ...System must be mounted The Printhead nozzle array will heat up to 135 C 275 F 1 After the power switch is engaged the system will boot up and the heater circuits will begin to heat the Printhead wax t...

Page 69: ...HEAD HTR Indicates that Printhead heating element is active Lit while Printhead is heating Cycles on off to maintain temp TANK AT Indicates that wax tank is connected and heating circuit is active Li...

Page 70: ...6 14 Installation Setup Figure 6 6...

Page 71: ...icates that system has passed power up tests Will be lit when system is running older systems will not use this indicator PC1 PC2 Photocell Trigger indicator Flashes when photocell triggers with no ph...

Page 72: ...move product sample and adjust photocell gain adjustment 2 two turns counter clockwise LED should go out Light colored products may require angling photocell beam 15 degrees form perpendicular to prod...

Page 73: ...y to the distance from product edge to print location then multiply the sum by the print DPI Dots Per Inch d d DPI DelayValue 1 2 where d1 distance between photocell and nozzle array in inches d2 dist...

Page 74: ...d assembly reaches temperatures as high as 135 C 275 F during operation Typically a one 1 hour cool down period is necessary after shut down Safety glasses and protective gloves are highly recommended...

Page 75: ...hole in the bulb and squeeze 2 or 3 times Wax should flow out of the nozzles Wipe faceplate gently while avoiding wiping the Array Plate 3 Repeat until wax flow is smooth and all channels are passing...

Page 76: ...h 4 of SW2 of the CPU PCB to the DOWN position 3 Select TE command on hand held terminal Do not press ENTER after inputting TE 4 Pass a sample card past the Printhead after triggering the photocell Re...

Page 77: ...unication port or card on PC the interface card should must be configured for the correct communications port and interrupt request line Alternatively a converter that converts RS232 to RS485 can be i...

Page 78: ...ontroller must have its CPU and Interface PCB switches and jumpers set appropriately The following pages show the CPU board setting for a typical installation Besides the switches and jumpers each con...

Page 79: ...U PCB to the DOWN position for RS 485 communications Ensure that jumpers are installed at JP3 JP4 if controller is last in network sequence to terminate the communication lines If controller is not th...

Page 80: ...The following table will assist in setting up an effective maintenance program Only use WaxJet Maintenance Spray S31091 on the Array Plate and only when Printhead is cooled A heat gun can be used to...

Page 81: ...any abrasive material or a scraper on the Printhead Assembly or the Array Plate Damage to the Printhead is likely and any warranties will be voided Cleaning Photocell Lens Photocell lenses can get di...

Page 82: ...e in the reservoir will become visible when the wax level falls below 200 ml Only add wax cubes when reminded by an WAX LOW indicator When adding wax cubes after an WAX LOW indicator light add no more...

Page 83: ...ervoir to help prevent dust from clogging the nozzle array plate 2 Open lid to the Wax Supply and open Wax package 3 Gently place the Wax Cube in the wax supply 4 Close lid 7 4 Service Do Not splash o...

Page 84: ...system is turned on When priming the system observe the following precautions The Printhead and Wax System must be at operating temperature before performing the Priming Procedure Touching the Printhe...

Page 85: ...es Wax should flow out of the nozzles Wipe faceplate gently while avoiding wiping the Array Plate 3 Repeat until wax flow is smooth and all channels are passing air free wax Priming too frequently or...

Page 86: ...Will only flash during communication process indicates Rear Port communication LED3 On some systems lights to indicate that encoder is selected in firmware doesn t affect operation Off on most system...

Page 87: ...7 8 Service Figure 7 1...

Page 88: ...Cycles on off to maintain temp TANK AT Indicates that wax tank is connected and heating circuit is active Lit after wax in tank reaches temp Should remain steady TANK HTR Indicates when wax hose reach...

Page 89: ...7 10 Service Figure 7 2...

Page 90: ...problems occur If wax flow is restricted due to lack of heating you can burn your hand when attempting to prime No Print Heater circuit failure Printhead Data Cable failure Encoder command and CPU SW2...

Page 91: ...e Power supply failure Driver board failure Bad thermistor Display Malfunction Hand held terminal failure or needs reconnecting Bad CPU board Power supply failure or blown fuse Bad Firmware Module Boo...

Page 92: ...ltage between them at both ends as shown in the drawing below If voltage is incorrect at one end one of the pico fuses is bad The heater indicators amber LED s will not light if one of the pico fuses...

Page 93: ...tting will load all default values and clear all memory data busses All data currently being saved in RAM will be lost however 1 Turn system off 2 Disconnect battery from CPU board for 5 10 seconds an...

Page 94: ...nk at Temp Tank cold 1 0 VDC 4 6 VDC Pins 6 12 Tank Heating Voltage Voltage while heating 36 VAC Pins 1 7 Wax Low Detect WAX OUT on WAX OUT off 4 6 VDC 1 0 VDC Pins 2 8 Hose Thermistor Hose at Temp Ho...

Page 95: ...7 16 Service Figure 7 3...

Page 96: ...5 36 Printhead Thermistor 3kS hot 100kS cold Power Supply Check Power supply voltages can be checked on the Power Supply board or on the cable that goes to the Driver Board Figure 7 2 Always turn syst...

Page 97: ...7 18 Service This page intentionally left blank...

Page 98: ...blies This chapter will detail the steps necessary to replace approved FRU s in operational and repair shop environments Figures 8 1 through 8 3 will assist in removing and replacing the major compone...

Page 99: ...5 Connect Driver data cable to J3 6 Connect battery to RAM circuits Use JP5 on boards with NI Cad battery or connect battery cable on boards with lithium battery CPU PCB s manufactured or repaired af...

Page 100: ...t boards Removal 1 Turn system power off 2 Remove Firmware Assembly from connector and remove from form standoff posts 3 Perform a Memory Reset refer to Service Procedures Installation 1 Inspect Firmw...

Page 101: ...standoff posts Installation 1 Place board on standoff posts and secure with screws 2 With system power off connect Printhead Data Cable to J1 3 Discharge high voltage capacitance from power cable pin...

Page 102: ...pect Power Supply Unit for damage that may have occurred during shipment 2 Place PSU in controller and secure with screws 3 Connect AC supply 4 With system power switch in the off position connect pow...

Page 103: ...rcuit boards Removal 1 Turn system power off 2 Disconnect all cables from the Connector Panel of the controller 3 Disconnect the cables at J1 J2 of Interface PCB 4 Remove the nuts on either side of ea...

Page 104: ...om CPU to J1 4 Connect power cable from PSU to J2 5 Re connect peripheral cables to proper plugs on Connector Panel 6 Apply system power ensure that the 5 green LED s on Interface PCB light 7 Test all...

Page 105: ...power off 2 Remove CPU PCB 3 Unsolder three pins to BT1 on CPU PCB FoxJet cannot be held responsible for damage to boards occurring from poor soldering techniques or faulty soldering equipment Any sol...

Page 106: ...t controller and when handling FoxJet printed circuit boards New battery must be installed before old battery is disconnected or all saved data in RAM will be lost 1 Measure new battery voltage Should...

Page 107: ...m J1 on the Driver board 3 Gently remove strain relief from connector if installed 4 Remove nut from cable shield and gently thread the connector the retaining nut 5 Feed the cable out the opening in...

Page 108: ...ller end of the Printhead data cable 5 Gently feed the connector through the retaining nut and feed the connector through the opening in the Connector Panel 6 Gently slide the retaining nut back over...

Page 109: ...ch step carefully and follow the prescribed sequence to avoid pitfalls The drawings included with the instructions and shown in this section are for illustrative purposes and are not necessarily exact...

Page 110: ...Assembly 4 Remove photocell mounting bracket and 6 screws from Printhead housing cover and remove housing cover 5 Disconnect the Printhead ribbon cable from the Printhead PCB 6 Remove the 4 screws sec...

Page 111: ...nthead to the faceplate and pull the Printhead off and discard 9 Remove any residual wax from the faceplate with a hot air gun DO NOT use a scraper of any kind 10 Carefully remove the rubber seal in t...

Page 112: ...6 Remove the yellow seal from the wax inlet opening on the back of the Printhead and secure the faceplate to the Printhead Housing Assembly Figure 8 6 7 Turn system on and Check system LED s for prop...

Page 113: ...oval 1 Turn system OFF and allow to cool down At least 1 hour 2 Support Printhead and remove Printhead mounting hardware 3 Disconnect 14 pin heater cable and open filler door of Wax System 4 Remove 8...

Page 114: ...l tank assembly away from wax line and turn tank assembly on to its side 16 Remove 4 baseplate mounting screws and remove baseplate 17 Remove heater pad 5 or 11 Figure 2 Note On systems manufactured b...

Page 115: ...8 18 Removal Replacement Procedures Figure 8 7...

Page 116: ...assembly 11 to the other connector of the cable assembly 6 Install cable assembly pin connectors into positions 6 and 12 on back of 14 pin connector of housing base 7 7 Reconnect and secure wax low de...

Page 117: ...n the Operators Manual and check for leaking at wax tank fitting connection If leak occurs at fitting tighten fitting nut turn at a time until leak stops 17 Resume normal operating procedures 8 20 Rem...

Page 118: ...Support Representative Removal 1 Turn system OFF and allow to cool down At least 1 hour 2 Support Printhead and remove Printhead mounting hardware 3 Disconnect 14 pin heater cable and open filler doo...

Page 119: ...amp around thermal fuse 8 and reconnect to side of tank assembly 4 4 Reinstall top insulation blanket 3 around tank assembly 4 5 Install and secure insulator plate 2 with screws 6 Re install wax syste...

Page 120: ...x Tube Replacement Kit X01184 001 40148 001 FITTING COMPRESSION 1 8 TO 1 4 X40147 001 TUBING ALUMINUM OD X40148 001 FITTING COMPRESSION 1 8 TO 1 4 Removal 1 Turn off power and allow wax system to cool...

Page 121: ...tallation 1 Slide new aluminum tubing through end of the hose heater from which the heater wires extend 2 Connect to the wax reservoir fitting and tighten finger tight Then tighten with a wrench 1 mor...

Page 122: ...unting bracket 8 Allow system to heat to operating temperature and check for leaks at fittings 9 If leaking occurs tighten fittings turn at a time until leaking stops 10 Re install Printhead housing a...

Page 123: ...ransfer Printhead Wax System from production line to a clean workbench environment 3 Support Printhead and remove Printhead mounting hardware 4 Remove photocell mounting bracket and rotational side mo...

Page 124: ...re 5 Connect heater hose wires and re install insulating foam and top plate Re install housing cover 6 Secure housing cover with screws and install rotational mounting bracket 7 Tighten heater hose li...

Page 125: ...8 28 Removal Replacement Procedures This page intentionally left blank...

Page 126: ...Printhead Replacement Kit Printhead Integrated Replacement Kit X01160 002 Part Description X41022 002 Print Head S6 Integrated Left X40157 001 Filter Screen SS 25 Micron Large X40097 001 Seal Heat Is...

Page 127: ...oxJet Part Where used Circuit Reference Volt Rating Current Rating Thermal Rating X12134 001 Wax Driver Bd F1 F2 125 7 N A X12121 001 I O X15021 001 F1 F2 F3 F4 F5 30 50 Trip 2 2 Trip 2 2 N A X12146 0...

Page 128: ...roller Conveyor Mounting Kit part S02200 001 is used to mount the standard controller to the sided of a conveyor or platform A Post 2 x 3 X20018 001 B C Controller Bracket Assy X22151 001 D Conveyor S...

Page 129: ...d Kit part 3 S02014 001 is used for mounting independent of the conveyor to minimize the effects of vibration from the conveyor A Post 2 x 6 X20042 001 B D Controller Bracket Assy X22151 001 C E F T S...

Page 130: ...6 001 can be mounted to the conveyor or used with a Floor Stand with the addition of a 90 cross block 1 by 2 A Flange Base X21094 001 B 1 x 18 Rod X20081 001 C 90 Cross block 1 1 X21093 001 D 1 x 12 R...

Page 131: ...print locations A set screw in the cross block secures the position after components have been placed in the desired position The drawing below shows the Linear Positioning Rod with a Series 7 Printh...