100% found this document useful (1 vote)

39K views948 pages

Domino Ax-Series Engineer's Guide

This document is an engineer's reference guide for installing, repairing, and maintaining Domino Ax-Series printers. It contains 26 parts that cover health and safety information, system descriptions and configurations, installation, operation, consumable replacement, connectivity and performance packs, accessories, statuses and fault finding, print head and electronics repairs, and software information. Engineers are warned to read and follow the health and safety information carefully, especially regarding inks and fluids, electrostatic discharge, and operation.

Uploaded by

DanhVô

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

100% found this document useful (1 vote)

39K views948 pages

Domino Ax-Series Engineer's Guide

Uploaded by

DanhVô

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

Domino Ax-Series

Engineer’s Reference Guide

Ax150i
Ax350i
Ax550i
THIS PAGE INTENTIONALLY LEFT BLANK

(2) EPT026795 Issue 17 June 2020

DOMINO Ax-SERIES
ENGINEER’S REFERENCE GUIDE
This engineer’s reference guide, Domino Part No. EPT026795, is for use in the installation, repair
and maintenance of Domino Ax-Series printers.
This engineer’s reference guide is the official authority for the operation, installation and
maintenance of the Domino Ax-Series range of printers. It is the source document for all
translated versions. It is the “Original Instructions” for the purposes of the Machinery Directive.
Based on software version 01.40.0407.
Engineer’s are warned that it is essential to read, understand and act according to the information
given in Part 1: Health and Safety. This part of the engineer’s reference guide also specifies a set
of symbols which are used elsewhere in the engineer’s reference guide to convey special
warnings or requirements. It is, therefore, essential that engineers are also familiar with these
symbols and act accordingly.
All rights reserved. No part of this publication may be reproduced, stored on a retrieval system, or
transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or
otherwise, without the prior permission of Domino Printing Sciences plc.

Domino Printing Sciences plc. has a policy of continuous product improvement, the company
therefore reserves the right to modify the specification contained in this engineer’s reference
guide without notice.
© Domino Printing Sciences plc. 2020.
For sales, service and inks please contact:
[Link]
[Link]

Domino UK Ltd. Domino North America

Bar Hill 1290 Lakeside Drive
Cambridge CB23 8TU Gurnee IL.60031
England U.S.A.
Tel: 01954 782551 Tel: 847 244 2501
Fax: 01954 782874 Fax: 847 244 1421

EPT026795 Issue 17 June 2020 (3)

CONTENTS
PART 1 HEALTH AND SAFETY

PART 2 SYSTEM DESCRIPTION

PART 3 SYSTEM CONFIGURATION

PART 4 INSTALLATION

PART 5 OPERATION

PART 6 CONSUMABLE REPLACEMENT

PART 7 CONNECTIVITY PACKS

PART 8 PERFORMANCE PACKS

PART 9 HARSH ENVIRONMENT PACKS

PART 10 ACCESSORIES

PART 11 STATUSES, ALERTS AND FAULT FINDING

PART 12 i-PULSE PRINT HEAD REPAIR

PART 13 i-PULSE DUO PRINT HEAD REPAIR

PART 14 i-PULSE RS PRINT HEAD REPAIR

PART 15 ELECTRONICS SYSTEM REPAIR

PART 16 INK SYSTEM REPAIR

PART 17 TOUCHSCREEN REPAIR

PART 18 SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

PART 19 ADVANCED SOFTWARE SETTINGS

PART 20 ADJUSTMENT SETTINGS

PART 21 DIAGRAMS

(4) EPT026795 Issue 17 June 2020

PART 22 CONTINUOUS PRINTING PACK

PART 23 CABLE AND WIRE SECTOR

PART 24 KOMAX M1630 JET

PART 25 HD INK SYSTEM FIELD CONVERSION KIT

PART 26 ITM TYPES

EPT026795 Issue 17 June 2020 (5)

AMENDMENT RECORD
Issue 17

Amendment Date
All parts at Issue 1 November 2016
All parts at Issue 2 December 2016
All parts at Issue 3 April 2017
All Parts at Issue 4 August 2017
All Parts at Issue 5 October 2017
All Parts at Issue 6 December 2017
All Parts at Issue 7 March 2018
All Parts at Issue 8 June 2018
All Parts at Issue 9 July 2018
All Parts at Issue 10 March 2019
All Parts at Issue 11 March 2019
All Parts at Issue 12 September 2019
All Parts at Issue 13 December 2019
All Parts at Issue 14 February 2020
All Parts at Issue 15 April 2020
All Parts at Issue 16 May 2020
All Parts at Issue 17 June 2020

(6) EPT026795 Issue 17 June 2020

PART 1 : HEALTH AND SAFETY

CONTENTS
Page
WARNINGS, CAUTIONS AND NOTES ..................................................................................... 1-3
Symbols ............................................................................................................................... 1-3
INKS AND FLUIDS INFORMATION .......................................................................................... 1-4
Basic Requirements ............................................................................................................. 1-4
Storage ................................................................................................................................. 1-4
Fire Risk ................................................................................................................................ 1-5
Spillages and Disposal ......................................................................................................... 1-5
ELECTRO-STATIC DISCHARGE .............................................................................................. 1-6
OPERATION .............................................................................................................................. 1-6

EPT026795 Issue 17 June 2020 1-1

HEALTH AND SAFETY

THIS PAGE INTENTIONALLY LEFT BLANK

1-2 EPT026795 Issue 17 June 2020

HEALTH AND SAFETY

WARNINGS, CAUTIONS AND NOTES

The warnings, cautions and notes used throughout this manual are highlighted by the use of
international hazard symbols. The following definitions for all three of these notices are described
below in the format they are presented in this manual.

WARNING: A hazard which may cause death or injury.

CAUTION: A hazard which may cause damage to equipment or environment

Note: Important additional information.

Symbols
The following symbols are used in this manual to highlight specific warnings and cautions used in
the procedure below the symbols.
Warning or Caution. Read and comply with the text underneath this symbol to avoid loss
of life, physical injury or damage to equipment.

Take care to avoid causing a fire by igniting flammable material.

Take care to avoid coming into contact with electricity.

Beware of Electrostatic Discharge (ESD). Electrostatic precautions must be used:

• Switch off machine first.
• Wear a wristband connected to the ESD connector provided.
• Avoid wearing clothing which can build up electrostatic voltages.
• Use ESD protective bags to transport PCBs.
• Only place PCBs on a mat made from a material which will dissipate electrostatic
voltages and which is connected to ground.

Eye protection must be worn.

Protective clothing must be worn. Use adequate protective gloves. Consult the relevant
Safety Data Sheet (SDS).

Disconnect power before carrying out maintenance or repair.

Connect an earth terminal from the product to an appropriate ground source.

Only trained personnel should carry out this procedure.

EPT026795 Issue 17 June 2020 1-3

HEALTH AND SAFETY

INKS AND FLUIDS INFORMATION

Domino supplies Safety Data Sheets (SDS) giving specific safety information for each of its ink,
make-up and wash fluids. Safety Data Sheets can be found on the MSDS section of the Domino
website. There are also warnings on each container. The following are general basic requirements:

WARNING: Flammable vapour. Risk of fire or explosion.

Install and operate the printer in a well ventilated environment. Do not install or
operate the printer in closed or sealed rooms or cabinets.

Basic Requirements
When used correctly, printing inks do not cause problems. However, everybody using them
should be familiar with the appropriate safety standards and be aware of the precautions that
should be taken. The following are basic requirements:
• Proper standards of industrial practice relating to cleanliness and tidiness must be
maintained.
• Inks and their containers must be stored and handled with care.
• Do not smoke or allow naked flames (or other sources of ignition) in the vicinity of any inks or
solvents as this is highly dangerous.
• All who come into contact with inks must be properly instructed in their use.
Directions for safe working practices vary according to the environment. The following are broad
principles so that necessary precautions may be taken:
• Contact with the mouth must be avoided. Therefore eating, drinking or smoking, or any
personal habits or actions which may transfer ink to the mouth, must be avoided.
• Contact with the eyes must be avoided. Suitable eye protection must always be worn
whenever there is any risk of splashing or misting. If ink does get into the eyes, first aid
treatment is to flood the affected eye for 15 minutes with saline solution, (or clean water if
saline solution is not available), taking care not to allow the water to run into an unaffected
eye. Medical aid must be obtained immediately.
• Most inks contain solvents which may injure the skin. Good working practice must always be
employed and risk assessments carried out. Safety Data Sheets are available that give
advice on personal protective equipment. Most gloves only offer limited and short term
exposure protection and must be changed after any splashing and on a frequent basis.
• Many inks contain materials which vaporise easily and can be inhaled. Good ventilation is
necessary.
• Any used cleaning materials, e.g. rags, paper wipes, are a potential fire hazard. They must be
collected for safe disposal after use. After exposure to ink, all possible traces must be
washed off as soon as possible at the nearest washing facility.
• It is possible to control the printer remotely. If operated in this manner it is vital that the
remote UI is disconnected before carrying out any cleaning or maintenance on the printer.

Storage
Printing inks must be stored in well ventilated buildings, in areas set aside for the purpose and
chosen for safety in case of fire. All fluids must be stored in accordance with local regulations.

1-4 EPT026795 Issue 17 June 2020

HEALTH AND SAFETY

Fire Risk
Observe all warnings given on the machine and the following safety instructions.
For an electrical fire, do not use water.
If there has been an accumulation of dried ink, do not use metal scrapers to remove it, as they can
produce sparks.
Fire risk is a most important consideration where printing inks are stored and used. The degree of
fire hazard will vary considerably from one type of ink or wash to another.
Water-based inks will not burn, although inks based on water-alcohol mixtures may burn if there
is sufficient alcohol present.
Prolonged exposure of water-based systems to high temperatures may evaporate the water to
give a flammable residue.
Solvent-based inks offer a greater degree of hazard depending on the particular solvent or solvent
combination. When there is a particular hazard the appropriate information is given on the SDS.
The printers place small electrostatic charges on the ink drops used for printing. In most
circumstances, such as when they arrive at the print surface, these electrostatic charges are
either conducted away or cannot accumulate. However, during maintenance, print drops may be
collected in a container, such as a beaker. It is essential that this container is made of conducting
material and is securely connected to ground/earth. The electrostatic charges will then be safely
conducted to ground/earth.
If there is a fire, there is a likelihood that dangerous fumes will arise from printing inks. For this
reason ink must be stored where it can be reached quickly by the fire fighting service, and where
it will not spread beyond the store.

Spillages and Disposal

WARNING: Flammable material. Risk of fire.

Do not allow ink to dry or allow any build-up of dried ink. Some dried inks are
highly flammable. Clean up all ink spillages immediately.

Spillages must be cleaned up as soon as possible with the appropriate solvent materials and with
regard to the safety of personnel. Care must be taken to prevent spillages or residue from
cleaning up entering drains or sewage systems.
Inks and associated fluids are materials which conduct electricity. Therefore, power to the printer
must be switched off while spillages inside the printer cabinet are being cleaned up.
Printing inks and associated fluids must not be treated as ordinary waste. They must be disposed
of using approved methods according to local regulations.

EPT026795 Issue 17 June 2020 1-5

HEALTH AND SAFETY

ELECTRO-STATIC DISCHARGE
To avoid static discharge from production line equipment, the equipment and everything on it
must be grounded correctly. While it is not Domino's responsibility to maintain the customer's
equipment, the customer must be aware of the importance of grounding. At the time of
installation of the printer the Domino (or Domino distributor) technician should ensure that the line
the printer is installed on is appropriately grounded. This means that all metallic items within 12
inches (300mm) of the print head location must be securely grounded. This should be checked
with respect to the print head chassis ground using an Ohm Meter, DVM or other suitable device.
It is essential that grounding is checked periodically and that if the printer is relocated to a
different production line, then the new production line is properly grounded. Additional static
dissipating devices, such as static brushes on the line, etc. are recommended.

OPERATION
For safe operation of the printer, follow all instructions given in this manual.

WARNING: Pressurised ink system. Risk of ink spray.

Read the procedure on page 6-7 before removing the ITM.

WARNING: High voltage electricity. Risk of death or injury from electric shock.

Disconnect the printer from mains power before accessing the printer electronics
enclosure.

1-6 EPT026795 Issue 17 June 2020

SYSTEM DESCRIPTION

PART 2 : SYSTEM DESCRIPTION

CONTENTS
Page
GENERAL .................................................................................................................................. 2-3
Description ........................................................................................................................... 2-3
Ax150i Printer ................................................................................................................... 2-4
Ax350i Printer ................................................................................................................... 2-5
Ax550i Printer ................................................................................................................... 2-6
Printer Configuration Labels ................................................................................................. 2-7
External Printer Configuration Label ................................................................................ 2-7
Internal Printer Configuration Label.................................................................................. 2-8
PRINTER SPECIFICATION ....................................................................................................... 2-9
Ax150i .................................................................................................................................. 2-9
Cabinet ............................................................................................................................ 2-9
Standard External Connections ....................................................................................... 2-9
Optional External Connections ........................................................................................ 2-9
Ink System ........................................................................................................................ 2-10
Environment ..................................................................................................................... 2-10
Intentional Transmitter (QMM) ......................................................................................... 2-10
i-Pulse Print Head............................................................................................................. 2-11
Ax350i .................................................................................................................................. 2-12
Cabinet ............................................................................................................................ 2-12
Standard External Connections ....................................................................................... 2-12
Optional External Connections ........................................................................................ 2-12
Ink System ........................................................................................................................ 2-13
Environment ..................................................................................................................... 2-13
Intentional Transmitter (QMM) ......................................................................................... 2-13
i-Pulse Print Head............................................................................................................. 2-14
i-Pulse Duo Print Head .................................................................................................... 2-14
i-Pulse RS Print Head ....................................................................................................... 2-15
Ax550i .................................................................................................................................. 2-16
Cabinet ............................................................................................................................ 2-16
Standard External Connections ....................................................................................... 2-16
Optional External Connections ........................................................................................ 2-16
Ink System ........................................................................................................................ 2-17
Environment ..................................................................................................................... 2-17
i-Pulse Print Head............................................................................................................. 2-18
i-Pulse Duo Print Head .................................................................................................... 2-18
i-Pulse RS Print Head ....................................................................................................... 2-19
User Interface ....................................................................................................................... 2-20
Remote TouchScreen 10" (Ax350i/Ax550i Only) ............................................................. 2-20
Remote TouchScreen 7" (Ax350i/Ax550i Only) ............................................................... 2-20
Printer Control ...................................................................................................................... 2-21
Cabinet Buttons ............................................................................................................... 2-21
Cabinet Status Lights ....................................................................................................... 2-22
QMM (Quality Management Module) Status Lights ......................................................... 2-24
QuickStep ......................................................................................................................... 2-25

EPT026795 Issue 17 June 2020 2-1

SYSTEM DESCRIPTION

Ax350i Printer

Ax350i Printer Cabinet with TouchScreen 7"

The Ax350i is a highly configurable printer featuring a stackable IP55 cabinet design with an IP66
electronics enclosure, a range of TouchScreen options, Domino Design ink system, i-Techx
advanced electronics and user interface and an i-Pulse or i-Pulse RS print head.
The Ax350i can be controlled using a Remote TouchScreen 7" or a Remote TouchScreen 10". The
TouchScreen can be mounted on top of the stainless steel cabinet. The TouchScreen can also be
mounted using a VESA 75 standard mounting, anywhere within range of the connecting cable.
Additional printer cabinets may be stacked and controlled via one TouchScreen.
The Ax350i printer can use a wide variety of inks. This gives the Ax350i flexibility to print on a wide
range of print surfaces. Where appropriate, a heavy duty ink system is fitted which is constructed
of materials resilient to inks with corrosive properties, this enables reliable operation and minimal
down time.
To maintain optimum performance the Ax350i only requires the colour coded consumables to be
replenished. Consumables such as the air and make-up filter, ink and make-up cartridges and
ITM are colour coded yellow for easy identification and user convenience.
The i-Techx system monitors ink and make-up consumption to calculate when consumables are
due for replacement. This is then indicated on both the TouchScreen user interface and on the
cabinet status lights.

WARNING: Pressurised ink system. Risk of ink spray.

Read the procedure on page 6-7 before removing the ITM.

Note: ITM replacement intervals will vary according to use and ink type. Contact Domino for
details.

EPT026795 Issue 17 June 2020 2-5

SYSTEM DESCRIPTION

Ax550i Printer

Ax550i Printer Cabinet with Remote TouchScreen 10"

The Ax550i is visually similar to the Ax350i. However, the cabinet of the Ax550i is constructed
from a higher grade of stainless steel (316 Grade) for use in more corrosive operating
environments.

WARNING: Pressurised ink system. Risk of ink spray.

Read the procedure on page 6-7 before removing the ITM.

Note: ITM replacement intervals will vary according to use and ink type. Contact Domino for
details.

2-6 EPT026795 Issue 17 June 2020

SYSTEM DESCRIPTION

Printer Configuration Labels

External Printer Configuration Label
The label illustrated below is an example of the configuration label which is located on the rear of
all Ax-Series printers.

Domino UK Limited
Bar Hill
R-NZ
Cambridge NTC
CB23 8TU Type Accepted
No. ESD - 1714229C
United Kingdom И005 16 CIDF17000009

T: +44 (0) 1954 782551 TA-2016/2715

F: +44 (0) 1954 782874 MSIP-REI-DK1-Ax350i

APPROVED
[Link]
Contains NCC ID: CCAJ16LP8750T6

AGREE PAR L’ANRT MAROC

Numéro d’agrément : MR 12955 ANRT 2016 Complies with
IMDA Standards
PRINTER CONFIGURATION Date d’agrément : 09 Dec 2016 DA107602

CMIIT ID: 2016DJ7134

Product - IP55 48024/SDPPI/2016 Contiene Módulo CNC ID: H-17059
5573
Electronics Compartment - IP66 TRC/LPD/2016/625
Connection and use of this communications equipment is permitted
100-240VAC:4A 50-60Hz by the Nigerian Communications Commission

Made in UNITED KINGDOM This device complies with part 15 of the FCC Rules. Operation is
subject to the following two conditions: (1) This device may not
MODEL TYPE: Ax350i cause harmful interference, and (2) this device must accept any
interference recieved including interference that may cause
SERIAL NUMBER: undesired operation.
Contains FCC ID: 2AHFK-EPT012462
Contains IC: 21200-EPT012462
AX0000001000

WARNING
This appliance must be
Buy genuine Domino parts at: connected to an earthed
[Link] mains supply

Printer Configuration Label

The external configuration label contains the following information:

• The product model name
• The product serial number
• The name, address and contact details of the manufacturer
• IP rating of the product
• IP rating of the electronics compartment
• Power supply requirements
• FCC notice
• Local conformance information
• Warning information.

EPT026795 Issue 17 June 2020 2-7

SYSTEM DESCRIPTION

Internal Printer Configuration Label

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Read the procedure on page 6-7 before removing the ITM.

The label illustrated below is an example of the internal configuration label which is located inside
the front door of all Ax-Series printers.

Internal Printer Configuration Label

The internal configuration label contains the following information:

• The product model name
• The product serial number
• The ink type which the printer is configured to use
• The make-up type which the printer is configured to use
• The wash type which should be used when cleaning the print head
• The address of the BuyDomino website
• Ink and make-up cartridge removal instructions
• Warning information.

SYSTEM DESCRIPTION

Environment
Temperature Range +5 ºC to +45 ºC (42 ºF to 112 ºF)
(working)*:
Temperature Range -20 ºC to +60 ºC (-4 ºF to +140 ºF) (machine dry - storage, wet
(Storage): dependent upon fluids)
Humidity: 0 - 90% RH (non-condensing)
Electrical Supply: 100-240V 50-60Hz (nominal), 4A, single phase Auto ranging
Power Consumption 40 Watt (idle)
80 Watt (printing)
Acoustic Noise Level: Not more than 70 dBA

Intentional Transmitter (QMM)

RF Frequency (QMM): 13.56 MHz
RF Power (QMM): 62 μW

EPT026795 Issue 17 June 2020 2-13

SYSTEM DESCRIPTION

i-Pulse Print Head

Standard Finish: Chassis: Stainless steel
Wire box: Acetal
Holster: Polymer (PTFE) coated aluminium
Dimensions: Width: 50.3mm (1.98")
Depth: 50.3mm (1.98")
Height including conduit retaining nut: 243mm (9.57")
Operating height with conduit at 90 degrees: 320mm (12.6")
Weight including 3m conduit: 1.8kg (4lbs)
Conduit Length and 3m (10ft) conduit with 40, 50, 60 or 75 micron nozzle
Nozzle Size: 4m (13ft) conduit with 40 or 50 micron nozzle
6m (20ft) conduit with 60 or 75 micron nozzle
Conduit minimum inside 65mm (2.55")
bend radius:
Recommended distance 75 micron nozzle: 14mm (0.55")
from print surface: 60 micron nozzle: 8mm (0.31")
50 micron nozzle: 6mm (0.23")
40 micron nozzle: 4mm (0.15")
Working height relative to 3m conduit: ±1m
cabinet base: 4m conduit: ±1m
6m conduit: ±3m

i-Pulse Duo Print Head

Standard Finish: Chassis: Stainless steel
Wire box: Moulded nylon
Holster: Plated aluminium
Dimensions: Width: 57mm (2.24")
Depth: 53mm (2.01")
Height: 255mm (10")
Weight including 3m conduit: 2.8kg (6.17lbs)
Conduit Length: 3m (10ft) or 6m (20ft)
Conduit minimum inside 65mm (2.55")
bend radius:
Nozzle size: 60 or 75 micron
Recommended distance 75 micron nozzle: 14mm (0.55")
from print surface: 60 micron nozzle: 8mm (0.31")
Working height relative to 3m conduit: ±1m
cabinet base: 6m conduit: ±3m

2-14 EPT026795 Issue 17 June 2020

SYSTEM DESCRIPTION

i-Pulse RS Print Head

Standard Finish: Stainless Steel
Dimensions: Width: 40mm (1.57")
Depth 40mm (1.57")
Height (60 micron nozzle): 243mm (9.56")
Height (75 micron nozzle): 252mm (9.92")
Weight including 3m conduit: 1.8kg (4lbs)
Conduit Length: 3m (10ft) or 6m (20ft)
Conduit minimum inside Fixed installation: 70mm (2.75")
bend radius: Continuous flex installation: 150mm (5.90")
Nozzle size: 60 or 75 micron
Nominal / recommended 75 micron nozzle: 14mm (0.55")
distance from print 60 micron nozzle: 8mm (0.31")
surface:
Working height relative to 3m conduit: ±1m
cabinet base: 6m conduit: ±3m

EPT026795 Issue 17 June 2020 2-15

SYSTEM DESCRIPTION

Ax550i
Cabinet
Standard Finish: 316 grade stainless steel
IP Rating: IP55 (electronics enclosure to IP66)
Dimensions: Width: 430mm (16.9")
Depth: 381mm (15.0")
Height: 411mm (16.2")
Height (with TouchScreen): 643mm (25.3")
Cabinet Controls: Buttons for Standby, Start/Stop, Single print and Alerts
Weight (dry): 22kg (48.5lb)

Standard External Connections

Interface Communication: 1 x non standard DVI connection providing 24V DC, 500 mA
Product Detect / Shaft 8-Way Socket x 2
Encoder Connector:
Power Connector: 3-Way Plug, cable supplied

Optional External Connections

2-16 EPT026795 Issue 17 June 2020

SYSTEM DESCRIPTION

Environment
Temperature Range +5 ºC to +45 ºC (42 ºF to 112 ºF)
(working)*:
Temperature Range -20 ºC to +60 ºC (-4 ºF to +140 ºF) (machine dry - storage, wet
(Storage): dependent upon fluids)
Humidity: 0 - 90% RH (non-condensing)
Electrical Supply: 100-240V 50-60Hz (nominal), 4A, single phase Auto ranging
Power consumption 40 Watt (idle)
80 Watt (printing)
Acoustic Noise Level: Not more than 70 dBA

EPT026795 Issue 17 June 2020 2-17

SYSTEM DESCRIPTION

i-Pulse Print Head

i-Pulse Duo Print Head

Standard Finish: Chassis: Stainless steel
Wire box: Moulded nylon
Holster: Plated aluminium
Dimensions: Width: 57mm (2.24")
Depth: 53mm (2.01")
Height: 255mm (10")
Weight including 3m conduit: 2.8kg (6.17lbs)
Conduit Length and 3m (10ft) or 6m (20ft)
Nozzle Size:
Conduit minimum inside 65mm (2.55")
bend radius:
Nozzle size: 60 or 75 micron
Recommended distance 75 micron nozzle: 14mm (0.55")
from print surface: 60 micron nozzle: 8mm (0.31")
Working height relative to 3m conduit: ±1m
cabinet base: 6m conduit: ±3m

2-18 EPT026795 Issue 17 June 2020

SYSTEM DESCRIPTION

i-Pulse RS Print Head

Standard Finish: Stainless Steel
Dimensions: Width: 40mm (1.57")
Depth: 40mm (1.57")
Height (60 micron nozzle): 243mm (9.56")
Height (75 micron nozzle): 252mm (9.92")
Weight including 3m conduit: 1.8kg (4lbs)
Conduit Length: 3m (10ft) or 6m (20ft)
Conduit minimum inside Fixed installation: 70mm
bend radius: Continuous flex installation: 150mm (5.90")
Nozzle size: 60 or 75 micron
Nominal / recommended 75 micron nozzle: 14mm (0.55")
distance from print 60 micron nozzle: 8mm (0.31")
surface:
Working height relative to 3m conduit: ±1m
cabinet base: 6m conduit: ±3m

EPT026795 Issue 17 June 2020 2-19

SYSTEM DESCRIPTION

User Interface
Remote TouchScreen 10" (Ax350i/Ax550i Only)
Standard Finish: Cast aluminium (rear), nylon plastic (front)
Mounting: Via angled bracket to cabinet top.
VESA 75 standard mounting.
Display: 10.4 inch SVGA full colour touch screen
Dimensions: Width: 307mm (12.1")
Height: 232mm (9.1")
Depth: 75mm (3")
Weight: 2.5Kg (5.5lb)
IP Rating: IP65
Temperature: 5 - 45°C
Humidity: 10 - 90% non-condensing
Power Supply: 24Vdc, 15W, 625mA over non standard DVI
Connectivity: Non standard DVI cable to rear of printer
Data Transfer: 2 x USB Type A

Remote TouchScreen 7" (Ax350i/Ax550i Only)

Standard Finish: Nylon plastic
Mounting: Via angled bracket to cabinet top.
VESA 75 standard mounting.
Display: 7 inch WVGA full colour touch screen
Dimensions: Width: 245mm (9.6")
Height: 160mm (6.3")
Depth: 50mm (2")
Weight: 0.75Kg (1.65lbs)
IP Rating: IP55
Temperature: 5 - 45°C
Humidity: 10 - 90% non-condensing
Power Supply: 24Vdc, 12W, 500mA over non standard DVI
Connectivity: Non standard DVI cable to rear of printer
Data Transfer: 2 x USB Type A

2-20 EPT026795 Issue 17 June 2020

SYSTEM DESCRIPTION

Printer Control
Cabinet Buttons
There are four hardware buttons on the printer cabinet as illustrated below. It is necessary to
press the buttons for at least 2-3 seconds as a precaution against accidental use. The cabinet
buttons also carry an indicator light.
All other functions are available using the QuickStep interface on the TouchScreen.

Cabinet Button Explanation

Standby Button The standby button is pressed to start up the printer and enter the
Idle state. In the Idle state the printer’s ink jet is off and the printer
will not print. However, the user interface can still be used.

The standby button can also be pressed for two to three seconds
to perform a controlled printer shut down.

If a fast shut down is required the standby button can be pressed

for 10 seconds to shut the printer down immediately. This should
only be carried out in an emergency, or if the printer experiences a
software lock-up. The flush sequence will not be carried out. If the
printer is left for a long period of time, ink will dry and block the ink
jet nozzle and gutter. Restart the printer as soon as possible to
prevent the nozzle and gutter becoming blocked.

See “Start-Up” on page 5-21.

Start/Stop Button The start/stop button is pressed to start up the printer and enter
the Ready state. In the Ready state the ink jet will be running and
the printer is ready to print. If a label is on-line, it will print on
receiving a product detect signal.

If the button is pressed when in a Ready state, the printer will

enter the Idle state. In the Idle state the printer’s ink jet is off and
the printer will not print. However, the user interface can still be
used.

See “Start-Up” on page 5-21.

Single Print Button The single print button is pressed to produce a single test print of
the current label. Typically used to identify what label is being
printed when a UI is not present.

Alert Button The alert button is pressed to display the current list of alerts on
the TouchScreen. The alert button also carries two status lights
described on page 2-22.

EPT026795 Issue 17 June 2020 2-21

SYSTEM DESCRIPTION

Cabinet Status Lights

There are a number of status lights on the printer cabinet as illustrated below.

Cabinet Status Light Explanation

Standby, Power The red light on the standby button will illuminate to indicate that
Connected the printer is connected to a power supply and the printer is in
standby mode.

Start Up The red light on the standby button will illuminate, and the green
light on the standby button will flash to indicate that the printer is
starting up.

Printer On / Shut Down The green light on the standby button will illuminate to indicate
that the printer is on.

The light will flash on and off to indicate that the printer is shutting
down.

Red Alert The red alert light will illuminate to indicate a red alert. A red alert
occurs when the printer has a fault which causes printing to stop.
If a TouchScreen is connected to the printer, a description of the
alert will be displayed on the TouchScreen’s status tab.

Amber Alert The amber alert light will illuminate to indicate an amber alert. An
amber alert occurs when the printer has a fault which requires
attention. If a TouchScreen is connected to the printer, a
description of the alert will be displayed on the TouchScreen’s
status tab.

Make-up Level Alert If the make-up level is ok, the light will be off.

The make-up light will illuminate to indicate when the make-up

level is low and the cartridge requires replacement.

2-22 EPT026795 Issue 17 June 2020

SYSTEM DESCRIPTION

Cabinet Status Light Explanation

Ink Level Alert If the ink level is ok, the light will be off.

The ink light will illuminate to indicate when the ink level is low and
the cartridge requires replacement.

EPT026795 Issue 17 June 2020 2-23

SYSTEM DESCRIPTION

QMM (Quality Management Module) Status Lights

The printer contains a QMM (Quality Management Module) to read and write data to RFID (Radio
Frequency IDentification) tags on the make-up cartridge, ink cartridge and ITM. This enables the
printer to alert the user when the ITM, ink or make-up cartridge need to be replaced to maintain
reliable and efficient printer operation. The printer will also display an alert if the wrong ink or
make-up or ITM type is inserted.
In addition, there are 3 status lights on the QMM inside the printer cabinet. The colour of each
light indicates whether the RFID tags on the consumables have been correctly read and identified.
For more detailed information about the QMM’s operation, and for QMM fault finding, refer to
“EPT026795 - QMM Detail Reference Guide” on the Domino Technical Information Portal (TIP).
The QMM status lights are shown below.

Make-up Ink Cartridge

Cartridge

ITM

Quality Management Module Status Lights

QMM Status Light

Explanation
Colour

Red The RFID tag has been read and a fault has been detected. An
alert will be displayed on the QuickStep status tab to explain the
fault.
Amber The RFID tag has not been read, either because an RFID tag is not
present or the RFID tag is faulty. An alert will also be displayed on
the QuickStep status tab to explain the fault.
Flashing Amber The QMM is in the process of reading the RFID tag.
Green The RFID tag has been correctly read and identified.

2-24 EPT026795 Issue 17 June 2020

SYSTEM DESCRIPTION

QuickStep
The QuickStep interface as displayed on the TouchScreen is shown below:

QuickStep Interface

Domino has developed QuickStep to be easy and intuitive to use. Training times, set up times and
coding errors are all reduced with QuickStep.
The operation of the printer using QuickStep is described in Part 5 : OPERATION.

EPT026795 Issue 17 June 2020 2-25

SYSTEM DESCRIPTION

THIS PAGE INTENTIONALLY LEFT BLANK

2-26 EPT026795 Issue 17 June 2020

PART 3 : SYSTEM CONFIGURATION

CONTENTS
Page
SYSTEM CONFIGURATION ..................................................................................................... 3-3
SYSTEM CONFIGURATION KEY ............................................................................................. 3-3
AX-SERIES DYE-BASED INKS - RECOMMENDED ................................................................. 3-6
AX-SERIES DYE-BASED INKS ................................................................................................. 3-7
AX-SERIES PIGMENTED INKS - RECOMMENDED ................................................................. 3-10
AX-SERIES PIGMENTED INKS ................................................................................................. 3-12

EPT026795 Issue 17 June 2020 3-1

SYSTEM CONFIGURATION

THIS PAGE INTENTIONALLY LEFT BLANK

3-2 EPT026795 Issue 17 June 2020

SYSTEM CONFIGURATION

B Configured (factory extended test)

Table 5: Conduit Configuration

3 metre 4 metre 6 metre

Symbol
(40μm/50μm only)
C   
D   
E   

Table 6: Nozzle Configuration

Symbol 40 micron 50 micron 60 micron 75 micron

G    
H    
J    
K    
L    
M   - -
N   - -
P    

3-4 EPT026795 Issue 17 June 2020

SYSTEM CONFIGURATION

Table 7: ITM Type

ITM Type Description

Type 2 Used for dye-based inks, Ink cartridge is filled to 0.825 litres
Type 3 Used for pigmented inks and carbon black inks, Ink cartridge is filled to 0.555
litres. Printer is fitted with heavy duty ink pump
Type 4 Functionally ITM04 has the same performance as an ITM02. ITM04 is a financial
product for approved distributors only, please contact your BDM for more
information.
Type 6 Run time ITM (3500 Jet Hours or 2.5years ITM life).

Table 8: Ink Grading

(for guidance only: performance may vary depending on site conditions)

Symbol Description

1 High performance inks which should run without operator intervention for at
least 2 weeks, 12 hour shift at a reasonable print rate.
2 Specialist inks which should run without operator intervention for at least 1
week, 12 hour shift at a reasonable print rate.
3 Niche inks which may require more frequent intervention, e.g. recommended
daily wash down.

Table 9: Notes

Note
Description
Number

Note 16 Ax150i / 2BK101 and Ax150i / 2CL158 only supported where a) temp < 35C and
RH < 50%, otherwise sell Ax350i with ADAD fitted.
Note 17 Ax150i / 2BK159 and Ax150i / 2YL856 supported where RH < 50%, otherwise
sell Ax350i with ADAD fitted.

EPT026795 Issue 17 June 2020 3-5

AX-SERIES DYE-BASED INKS - RECOMMENDED
3-6

Table 10: Ax-Series Inks (Dye-Based)

Ax350i Ax350i
Ax350i Ax350i
Ax150i Ax550i Ax550i
Ax550i Ax550i
Ink i-Pulse i-Pulse/RS i-Pulse
Ink Type Description i-Pulse i-Pulse ITM Type
Grading Print Head Print Duo Print
Print Head Print Head
60μ Only Heads Head
40μ 50μ
60μ/75μ 60μ/75μ

1BK111 Ethanol black plastic ink 1 ACK ADH - BEN BDH Type 2, 4, 6
2BK106 Fast dry black ink 1 ACK ADH BEP/10 BEN BDH Type 2, 4, 6

SYSTEM CONFIGURATION
2BK124 Fast dry black plastic ink 1 ACK ADH BEP/10 BEN BDH Type 2, 4, 6
2BK126 Black food packaging ink 1 ACK ADH - - BDH Type 2 & 6
(heat seal resistant)
EPT026795 Issue 17 June 2020
AX-SERIES DYE-BASED INKS
EPT026795 Issue 17 June 2020

Table 11: Ax-Series Inks (Dye-Based)

1RD112 Ethanol red UV- 1 - BDH/5/6 BEP/5/6/10 BEN5/6 BDH5/6 Type 2 & 6
fluorescent ink

SYSTEM CONFIGURATION
1BK101 Ketone-free black ink, 1 BCK/5/7 BDH/5/6 - - BDH/5/6 Type 2 & 6
ethanol-based
2BK101 High adhesion steam 1 BCK/2/10 BDH/2 BEP/2/10/1 BEN/2 BDH/2 Type 2 & 6
sterilisiable fast dry black (See note 6
ink 16)
2BK103 Heavy metal and halogen 1 BCK BDH BEP/10 BEN BDH Type 2
free, alcohol resistant, fast
dry black ink
2BK119 Fast dry black ink 1 BCK BDH BEP/10 BEN BDH Type 2 & 6
2BK130 Food oil-resistant black 1 BCK BDH BEP/10 BEN BDH Type 2 & 6
ink
2BK152 Black cable marking ink 1 BCK BDH - - - Type 2 & 6
with solvent resistance
2BK153 Black fast dry ink for 1 BCK BDH - - - Type 2 & 6
printing on industrial oily
surfaces
3-7
Table 11: Ax-Series Inks (Dye-Based)
3-8

2BK159 Black fast dry water 1 BCK BDH BEP/10 BEN BDH Type 2 & 6
resistant ink
2BL107 Fast dry blue ink 1 BCK BDH BEP/10 BEN BDH Type 2 & 6
2RD132 Fast dry red ink 1 BCK BDH BEP/10 BEN - Type 2 & 6

SYSTEM CONFIGURATION
8BK165 Very fast dry black ink 1 BCK/10 BDH/10 - BEN/10 BDH/10 Type 2 & 6
1BK104 Ketone-free black ink, 2 - BDH/1/7/9 - - BDH/1/7/9 Type 2
ethanol based
1BK110 Nitrate-free, water 2 BCK BDH - - - Type 2
washable ink for marking
metals
1CL102 Ethanol clear UV- 3 - BDH/5/6/15 - - - Type 2
florescent ink
1GY103 Water-washable grey ink 2 BCK/10 BDH/10 - - - Type 2 & 6
EPT026795 Issue 17 June 2020

2BK118 Wet glass, alkali washable 3 - BCH/1/7/9/ - - BCH/1/7/9/ Type 2

fast dry black ink 15 15
2BK128 Fast dry aerospace black 2 BCK/7 BDH/7 BEP/7/10 BEN/7 - Type 2
ink
2BK154 Black fast dry ink with IPA 2 - BDH/2 - - - Type 2 & 6
resistance
2BK156 Black fast dry alkali 2 - ADH/1 BEP/1/10 BEN/1 BDH/1 Type 2 & 6
washable ink
Table 11: Ax-Series Inks (Dye-Based)
EPT026795 Issue 17 June 2020

2CL158 Clear florescent ink with 3 ACK/2/15 ADH/2/15 BEP/2/10/1 BEN/2/15 - Type 2
retort resistance See Note 5
16
3BK102 Thermochromic black-to- 2 - BDH/1/10 - - - Type 2
red ink, vegetable oil

SYSTEM CONFIGURATION
resistant
4BL104 Blue egg ink (EU/FDA 2 BCK/5/7/9 BDH/5/6/9 BEP/5/6/9/ BEN5/6/9 - Type 2 & 6
conformance) 10
4RD103 Red egg ink (FDA 2 BCK/12 BDH/12 BEP/8/10 BEN/8 - Type 2 & 6
conformance)
4RD106 Red egg ink (EU/FDA 2 BCK/5/7/9 BDH/5/6/9 BEP/5/6/9/ BEN5/6/9 - Type 2 & 6
conformance) 10
7BK104 Thermochromic black-to- 3 BCK BDH BEP/10 BEN BDH Type 2
blue fast dry ink
3-9
AX-SERIES PIGMENTED INKS - RECOMMENDED
3-10

Note: Best inks in class.

Table 12: Ax-Series Inks (Dye-Based)

1BK870 Pigmented keton free 1 - BDH/5/6 - BEN/5/6 - Type3

SYSTEM CONFIGURATION
black ink
2BK861 Pigmented fast dry black 1 - BDH BEP/10 BEN - Type 3
electronics ink - High
contrast
2BK868 Pigmented fast drying 1 - BDH BEP/10 BEN - Type 3
food packaging black ink
2WT840 Pigmented high opacity 3 - BDH/15 - BEN/15 - Type 3 (W)
fast dry white ink (7 only 75μ)
2WT854 White PE Cable Ink 2 - BDH - BEN - Type 3 (W)
EPT026795 Issue 17 June 2020

2WT860 Pigmented high opacity 2 - BDH - BEN - Type 3 (W)

fast dry white PVC cable
ink
2YL812 Pigmented fast dry yellow 2 - BDH/1 - - - Type 2
ink
2YL856 Yellow PVC and industrial 2 BCK/2 DH/2 - - - Type 2
ink (See note
17)
Table 12: Ax-Series Inks (Dye-Based)
EPT026795 Issue 17 June 2020

8BK871 Pigmented MEK free very 1 - BDH/10 BEP/10 BEN/10 - Type 3

fast dry black ink

SYSTEM CONFIGURATION
3-11
AX-SERIES PIGMENTED INKS
3-12

Table 13: Ax-Series Inks (Dye-Based)

2BL859 High contrast pigmented 2 - BDH - - - Type 3 (W)

fast dry light blue cable
ink

SYSTEM CONFIGURATION
2BK842 Pigmented low transfer 3 - BDH/2/10 - BEN/2/10 - Type 3 (W)
fast dry black cable ink
2BK845 Pigmented UV curing 3 - BDH/1/7/10 - - - Type 3 (W)
black ink
2BL808 Pigmented low-transfer 3 BCK/7/10/ BDH/7/10/ - - - Type 2
fast dry blue cable ink 15 15
2GR846 Pigmented low transfer 3 - BDH/2 - - - Type 3 (W)
fast dry green cable ink
2GY847 Pigmented low transfer 3 - BDH - - - Type 3 (W)
EPT026795 Issue 17 June 2020

fast dry grey cable ink

2OR844 Pigmented low transfer 3 - BDJ - - - Type 2 (W)
fast dry orange cable ink
2RD810 Pigmented low-transfer 3 BCK/7/10/ BDH/7/10/ - - - Type 2 (W)
fast dry red cable ink 15 15
2WT843 Pigmented low transfer 3 - BDH/15/16 - BEN/15/16 - Type 3 (W)
fast dry white cable ink
Table 13: Ax-Series Inks (Dye-Based)
EPT026795 Issue 17 June 2020

2WT848 Pigmented UV curing 3 - BDH - - - Type 3 (W)

white ink
2WT850 Pigmented high opacity 3 - BDH/2 - - - Type 3 (W)
pigmented fast dry white
ink

SYSTEM CONFIGURATION
2YL855 Yellow fast dry alkali 2 - BDH/1 - - - Type 2
washable ink
8WT853 Pigmented very fast dry 3 - BDH/10 - - - Type 3 (W)
white cable ink
3-13
SYSTEM CONFIGURATION

THIS PAGE INTENTIONALLY LEFT BLANK

3-14 EPT026795 Issue 17 June 2020

INSTALLATION

PART 4 : INSTALLATION

4-4 EPT026795 Issue 17 June 2020

INSTALLATION

INTRODUCTION
WARNING: High Voltage Electricity. Risk of physical injury.

There are high voltage components inside the printer’s electronics compartment.
Do not allow unskilled personnel to open the printer’s electronics compartment.

WARNING: Class 1 Equipment. Risk of physical injury.

The printer is Class 1 equipment and requires a protective earth.

WARNING: High Voltage Electricity. Risk of physical injury.

For the safety of personnel, all items in the printer requiring connection to
earth/ground have cables for this purpose. Any earth/ground cables disconnected
at any time must be refitted before the printer is returned to operation.

Note: The printer requires an H05 RR-F approved mains lead.

Installation of the printer consists of:
• Checking that all items have been delivered.
• Installing the printer and its associated equipment.
• Preparing the printer for use.
There is a wide range of possible work areas and it is not possible to give specific instructions for
each area. The information provided in this document consists of the basic requirements and
general information. Ensure that the basic requirements can be met before installing the printer.

EPT026795 Issue 17 June 2020 4-5

INSTALLATION

PRINTER INSTALLATION
The following is general information for installing the printer in a wide range of working areas.

Cabinet Positioning
WARNING: Heavy object. Risk of physical injury.

Carry out a risk assessment before moving the printer cabinet.

Note: For dry weight of specific printer models, see the specification on page 2-9.
This equipment is not suitable for use in locations where children are likely to be present.
The cabinet must be positioned in a location with enough clearance to open the doors and give
access to the cabinet’s front and rear. The cabinet must also be positioned on a level surface and
electrically isolated from other equipment, except for a normal data interface.
The printer must be positioned in an area where the temperatures will remain within +5 °C and
+45 °C (42 ºF to 112 ºF) and the relative humidity must remain within 10% to 90%
(non-condensing). The printer draws in and expels cooling air through vents underneath of the
cabinet. The air vents must not be obstructed.
To ensure stability and minimise vibration, mount the printer on a Domino Printer Stand with the
Domino Stacking Kit. If a Domino Printer Stand is not used, then the printer base must be secured
to the mounting surface using M6 mounting bolts. Use spacers to ensure the mounting bushes
are flush with the mounting surface.
Printer cabinets can be stacked, see page 4-8 for more details.

Conduit and Print Head Positioning

Keep the conduit and print head away from power supply cables and other wiring capable of
producing electrical noise. Use the nylon print head mounting bracket supplied with the printer to
reduce electrical noise. Keep the conduit and print head as free as possible from vibration. Mount
the print head perpendicular to the printing surface.
If it is possible, position the print head to the recommended distance away from the print surface
as described in the table below.

i-Pulse Duo i-Pulse Duo

Nozzle Diameter i-Pulse/i-Pulse RS
(Standard Labels) (Stitched Labels)

75 micron 14mm 14mm 20mm

60 micron 8mm 6mm 12mm
50 micron 6mm N/A N/A
40 micron 4mm N/A N/A

4-6 EPT026795 Issue 17 June 2020

INSTALLATION

Ventilation
WARNING: Flammable vapour. Risk of fire or explosion.

Install and operate the printer in a well ventilated environment. Do not install or
operate the printer in closed or sealed rooms or cabinets.

Solvent based printing inks and their vapours are flammable. As well as ensuring that all
equipment is earthed, and that anti-static precautions are followed, an extraction system must be
provided to remove fumes and vapours from the production line and anywhere else that the
printer may be operated.
The ventilation system must achieve a minimum of 10 air changes per hour (20 air changes per
hour recommended).

Electrical Supply
WARNING: Electricity. Risk of injury from electric shock.

Earth the printer cabinet for the safety of personnel working on the printer.

WARNING: Electricity. Risk of fire. Risk of injury from electric shock.

Tighten both screws on the power supply plug to prevent moisture entering the
power supply socket. Use a screwdriver to ensure the screws are properly
tightened.

Connect the printer using a suitable plug and socket outlet which is accessible and close to the
equipment so that power can be quickly disconnected. If a fused power connector is used, it
should be fitted with a 5A fuse. If a fused power connector is not used, then the supply circuit
should have a circuit breaker or fuse rated at 5A.
The supply must be free from electrical noise. Domino can give advice on suitable devices to
ensure trouble-free operation.

EPT026795 Issue 17 June 2020 4-7

INSTALLATION

Printer Cabinet Stacking

WARNING: Topple Hazard. Risk of injury.
Do not stack two printer cabinets on the top shelf of a type 1 printer stand. Two
printer cabinets can only be stacked on the top shelf of a type 2 printer stand (with
a third printer cabinet or a cupboard assembly on the bottom shelf).

WARNING: Topple Hazard. Risk of injury.

Do not stack two printer cabinets on the top shelf of the printer stand if the bottom
shelf is empty. Mount one printer on the top shelf and one printer on the bottom
shelf.

WARNING: Topple Hazard. Risk of injury.

Use a stacking kit to secure the top two printer cabinets if two printer cabinets are
stacked on the top shelf of a type 2 printer stand (with a third printer or a cupboard
assembly on the bottom shelf).

To increase stability, the stacking kit (EPT011760) can be used to secure a type 1 or type 2 stand
to the ground. The kit also allows two Ax350i/Ax550i printer cabinets to be stacked on the top
shelf of a Type 2 stand, if a third cabinet or cupboard is on the bottom shelf.
Cabinet stacking configurations are dependent on the printer type and stand type.
The possible printer stacking configurations are listed in the below:
Table 1: 1 x Ax150i

Stacking Kit
Type 1 Printer Stand Type 2 Printer Stand
Required?

4-8 EPT026795 Issue 17 June 2020

INSTALLATION

Table 2: 1 x Ax150i and Cupboard Assembly

Stacking Kit
Type 1 Printer Stand Type 2 Printer Stand
Required?

Table 3: 2 x Ax150i

Stacking Kit
Type 1 Printer Stand Type 2 Printer Stand
Required?

Table 4: 1 x Ax350/Ax550i

Stacking Kit
Type 1 Printer Stand Type 2 Printer Stand
Required?

EPT026795 Issue 17 June 2020 4-9

INSTALLATION

Table 5: 1 x Ax350/Ax550i and Cupboard Assembly

Stacking Kit
Type 1 Printer Stand Type 2 Printer Stand
Required?

Table 6: 2 x Ax350/Ax550i

Stacking Kit
Type 1 Printer Stand Type 2 Printer Stand
Required?

4-10 EPT026795 Issue 17 June 2020

INSTALLATION

Table 7: 3 x Ax350/Ax550i

Stacking Kit
Type 1 Printer Stand Type 2 Printer Stand
Required?

Type 1 Printer Stand is not rated for Stacking kit must

this configuration. be used. Refer to
stacking kit
instructions
(EPT029265).

Table 8: 2 x Ax350/Ax550i and Cupboard Assembly

Stacking Kit
Type 1 Printer Stand Type 2 Printer Stand
Required?

Type 1 Printer Stand is not rated for Stacking kit must

this configuration. be used. Refer to
stacking kit
instructions
(EPT029265).

EPT026795 Issue 17 June 2020 4-11

INSTALLATION

Installation Dimensions
Ax150i

373mm
400mm 394mm

Ax150i Cabinet

Ax350i/Ax550i

411mm

430mm 381mm

Ax350i/Ax550i Cabinet

4-12 EPT026795 Issue 17 June 2020

INSTALLATION

i-Pulse Print Head

65mm (2.56")
Minimum bend
radius.

21.5mm
(0.85")
221.5mm (8.72")

135mm (5.31")

50mm (2.0") 50mm (2.0")

i-Pulse Print Head Dimensions

EPT026795 Issue 17 June 2020 4-13

INSTALLATION

i-Pulse Duo Print Head

65mm (2.56")
Minimum bend
radius.

28mm
(1.10")
255mm (10")

3.30mm
(0.13")
7.60mm
(0.30")
148mm (5.83")

57mm (2.24") 49.7mm

(1.96")

i-Pulse Duo Print Head Dimensions

4-14 EPT026795 Issue 17 June 2020

INSTALLATION

i-Pulse RS with 60μ Nozzle

70mm minimum inside bend

radius for a fixed installation.
150mm best radius for a
continuous flex installation
72.5mm
243.1mm

111.5mm

Ø 40mm

i-Pulse RS Print Head Dimensions

EPT026795 Issue 17 June 2020 4-15

INSTALLATION

i-Pulse RS with 75μ Nozzle

70mm minimum inside bend

radius for a fixed installation.
150mm best radius for a
continuous flex installation
72.5mm
251.6mm

120mm

Ø 40mm

i-Pulse RS Print Head Dimensions

4-16 EPT026795 Issue 17 June 2020

INSTALLATION

External Connections
Ax150i
* - Standard Fit.
** - Optional Fit.

Product Detect /
Shaft Encoder*
Alarm**
PNP/NPN Selection
Switches*
Beacon**
Product Detect /
Shaft Encoder*

Ethernet**

RS232**

USB Type A**

GPIO**

Ax150i External Connections Left View

DCI Socket**

Power
Connector*

Ax150i External Connections Rear View

EPT026795 Issue 17 June 2020 4-17

INSTALLATION

Ax350i/Ax550i
* - Standard Fit.
** - Pack Option.
*** - DCI.

Product Sensor / PNP/NPN Selection

Shaft Encoder* Switches*

TouchScreen Product Sensor /

Connector* Shaft Encoder*

Extended GPIO**

GPIO**

RS232** Beacon
Connector**

Alarm
Connector**
Ethernet**

Powered HMI**
or
USB Type A**
DCI Socket**

Control
Port**

Power
Connector*

Ax350i/Ax550i External Connections

4-18 EPT026795 Issue 17 June 2020

INSTALLATION

Product Detect / Shaft Encoder Socket Description

CAUTION: Risk of product detect sensor or shaft encoder damage.
The product detect sensor or shaft encoder can be damaged if the pins on the
plug make contact with the wrong pins on the PD/SE socket. To ensure the
product detect sensor or shaft encoder is not damaged when they are connected
to or disconnected from the printer; shut down the printer and disconnect the
power lead from the rear of the printer before connecting or disconnecting a
product detect sensor or shaft encoder.

Note: Ensure the sealing caps are fitted to maintain the printer cabinet’s IP rating.
As standard, Ax-Series printers are equipped with two product detect and shaft encoder sockets.
The socket locations are illustrated on page 4-17 for the Ax150i and page 4-18 for the
Ax350i/Ax550i.
The printer provides a 24V DC supply for use by a product sensor and selectable 24V NPN
(Default) or PNP input for signals from a shaft encoder. NPN or PNP can be selected by changing
the micro-switches on the PCB as described on page 4-20.
The diagram and table below illustrate the pin out for the product detect / shaft encoder sockets.

Pin Description

1 24V Power Supply

2 Ground
2
3 Product Detect (+) 4 5

4 Product Detect (-) 1 3

8
5 Encoder Channel A (+) 6 7

6 Encoder Channel A (-)

7 Encoder Channel B (+)
8-Way PD / SE Socket
8 Encoder Channel B (-) (external cabinet view)
Shell EMC_GND via panel mounting

EPT026795 Issue 17 June 2020 4-19

INSTALLATION

Product Detect / Shaft Encoder PNP and NPN Selection

The pictures below illustrate the PNP/NPN selection switches on the Product Detect/Shaft
Encoder PCB. The configuration of these switches will set the product sensor and shaft encoder
inputs to either PNP or NPN. There are LEDs on the PCB to indicate that the signal is correct.
The switches are accessed by removing the rubber grommet shown on page 4-17 for the Ax150i
and page 4-18 for the Ax350i/Ax550i.
Note: Refit the rubber grommet to maintain the printer cabinet’s IP rating.
When a single channel (non-quadrature) shaft encoder is used, only the channel SE_A can be
utilised.
When a quadrature shaft encoder is used, both the Channels SE_A and SE_B can be utilised.
For information on the settings:

PD = Product Detect Sinking = NPN Configuration

SE_A = Shaft Encoder 1 > Shaft Encoder Phase A Sourcing = PNP Configuration
SE_B = Shaft Encoder 1 > Shaft Encoder Phase B

Switches set to PNP

Switches set to NPN

4-20 EPT026795 Issue 17 June 2020

INSTALLATION

PRODUCT DETECT SENSOR INSTALLATION

CAUTION: Risk of product detect sensor damage.
The product detect sensor can be damaged if the pins on the plug make contact
with the wrong pins on the PD/SE socket. To ensure the product detect sensor is
not damaged when it is connected to or disconnected from the printer; shut down
the printer and disconnect the power lead from the rear of the printer before
connecting or disconnecting the product detect sensor.

Details are given in Part 10 : ACCESSORIES of the following types of product detector:
• Reflector
• Proximity
• Inductive
• Fibre Optic
• Special Application Product Detectors.
More details of product detectors available for the Ax-Series can be found in the Ax-Series
Accessories Catalogue on myDomino.
Product detectors are connected to the printer via one of the printer’s product detect/shaft
encoder sockets, see page 4-19.

Product Detect Sensor Positioning

Position the product detector at a location where it will detect the product before the product
reaches the print head. Either the leading or trailing edge of the product detect signal can be used
trigger a print.
The product detect sensor should be positioned as close as possible to the print head to avoid
the next product being detected before the current print is complete.
On a very high speed production line, try to ensure the print head and product detect sensor are
only one product apart. To allow a good amount of delay a minimum distance between the print
head and product detect sensor of 30mm is recommended.
If it is not possible to position the product detect sensor close to the print head; the Product
queue depth setting (page 4-57) can be set to define the number of products that come between
the print head and product detect sensor.

EPT026795 Issue 17 June 2020 4-21

INSTALLATION

TOUCHSCREEN INSTALLATION (Ax350i/Ax550i)

Ax350i and Ax550i printers are operated either via Remote TouchScreen 7", Remote TouchScreen
10", or via a PC.

Remote TouchScreen 10"

The Remote TouchScreen 10" is a user interface with a 10.4 inch touch screen. It has 2 USB ports
for data transfer and a connector to provide control of Ax350i/Ax550i printers.

Remote TouchScreen 10" Front View

TouchScreen to Printer
Connection USB Type A

Remote TouchScreen 10" Connections

4-22 EPT026795 Issue 17 June 2020

INSTALLATION

Remote TouchScreen 7"

The Remote TouchScreen 7" is a user interface with a 7 inch touch screen. It has 2 USB ports for
data transfer and a connector to provide control of Ax350i/Ax550i printers.

Remote TouchScreen 7" Front View

TouchScreen Connectivity
The Remote TouchScreen 7" and 10" are connected to the TouchScreen connector on the rear of
the Ax350i/Ax550i printer. The TouchScreen will display the user interface relating to that printer
when the printer is turned on.

CAUTION: Vulnerable cable. Risk of damage to cable or equipment.

Securely route the TouchScreen cable away from moving equipment and other
hazards.

TouchScreen Connection

4-26 EPT026795 Issue 17 June 2020

INSTALLATION

PREPARING THE INK SYSTEM

Ax-Series Ink System

The procedures described in this section must be followed when the ITM, ink and make-up
cartridges are installed for the first time or following a long shut-down after ITM removal.

Start Up
To start up the printer:
(1) Connect the power cable to the power socket on the rear of the printer and plug the power
cable into the power supply.
(2) Press and hold the standby button on the printer cabinet for 2 seconds.
(3) Wait for the printer to start up.
End of procedure.

EPT026795 Issue 17 June 2020 4-27

INSTALLATION

Print Head Preparation

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

To prepare the print head:

(1) Remove the print head cover.
(2) Remove the silicone tube cap over the gutter (if fitted).Check that the print head is clean and
dry.
Note: Image shows a single jet i-Pulse Print Head.

Silicone Tube Cap

Silicone Tube Cap Removal

(3) Replace the print head cover.

(4) Fit the print head into a wash station, or place a beaker made of a conducting material and
connected to earth (ground) underneath the print head.
End of procedure.

4-28 EPT026795 Issue 17 June 2020

INSTALLATION

ITM Installation
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Hazardous chemicals. Risk of environmental damage.

Used paper towels will contain chemicals that are hazardous to the environment.
Follow local waste disposal regulations to safely dispose of used paper towels.

This procedure should be followed when installing the ITM for the first time, or following long shut
down after ITM removal. If replacing an expired ITM follow the procedure described on page 6-7.
Tools required: Paper towels (or similar) and wash.
To install the ITM:
(1) Open the printer ink cabinet.
(2) Place paper towel (or similar) on top of the level sensor modules to catch excess fluid. Use
the correct wash to remove any dried residual ink from the ink block valve face.

Washing the ink block valve face

EPT026795 Issue 17 June 2020 4-29

INSTALLATION

(3) Unpack the new ITM and remove the sealing strip that protects the ITM manifold pipes.

Removing the ITM Sealing Strip

(4) Place paper towel (or similar) under the ITM manifold pipes and lubricate the pipes with
wash.

CAUTION: Important step. Risk of fluid leak

Ensure you lubricate the ITM manifold pipes with wash. If you do not, it may be
difficult to create a good seal between the ink block and ITM. A bad seal between
the ink block and ITM could cause fluid to leak.

Washing the ITM manifold pipes

4-30 EPT026795 Issue 17 June 2020

INSTALLATION

(5) Insert the ITM between the retaining clips and firmly push the ITM manifold pipes into the
ink block.

Inserting the ITM

WARNING: Pressurised ink system. Risk of ink spray.

When replacing the ITM, ensure the retaining clips are fully engaged.

(6) Continue pushing until the retaining clips engage with a click.

Retaining Clip Engaged Retaining Clip Not Engaged

(7) Close the printer ink cabinet.

(8) Dispose of used paper towels by following local waste disposal regulations.
End of procedure.

EPT026795 Issue 17 June 2020 4-31

INSTALLATION

Ink and Make-up Cartridge Installation

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

If the ink jet is misaligned out of the gutter and a beaker is placed underneath the
print head, the build of ink in the beaker and the electrostatic charge on ink drops
from the print head are a fire risk. Use a wash station, or position the print head
over a beaker made of a conducting material securely connected to earth (ground).

The ink system must be primed before the printer can be used for the first time.
This ink system must also be primed if the ITM is removed from the printer and the same ITM is
re-fitted. The printer will automatically prime the ink system when a new ITM with a new serial
number is recognised. However, if an old ITM is re-used the printer will not recognise that the ITM
has been removed and replaced.
Before starting this procedure, ensure that the ink and make-up levels are at least half full. This
will be indicated by yellow or green make-up and ink level icons on the information bar on the
TouchScreen, see page 5-5.
To prime the ink system:
(1) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(2) Select Start ink priming.
Note: The ink priming will take 12 minutes to complete
(3) Select Complete when the ink priming process is finished.
(4) Check the ink jet alignment: must now be checked.
• i-Pulse print head, see page 12-17.
• i-Pulse duo print head, see page 13-16.
• i-Pulse RS print head, see page 14-21.
End of procedure.

EPT026795 Issue 17 June 2020 4-35

INSTALLATION

WAKE-UP MODE
Note: Wake-up mode is normally required for heavy duty ink types.
When enabled, the wake-up routine will run the printer’s main pump for 2-3 minutes every 20
minutes to agitate the ink. The wake-up mode time interval can also be customised.
The primary purpose of wake-up mode is to ensure the pigment in heavy duty ink does not fall
from suspension and form sediment in the ink system. Wake-up mode may also be enabled to
help the ink remain at a good viscosity during long periods of idle time or for production lines with
a low print rate.

Enable/Disable Wake-up Mode

To enable or disable wake-up mode:
(1) On the TouchScreen, select Home > Setup > Advanced > Hardware.
(2) Scroll down to the Wake-up mode drop down setting and select one of the options
described below:

Setting Name Explanation

Factory default Set the wake-up mode to the factory default setting.
On Enable wake-up mode.
Off Disable wake-up mode.

Note: The wake-up mode suppressed tick box illustrates the current status of wake-up
mode. For example, wake-up mode can be set to On, but is automatically suppressed
when an engineer’s USB key is inserted into the printer. This prevents the wake-up
sequence interfering with work that an engineer is performing.
End of procedure.

Set a Custom Wake-up Mode Interval

To set a custom wake-up mode time interval:
(1) On the TouchScreen, select Home > Setup > Advanced > Hardware.
(2) Scroll down to the Wake-up mode settings and tick the Custom wake-up time enabled
tickbox.
(3) Adjust the Wake-up time (min) value to set the number of minutes in between wake-up
mode cycles.
End of procedure.

4-36 EPT026795 Issue 17 June 2020

INSTALLATION

ENABLE RESET COUNTERS ON HOME SCREEN

A button can be displayed or hidden on the Home screen, to allow users to easily reset the
counter elements in the currently printing label.
To enable the reset counters button on the Home screen:
(1) Select Home > Setup > Printer status > Counters.
(2) Tick the Enable reset counters on home screen tick box.
End of procedure.

ENABLE GPI COUNTER UPDATES ONLY

The printer can be setup so counter elements in labels will only update, when a configured
general purpose input is triggered. All other counter update triggers will be ignored when this
setting is enabled.
Up to 4 counters in each label can be updated using 4 different inputs. To configure the inputs,
see page 7-67.
To enable GPI counter updates only:
(1) Select Home > Setup > Printer status > Counters.
(2) Tick the GPI counter updates only tick box.
End of procedure.

EPT026795 Issue 17 June 2020 4-37

INSTALLATION

INSTALLATION WIZARD
The Installation Wizard configures the language of the user interface, system pre-sets and basic
settings and for the printer to operate.
Note: The correct System Date and System Time values must be entered to print accurate
date or time elements within labels.
To start the printer and use the Installation Wizard:
(1) If the printer is not already on, press and hold the standby button for 2 seconds and
wait for the printer to start up.
(2) Select Setup > Wizards > Installation.
(3) Use the drop down settings to select the required Language, Keyboard layout and Primary
currency.
(4) Select the Next Screen icon.

(5) Select the System date and enter the current date.
(6) Select Save.
(7) Select the System time and enter the current time.
(8) Select Save.
(9) Select Complete.
End of procedure.

4-38 EPT026795 Issue 17 June 2020

INSTALLATION

PRODUCTION LINE SETUP

The following settings should be configured to set the printer up on a production line.

Line Movement
Home > Production line setup > Line movement
The settings shown on the Line movement screen configure how the printing speed is set or
measured. There are 2 different encoder input methods available which are described in the table
below.
Notes: (1) It is recommended to use an external shaft encoder if the speed of the production line
varies or there is a requirement to print barcodes or images.
(2) Connect a quadrature shaft encoder instead of a single ended shaft encoder if there is
a requirement to detect changes in the production line direction. A quadrature shaft
encoder will also guarantee that the printer does not receive false production line
movement signals when the production line is stationary.

Encoder Input Method Explanation

Internal If a shaft encoder is not connected to the printer, a simulated

encoder signal will be internally generated to set a fixed printing
speed. To setup an internal encoder, follow the procedure
described on page 4-40.
External Use an external shaft encoder to measure the production line
speed in real time. To setup an external shaft encoder, follow the
procedure described on page 4-42.

If a quadrature shaft encoder is connected to the printer, the

encoder mode can also be set to detect changes in the
production line’s direction. To setup an quadrature shaft encoder,
follow the procedure described on page 4-45.

EPT026795 Issue 17 June 2020 4-39

INSTALLATION

Internal Encoder (Fixed Printing Speed) Setup

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Tools required: Metric ruler.

To setup an internal encoder with a fixed printing speed:
(1) Create a test label that includes a text element in the label design, refer to page 5-25.
(2) In the label creator, select the Preview tab at the top of the screen.
(3) Make a note of the Label width value.
(4) Select the Print icon, select Just print and select OK.

(5) Select Home > Production line setup > Line movement.
(6) Select the START icon and select Sequence On.

(7) Select the Encoder input drop down setting and select Internal.
(8) Select the Speed (mm/s) setting and enter the print speed in millimetres per second.
(9) Run the production line to make a test print.
(10) Measure the width of the test print.
(11) If the width of the test print is not equal to the width noted at step (3), adjust the Speed
(mm/s) setting and repeat step (9) and step (10). The equation below can also be used to
calculate the correct Speed (mm/s) value.
New speed (mm/s) value = N
N = O x (P ÷ E) Old speed (mm/s) value = O
Printed label width = P
Label width value = E

4-40 EPT026795 Issue 17 June 2020

INSTALLATION

(12) If the label width needs to be adjusted after the Speed (mm/s) setting has been set, adjust
the Global stroke pitch goal (mm/stroke) setting to change the distance between print
strokes (Default value: 0.43mm).
Note: A print stroke is the line of ink drops which make up each printed character as shown
in the illustration below.
Print Stroke

Ink Drop Unused Position

(13) If the Print Stretch Detected alert occurs, the bullet points below list several possible fixes to
prevent the alert re-occurring:
• Reduce the production line speed.
• Increase the label’s Stroke pitch (mm/stroke) value, see page 5-26.
• Reduce the label’s Type setting to enable the label to be printed faster, see page 5-26.
• If some print stretch is acceptable, adjust the Print stretch threshold (mm) setting. This
setting adjusts the amount of print stretch allowed before the alert is triggered.
End of procedure.

EPT026795 Issue 17 June 2020 4-41

INSTALLATION

External Single Ended Shaft Encoder Setup

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of shaft encoder damage.

The shaft encoder can be damaged if the pins on the plug make contact with the
wrong pins on the PD/SE socket. To ensure the shaft encoder is not damaged
when it is connected to or disconnected from the printer; shut down the printer and
disconnect the power lead from the rear of the printer before connecting or
disconnecting the shaft encoder.

Tools required: Metric ruler.

To setup an external single ended shaft encoder to measure the speed of the production line:
(1) Create a test label that includes a text element in the label design, refer to page 5-25.
(2) In the label creator, select the Preview tab at the top of the screen.
(3) Make a note of the Label width value.
(4) Select the Print icon, select Just print and select OK.

(5) Select Home > Production line setup > Line movement.
(6) Select the START icon and select Sequence On.

(7) Select the Encoder input drop down setting and select External.
(8) Select the Print optimisation drop down setting and select Message width.
(9) Scroll to the bottom of the Line movement menu, select the Stroke go multiplier setting and
select x1.
(10) Select the Encoder mode setting and select Single mode.
(11) Select Set calibration settings.
(12) To calibrate the shaft encoder, the production line will need to run for a measured distance.
Enter the distance that the production line will run for in the Calibration distance (mm)
setting.
(13) Select Start.
(14) Run the production line over the distance that was set at step (12).
(15) Scroll to the bottom of the Calibration settings window and note the Velocity encoder pulse
count value.
(16) Enter the Velocity encoder pulse count value into the Calibration pulse count (pulses)
setting.

4-42 EPT026795 Issue 17 June 2020

INSTALLATION

(17) Adjust the Digital gearbox multiplier and Digital Gearbox divider settings to set the Encoder
stroke resolution to the correct value for the print application.
Notes: (1) Use the lowest possible Digital gearbox multiplier value to achieve a good Encoder
stroke resolution value.
(2) The Save button will not be available for selection if the Encoder stroke resolution
(pulses/stroke) value is too high. The Encoder stroke resolution (pulses/stroke) range is
1 - 100.

Print Application Encoder Stroke Resolution Value

High speed printing. 10, or close to 10.

Medium and low speed printing. Between 10 and 20.

(18) Select Save.

(19) Run the production line to make another test print.
(20) Measure the width of the test print, and inspect the distance between each print stroke. If
the width of the test print does not match the value noted at step (3), or if the spaces
between print strokes varies, refer to the table below to diagnose and correct the problem.
Note: A print stroke is the line of ink drops which make up each printed character as shown
in the illustration below.
Print Stroke

Ink Drop Unused Position

EPT026795 Issue 17 June 2020 4-43

INSTALLATION

Problem Description Reason Solution

The width of the test The Calibration distance Repeat step (12) to step (20).
print does not match (mm) value is inaccurate.
the Label width value.
The encoder has stopped Repeat step (12) to step (20).
at the exact position
where a pulse is Use the equation below to calculate the
generated. This will cause correct Calibration pulse count (pulses)
the encoder to generate value.
multiple pulses when the N = O x (E ÷ P)
encoder is not moving and
create an inaccurate N = New pulse count (pulses) value
O = Old pulse count (pulses) value
Velocity encoder pulse E = Label width value
count value. P = Printed label width

There is noise on the shaft Close the Calibration settings window and
encoder input signal adjust the Encoder persistence (ms) value.
causing false pulses. This value sets the length of time the shaft
encoder signal must be active for before
the printer recognises the signal as valid
(Default value: 0.001).
Note: Set the persistence value as
low as possible. If too high a
value is set, the shaft encoder
signal may not be detected at
high frequencies.
The space between The resolution of the shaft Change the Stroke go multiplier setting to
each print stroke varies encoder is not accurate x2 and repeat step (11) to step (19).
across the test print. enough to measure a x1 = A stroke go pulse is detected on the
consistent stroke go rising edge of channel SE_A only.
pulse. x2 = A stroke go pulse is detected on the
rising and falling edge of channel SE_A.

(21) If the width of the label needs to be adjusted to fit the print surface after the shaft encoder
has been calibrated, adjust the Global stroke pitch goal (mm/stroke) setting to change the
distance between print strokes. The default Global stroke pitch goal (mm/stroke) value is
0.43mm.
(22) If the Print Stretch Detected alert occurs, the bullet points below list several possible fixes to
prevent the alert re-occurring:
• Reduce the production line speed.
• Increase the label’s Stroke pitch (mm/stroke) value, see page 5-26.
• Reduce the label’s Type setting to enable the label to be printed faster, see page 5-26.
• If some print stretch is acceptable, adjust the Print stretch threshold (mm) setting. This
setting adjusts the amount of print stretch allowed before the alert is triggered.
End of procedure.

4-44 EPT026795 Issue 17 June 2020

INSTALLATION

External Quadrature Shaft Encoder Setup

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of shaft encoder damage.

Required tools: Metric ruler.

If the production line can change direction, a quadrature shaft encoder can be used to measure
the production line speed and detect the direction of travel. Four different encoder modes are
available to define the printers behaviour when the direction changes.
A quadrature shaft encoder will also guarantee that the printer does not receive false production
line movement signals when the production line is stationary.
To setup a quadrature shaft encoder:
(1) Create a test label that includes a text element in the label design, refer to page 5-25.
(2) In the label creator, select the Preview tab at the top of the screen.
(3) Make a note of the Label width value.
(4) Select the Print icon, select Just print and select OK.

(5) Select Home > Production line setup > Line movement.
(6) Select the START icon and select Sequence On.

EPT026795 Issue 17 June 2020 4-45

INSTALLATION

(14) Scroll to the bottom of the Calibration settings window and note the Velocity encoder pulse
count value.
(15) Scroll to the top of the Calibration settings window and enter the Velocity encoder pulse
count value into the Calibration pulse count (pulses) setting.
(16) Adjust the Digital gearbox multiplier and Digital Gearbox divider settings to set the Encoder
stroke resolution to the correct value for the print application.
Notes: (1) Use the lowest possible Digital gearbox multiplier value to achieve a good Encoder
stroke resolution value.
(2) The Save button will not be available for selection if the Encoder stroke resolution
(pulses/stroke) value is too high. The Encoder stroke resolution (pulses/stroke) range is
1 - 100.

Print Application Encoder Stroke Resolution Value

High speed printing. 10, or close to 10.

Medium and low speed printing. Between 10 and 20.

(17) Select Save.

(18) Run the production line to make another test print.
(19) Measure the width of the test print, and inspect the distance between each print stroke. If
the width of the test print does not match the value noted at step (3), or if the space
between print strokes varies, refer to the table below to diagnose and correct the fault.
Note: A print stroke is the line of ink drops which make up each printed character as shown
in the illustration below.
Print Stroke

Ink Drop Unused Position

4-46 EPT026795 Issue 17 June 2020

INSTALLATION

Problem Description Reason Solution

The width of the test The Calibration distance Repeat step (11) to step (19).
print does not match (mm) value is inaccurate.
the Label width value.
The encoder has stopped Set an encoder mode that uses both
at the exact position encoder channels, see page 4-49.
where a pulse is
generated. This will cause Repeat step (11) to step (19).
the encoder to generate
Use the equation below to calculate the
multiple pulses when the
correct Calibration pulse count (pulses)
encoder is not moving and
create an inaccurate value.
Velocity encoder pulse N = O x (E ÷ P)
count value. N = New pulse count (pulses) value
O = Old pulse count (pulses) value
E = Label width value
P = Printed label width

(20) If the width of the label needs to be adjusted to fit the print surface after the shaft encoder
has been calibrated, adjust the Global stroke pitch goal (mm/stroke) setting to change the
distance between print strokes. The default Global stroke pitch goal (mm/stroke) value is
0.43mm.

EPT026795 Issue 17 June 2020 4-47

INSTALLATION

(21) If the Print Stretch Detected alert occurs, the bullet points below list several possible fixes to
prevent the alert re-occurring:
• Reduce the production line speed.
• Increase the label’s Stroke pitch (mm/stroke) value, see page 5-26.
• Reduce the label’s Type setting to enable the label to be printed faster, see page 5-26.
• If some print stretch is acceptable, adjust the Print stretch threshold (mm) setting on the
Home > Setup > Production line setup > Line movement screen. This setting adjusts the
amount of print stretch allowed before the alert is triggered.
End of procedure.

4-48 EPT026795 Issue 17 June 2020

INSTALLATION

Encoder Mode Setup

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

<< Forward Backward >>
Printing

Printing

4-50 EPT026795 Issue 17 June 2020

INSTALLATION

(4) Select Backlash direction drop down setting and select which direction the shaft encoder
will detect as forward:

Backlash Direction Explanation

A leads B Forward movement will be detected when the shaft encoder turns
clockwise.
B leads A Forward movement will be detected when the shaft encoder turns
anti-clockwise.

End of procedure.

EPT026795 Issue 17 June 2020 4-51

INSTALLATION

Stroke Release Mode

Note: This setting was added in software version 01.30.0073.
This setting defines the stroke release, or time of flight compensation mode. Do not adjust this
setting unless there is a problem with the print quality.
For the purpose of this setting, time of flight is defined as the time period between an ink drop
breaking off from the ink jet, and an ink drop making contact with a specific point on the print
surface. The time of flight changes as the production line accelerates and decelerates. The stroke
release mode setting can be enabled to calculate the time of flight so the printer can accurately
position each print stroke.
Stroke Release Mode Setup
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

To set the stroke release mode:

(1) Select Home > Setup > Production line setup > Line movement.
(2) Select the Stroke Release mode drop down setting.
(3) Select one of the settings described below:

Setting Name Explanation

Off Do not correct the print stroke release for the time of flight.
Continuous Continuously correct each print stroke release (default setting).
First stroke only Make a correction for the first stroke of each printed label, but do not make
any corrections during the print.

End of procedure.
Setup Notes
The printer will be unable to correctly calculate the time of flight if the shaft encoder is inaccurate.
Therefore, set the Stroke release mode to First stroke only. If the print quality does not improve,
set the Stroke release mode to Off.
Other setup notes are listed in the table below:

Print Examples Recommendations

No action required.

Set Stroke release mode to First

stroke only.

4-52 EPT026795 Issue 17 June 2020

INSTALLATION

Print Examples Recommendations

Set Print optimisation mode to

Stroke pitch.
Increase the Encoder stroke
resolution value.
Set Stroke release mode to
Continuous.
Or

EPT026795 Issue 17 June 2020 4-53

INSTALLATION

Print Trigger
CAUTION: Risk of product detect sensor damage.
The product detect sensor can be damaged if the pins on the plug make contact
with the wrong pins on the PD/SE socket. To ensure the product detect sensor is
not damaged when it is connected to or disconnected from the printer; shut down
the printer and disconnect the power lead from the rear of the printer before
connecting or disconnecting the product detect sensor.

Printing can be triggered by one of two different methods which are described in the table below.
Note: It is recommended to use the external print trigger if the space between products
varies on the production line.

Print Trigger Method Explanation

Internal Generate a simulated print trigger signal internally at fixed

distance intervals. To setup an internal print trigger, follow the
procedure described on page 4-54.
External Use an external product sensor to generate a print trigger signal.
To setup an external print trigger, follow the procedure described
on page 4-55.

Internal Print Trigger Setup

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

To setup a simulated internal print trigger signal at fixed distance intervals:

(1) On the TouchScreen, select Home > Setup > Production line setup > Print trigger.
(2) Select the Trigger by drop down setting and select Internal.
(3) Select the Print delay (mm) setting and set the delay for the first label after a production run
begins.
(4) Select the Distance interval (mm) setting and set the distance between each printed label.
Note: The distance interval is measured from the start of one label to the start of the next
label.
Distance Interval

Distance Interval Measurement

(5) If the “Print trigger occurred while printing” alert is displayed, increase the Distance interval
(mm) value so that it is larger than the width of the label.
End of procedure.

4-54 EPT026795 Issue 17 June 2020

INSTALLATION

External Print Trigger Setup

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of product detect sensor damage.

The product detect sensor can be damaged if the pins on the plug make contact
with the wrong pins on the PD/SE socket. To ensure the product detect sensor is
not damaged when it is connected to or disconnected from the printer; shut down
the printer and disconnect the power lead from the rear of the printer before
connecting or disconnecting the product detect sensor.

To setup an external print trigger:

(1) On the TouchScreen, select Home > Setup > Production line setup > Print trigger.
(2) Select the Trigger by drop down setting and select External.
(3) Select the Active level drop down setting and select whether a High or Low input signal will
trigger a print.
Note: Current level displays the current print trigger input signal level, either high or low.
(4) Select the Print delay (mm) setting and set the distance the product will move past the
product detect sensor before the label is printed.
Notes: (1) The Offset settings described on page 5-65 are used to position the label on the
product.
(2) The Print delay (mm) range depends on the printer configuration.
(3) If the “Print delay too short” alert occurs, increase the Print delay (mm) value. Or move
the product detect sensor further away from the print head.
(4) On a very high speed production line, ensure the print head and product detect sensor
are one product apart. To allow a good amount of delay a print delay of 30mm is
recommended.

EPT026795 Issue 17 June 2020 4-55

INSTALLATION

Print Head Product Detect

Sensor

ABC
Print Delay (mm) Print Offset
(See page 5-65)

Direction of Travel

Print Delay Diagram

(5) If there is more than 1 product between the product detect sensor and print head; the
Product queue depth setting should be adjusted to a value at least three more than the
maximum number of products between the print head and product detect sensor to ensure
reliable operation.
(6) If required, the Product detect persistence (mm) setting can be set to ensure that any noise
on the product detect input signal does not create false product detect triggers. The
product detect signal must be active longer than the Product detect persistence value
before the signal is recognised as valid (Default value: 1mm).
Notes: (1) Set the Product detect persistence value as low as possible. If a high value is set then
the accuracy of Print delay setting will be affected.
(2) If the print trigger signal is generated by an external machine, for example: An
extrusion line set to generate a print trigger after every meter of material has been
extruded. It is recommended to change the unit of measurement for the Product
detect persistence value to time. The unit of measurement can be changed by a
certified engineer with a USB key.
(3) If the print trigger signal is generated by a product sensor detecting physical products.
It is recommended to set the unit of measurement for the Product detect persistence
value by distance. The unit of measurement can be changed by a certified engineer
with a USB key.
End of procedure.

4-56 EPT026795 Issue 17 June 2020

INSTALLATION

Product Queue Depth

The product queue depth setting enables the printer to react to more than 1 print trigger signal.
This will enable there to be more than one product between the print head and product detect
sensor.
Each print trigger signal is serviced by its own independent counter that counts down the
distance between the product and the print head.
Under most conditions a shaft encoder is required for acceptable performance.
Ensure that only one print trigger signal is received for each product.
Ensure that the product queue depth value is set to at least 3 more than the maximum number of
products that can come between the product detect sensor and print head.
The product queue depth setting can be found by selecting Home > Setup > Production line
setup > Print trigger.
Example
In the example below, the Print delay (mm) value is set to 750mm. There are four products
between the print head and product detect sensor, so the recommended Product queue depth
value is seven.

Print Head Product Detect

Sensor

Print delay (mm)

(750mm)

Product 1 Product 2 Product 3 Product 4

Counter 4
(750mm)
Counter 3
(500mm)
Counter t 2
(250mm)
Counter 1
(0mm)
Direction
of Travel

Product Queue Depth Diagram

EPT026795 Issue 17 June 2020 4-57

INSTALLATION

Ink Jet Throw Distance Setup (i-Pulse and i-Pulse RS)

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

The throw distance setting is used to define the distance between the bottom of the print head
and the print surface.
Tools required: Metric ruler.
To setup the throw distance:
(1) Measure the distance between the bottom of the print head and the print surface.
(2) If it is possible, position the print head to the recommended distance away from the print
surface as described in the table below.
Note: The nozzle diameter of the printer can be found on the TouchScreen by selecting
Home > Setup > System information and viewing the Nozzle diameter (μm) value.

Nozzle Diameter Recommended Throw Distance

75 micron 14mm
60 micron 8mm
50 micron 6mm
40 micron 4mm

(3) On the TouchScreen, select Home > Setup > Production line setup > Print trigger.
(4) Scroll down to the Throw distance (mm) setting and select it.
(5) Enter the actual distance between the bottom of the print head and the print surface.
(6) Select the green Tick icon.
End of Procedure.

4-58 EPT026795 Issue 17 June 2020

INSTALLATION

Ink Jet Throw Distance Setup (i-Pulse Duo)

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

The throw distance setting is used to define the distance between the bottom of the print head
and the print surface. Two different distances are recommended for i-Pulse Duo print heads
depending on the application:
• Stitched - The two ink jets will be stitched together to create one large label.
• Standard - The two ink jets will print separately.
Tools required: Metric ruler.
To setup the throw distance:
(1) Measure the distance between the bottom of the print head and the print surface.
(2) If it is possible, position the print head to the recommended distance away from the print
surface as described in the table below.
Note: The nozzle diameter of the printer can be found on the TouchScreen by selecting
Home > Setup > System information and viewing the Nozzle diameter (μm) value.

Recommended Throw Recommended Throw

Nozzle Diameter
Distance for Standard Labels Distance for Stitched Labels

75 micron 14mm 20mm

60 micron 8mm 12mm

EPT026795 Issue 17 June 2020 4-59

INSTALLATION

Ink Jet Velocity Setup

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

The Jet velocity (mm/s) setting is used to define the velocity of the ink drops between the nozzle
and the print surface. However, it is recommended to leave this value at the default setting.
To setup the ink jet velocity:
(1) On the TouchScreen, select Home > Setup > Production line setup > Print trigger.
(2) Scroll down to the Jet velocity (mm/s) setting and select it.
(3) Enter a jet velocity value (Range: 15000 - 25000).
(4) Select the green Tick icon.
End of Procedure.

4-60 EPT026795 Issue 17 June 2020

INSTALLATION

PRINT HEIGHT CALIBRATION WIZARD

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Note: For printers equipped with a duo print head this procedure will run twice, once for
each ink jet.
Print height calibration is a tool which is used to set the optimum default print height.
Required tools: Metric ruler.
To run the print height calibration:
(1) Check that the print head is set to the correct distance away from the print surface. The
print head distance can be set by following the Ink Jet Thr ow Distance procedure on
page 4-58.
(2) If the ink jet is not already running, press the Start/Stop button on the printer cabinet and
wait for the ink jet to sequence on.
(3) On the TouchScreen, select Home > Setup > Wizards > Print height calibration.
(4) Check that the print quality metrics listed on the TouchScreen have green ticks next to
them. If any of the items are marked with a red cross, wait a few minutes to see if the ink
system stabilises and a green tick appears. If the red cross remains, an engineer certified by
Domino can investigate the fault.
(5) Select the Next Screen icon.

(6) Select Testing raster and select a suitable raster to test.

(7) Select Test print, and run the production line to make a test print.
(8) The printer will print the letter H. Measure the height of the printed letter H in millimetres.
(9) Enter the measured height of the printed letter H in the Measured print height (mm) setting.
(10) If the measured print height is different from the expected height, the printer will recommend
a different charge scaling (%) value. Select Apply to apply the recommended value and
double check the print height by repeating step (7) to step (10).
(11) Select Complete.
End of procedure.

EPT026795 Issue 17 June 2020 4-61

INSTALLATION

NETWORK SETUP
The printer can be fully controlled over a network connection using a PC which has Domino
QuickStep software installed or via web browser.
TouchScreens can also be used to control other printers on the same network.
Only 1 printer can be controlled at the same time.

Network Connectivity Diagrams

Printers can be connected to a network as illustrated in the diagrams below.

Cat.5 UTP RJ45 Cable

Standard PC IP Address Fixed

IP Address Fixed
(192.168.1.a)
(192.168.1.b)

Single printer to single PC (max 1 printer) PC not connected to network

Network card 2
IP Address Fixed or
dynamic Cat.5 UTP RJ45 Cable
Network
Cat.5 UTP RJ45
Cable
RJ45 Cable

Network card 1
Cat.5 UTP

IP Address Fixed IP Address Fixed

(192.168.1.a) (192.168.1.b)

Standard PC fitted with

2 network cards

Single printer to single PC (max 1 printer) PC connected to network

4-62 EPT026795 Issue 17 June 2020

INSTALLATION

Cat.5 UTP Cat.5 UTP RJ45 Cable

RJ45 Cable IP Address Fixed

(192.168.1.c)
Standard PC IP Address
Fixed (192.168.1.a)

Cat.5 UTP Cat.5 UTP RJ45 Cable

RJ45 Cable IP Address Fixed

(192.168.1.d)
Standard PC IP Address
Fixed (192.168.1.b)

Cat.5 UTP RJ45 Cable

10/100 Ethernet IP Address Fixed

network switch (192.168.1.e)

Multiple printers to PC through switch. PC not connected to network

Cat.5 UTP RJ45 Cable

IP Address Fixed
(192.168.1.b)

Standard PC
IP Address fixed or
dynamic (192.168.1.a)

Cat.5 UTP
Cat.5 UTP RJ45 Cable
RJ45 Cable
IP Address Fixed
(192.168.1.c)
DHCP network
server

Cat.5 UTP RJ45 Cable

Network
IP Address Fixed
10/100 Ethernet (192.168.1.d)
network switch

Multiple printers to PC through switch. PC connected to network

EPT026795 Issue 17 June 2020 4-63

INSTALLATION

Cat.5 UTP RJ45 Cable

IP Address Fixed
(192.168.1.a)
Cat.5 UTP
Standard PC RJ45 Cable
IP Address fixed
or dynamic

Cat.5 UTP RJ45 Cable

Network
IP Address Fixed
(192.168.1.b)

Cat.5 UTP Cat.5 UTP RJ45 Cable

RJ45 Cable IP Address Fixed

(192.168.1.c)
DHCP network
server

Multiple printers to PC through network

4-64 EPT026795 Issue 17 June 2020

INSTALLATION

PC to Networked Printer Settings

Note: Restart the printer after changing any network settings to ensure the new settings are
saved.
To setup the PC to Printer network settings:
(1) Install the QuickStep software on the PC which will be used to control the printer.
(2) Ensure the printer is correctly connected to the network.
(3) On the printer’s TouchScreen, select Home > Setup > Printer network.
(4) Select Edit...
(5) Two different actions are available for this step depending on whether the network has a
DHCP server enabled or not:

Network DHCP Server Required Action

Enabled Ensure that the Enable DHCP tick box is selected.

Not Enabled Ensure that the Enable DHCP tick box is not selected. Change the
IP address of the printer so that it is in the same range as the PC.
For example, if the PC’s IP address is [Link] change the
printers IP address to [Link].

(6) Make a note of the Host name and IP address.

(7) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
(8) Start the QuickStep software on the PC.
(9) Select the Lock icon.

(10) Select Unlock UI settings.

(11) Enter the UI password (Default password: QS).
(12) Select the green Tick icon.
(13) Select OK.
(14) Select the UI Settings icon.
(15) Select the Connection Method drop down setting and select one of the options described
below:

Connection Method Explanation

Broadcast Automatically search and display a list of the printers available on

the network.
Favourite Create a list of favourite printers if there are multiple printers
available on the network.
Direct Connect to a single printer on the network.

EPT026795 Issue 17 June 2020 4-65

INSTALLATION

(16) If the Broadcast connection method is used, proceed to step (20). If the Favourite
connection method is used, select Add favourite... If the Direct connection method is used,
select Add direct...
(17) Enter the following information:

Setting Name Explanation

Name Enter the name of the printer.

Type Select the type of printer which the QuickStep emulator is
connecting to. For an Ax-Series printer, select CIJ.
IP address Enter the IP address of the printer.
Host Enter the host name.

(18) Select the green Tick icon.

(19) Details of the printer will now appear on the screen.
(20) Select the Network icon in the bottom left corner of the PC’s QuickStep programme.

(21) Select Connect to connect to a printer.

End of procedure.

4-66 EPT026795 Issue 17 June 2020

INSTALLATION

PC Web Browser to Networked Printer Setup

If the webserver is enabled in the printer’s settings, the printer can be controlled from a desktop
PC or a laptop using a standard web browser.
Enable Webserver
To enable the webserver in the printer’s settings:
(1) Connect a TouchScreen to the printer and select Home > Setup > Printer network.
(2) Tick the Enable WebServer tickbox.
(3) Make a note of the printer’s IP address.
(4) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.
Control the Printer from a PC
To control the printer using a PC based web browser:
(1) Connect the PC to the printer directly via the Ethernet port on the rear of the printer cabinet.
Or ensure that the PC and Printer are both setup and connected to the same network, see
page 4-27.
(2) Power on the printer and start the PC.
(3) Open a web browser on the PC.
(4) Enter “[Link] address of the printer]” in the address bar of the web browser.
End of procedure.

EPT026795 Issue 17 June 2020 4-67

INSTALLATION

TouchScreen to Networked Printers

One TouchScreen can control multiple printers in the same network if required. However, the
TouchScreen can only connect to 1 printer at a time.
Create a List of Favourite Printers
It is recommended to create a list of favourite printers in the TouchScreen if there is more than 1
printer on the same network which the TouchScreen can connect to.
To create a favourite list of the printers:
(1) Select the Lock icon on the bottom right corner of the TouchScreen screen.

(2) Select Disconnect from printer.

(3) Select the Lock icon on the bottom right corner of the TouchScreen screen.
(4) Select Unlock UI settings.
(5) Enter the UI password (Default password: QS).
(6) Select the green Tick icon.
(7) Select OK.
(8) Select UI Settings.
(9) Select the Connection Method drop down setting and select Favourite.
(10) Select Add favourite.
(11) Enter the following information:

Setting Name Explanation

Favourite name Enter the name of the printer. This name will be used to identify
the printer in the favourites list.
Type Select the type of printer which the TouchScreen is connecting to.
For an Ax-Series printer, select CIJ.
Enter IP Select either:
Manually - To manually enter the printer’s IP Address.
Via broadcast - To search the network for the printer’s IP address.
IP address Enter the IP address of the printer.

(12) Select Save.

4-68 EPT026795 Issue 17 June 2020

INSTALLATION

(13) The printer’s name will now appear on the user interface. The table below explains the next
three options:

Next Option Explanation

Delete the printer

Select the icon to delete the printer from the favourites list.

Add another printer. Select Add favourite to add another printer to the favourites list.
Connect to a printer.
Select the icon in the bottom left of the TouchScreen screen
to view the favourites list and connect to a printer.

End of procedure.
Connect to a Different Printer in the Network
Details about the printer being controlled can be viewed by selecting Home > Setup > System
Information.
If a favourite list of printers has been set up, follow the procedure below to connect the
TouchScreen to a different printer in the network.
(1) Select the Lock button.
(2) Select Disconnect from printer.
(3) Select the required printer.
End of procedure.

EPT026795 Issue 17 June 2020 4-69

INSTALLATION

COMMUNICATION PROTOCOL SETUP

Note: The protocol setting drop down on the protocol settings screen will only change the
settings that are displayed on this screen. This drop down setting does not enable or
disable any communication protocols.

Protocol Settings Screen

Codenet Protocol Setup

Codenet is a communication protocol that can be used by external equipment to send commands
to the printer. Codenet commands can be sent to the printer via RS232 or Ethernet.
RS232
To setup and enable the Codenet communication via RS232:
(1) On the TouchScreen, select Home > Setup > Printer network > Protocol settings.
(2) Select the Protocol Setting drop down setting and select Codenet.
(3) Un-tick the Protocol enabled tick box.
(4) Select the Protocol Mode drop down setting and select Serial.
(5) Select the Serial Com drop down setting and select either:
• COM1 - For communication via the RS232 Pack’s RS232 Socket (if fitted).
• COM2 - For communication via the Extended IO Pack’s 37-Way Socket (if fitted).
(6) Select Advanced.

4-70 EPT026795 Issue 17 June 2020

INSTALLATION

(7) The settings described in the table below can be set using the drop down boxes.

Table 9: Advanced Settings

Setting Name Description

Baud rate Select the baud rate between the printer and the device the printer is
connected to.
Range: 1200-115200
Default setting: 9600
Data bits Select the number of data bits in each character.
Default setting: 8
Parity Select the type of parity bit that will be expected. A parity bit is an extra
data bit that will be sent with each data character to detect errors in the
RS232 transmission.
Default setting: No parity

No parity - No parity bit will be expected.

Odd - An odd parity bit will be expected.
Even - An even parity bit will be expected.
Mark - The parity bit will always be 1 but will not be used.
Space - The parity bit will always be 0 but will not be used.
Stop bits Select the number of stop bits that will be sent at the end of each
character to enable the detection of the end of the character.
Default setting: 1
Flow control Select the type of handshake signal that will be used to pause and
resume the transmission of data.
Default setting: None

(8) Select Save.

EPT026795 Issue 17 June 2020 4-71

INSTALLATION

(9) Codenet protocol settings described in the table below can now be defined. After the
settings have been defined tick the Protocol Enabled tick box.

Table 10: Protocol Settings

Setting Name Description

Response length Define the length of the response data package:

Variable - The positive acknowledgment (ACK) is one byte and the

negative acknowledgement (NAK) is four bytes.

Fixed - Both the positive (ACK) and negative (NAK) acknowledgements

are four bytes.
Send response Define when a response to a data packet is sent from the printer.

On Processed - A positive (ACK) or negative (NAK) acknowledgement

will be sent after the printer has processed the data packet.

On Received - A positive acknowledgement (ACK) will be sent as soon

as the printer receives the data packet. Note: the data has not yet been
validated as correct.
LED state This setting allows the LEDs on the printer cabinet to mimic the
behaviour of other printer types. This is useful if an Ax-Series printer is
used to replace another printer type.

Standard - The LEDs on the printer cabinet will mimic the behaviour of
A-Series i-Tech and A-Series plus printers.

Green + Flash - The LEDs on the printer cabinet will mimic the
behaviour of an A-Series classic printer.
Printer ID This setting allows the printer to respond using the ID of other printer
types. This is useful if an Ax-Series is used to replace another printer
type as the controller may be expecting a different response signal.

00 = Codebox
01 = Solo
02 = Solo Twin Head
03 = A300
04-19 = Not Allocated
20 = Macrojet
21 = Casecoder
22 = A-Series plus A100
23 = A-Series plus A300
24 = A-Series plus Duo
25-29 = Not Allocated
30 = Ax-Series
31 - 99 = Not Allocated
Label format Select which label format/raster will be used when a data packet
containing a label design is sent to the printer.

4-72 EPT026795 Issue 17 June 2020

INSTALLATION

Table 10: Protocol Settings

Setting Name Description

Backward This tick box currently has no function. It may be removed in a later
compatible software update.

(10) Tick the Protocol enabled tick box.

(11) To save the new printer settings, select Home > Setup > Production line setup > Power
options > Restart and wait for the printer to restart.
End of procedure
Ethernet
To setup and enable the Codenet communication via Ethernet:
(1) On the TouchScreen, select Home > Setup > Printer network > Protocol settings.
(2) Select the Protocol Setting drop down setting and select Codenet.
(3) Un-tick the Protocol enabled tick box.
(4) Select the Protocol Mode drop down setting and select TCP.
(5) Codenet protocol settings described in the table below can now be defined. After the
settings have been defined tick the Protocol Enabled tick box.

Table 11: Protocol Settings

Setting Name Description

TCP Port Define the port that will be used for codenet communication.
Default setting: 7000
Response length Define the length of the response data package:

Variable - The positive acknowledgment (ACK) is one byte and the

negative acknowledgement (NAK) is four bytes.

Fixed - Both the positive (ACK) and negative (NAK) acknowledgements

are four bytes.
Send response Define when a response to a data packet is sent from the printer.

On Processed - A positive (ACK) or negative (NAK) acknowledgement

will be sent after the printer has processed the data packet.

On Received - A positive acknowledgement (ACK) will be sent as soon

as the printer receives the data packet. Note: the data has not yet been
validated as correct.

EPT026795 Issue 17 June 2020 4-73

INSTALLATION

Table 11: Protocol Settings

Setting Name Description

LED state This setting allows the LEDs on the printer cabinet to mimic the
behaviour of other printer types. This is useful if an Ax-Series printer is
used to replace another printer type.

Standard - The LEDs on the printer cabinet will mimic the behaviour of
A-Series i-Tech and A-Series plus printers.

00 = Codebox
01 = Solo
02 = Solo Twin Head
03 = A300
04-19 = Not Allocated
20 = Macrojet
21 = Casecoder
22 = A-Series plus A100
23 = A-Series plus A300
24 = A-Series plus Duo
25-29 = Not Allocated
30 = Ax-Series
31 - 99 = Not Allocated
Label format Select which label format/raster will most likely be used when a data
packet containing a label design is sent to the printer.
Backward This tick box currently has no function. It may be removed in a later
compatible software update.

(6) Tick the Protocol enabled tick box.

(7) To save the new printer settings, select Home > Setup > Production line setup > Power
options > Restart and wait for the printer to restart.
End of procedure

4-74 EPT026795 Issue 17 June 2020

INSTALLATION

EDC Setup
EDC (external data capture) enables pre-defined parts of a label to be populated with data sent
from an external source. External data is stored in a buffer queue in the printer in advance of
printing.
RS232
To setup and enable EDC protocol via RS232:
(1) On the TouchScreen, select Home > Setup > Printer network > Protocol settings.
(2) Select the Protocol Setting drop down setting and select EDC Serial.
(3) Un-tick the Protocol enabled tick box.
(4) Select the Serial Com drop down setting and select either:
• COM1 - For communication via the RS232 Pack’s RS232 Socket (if fitted).
• COM2 - For communication via the Extended IO Pack’s 37-Way Socket (if fitted).
(5) Select Advanced.
(6) The settings described in the table below can be set using the drop down boxes.

Table 12: Advanced Settings

Setting Name Description

No parity - No parity bit will be expected.

(7) Select Save.

EPT026795 Issue 17 June 2020 4-75

INSTALLATION

(8) EDC settings described in the table below can now be defined. After these settings have
been defined, tick the Protocol Enabled tick box.

Table 13: EDC Settings

Setting Name Description

Encoding Set the data packet encoding method:

• ASCII
• UTF-8
• Unicode(BE)
• Unicode(LE)
Start marker Define the start marker that is used to mark the start of printable items
in the data packet.

Default setting: <STX>

End marker Define the end marker that is used to mark the end of printable items in
the data packet.

Default setting: <ETX>

Packet length If “Data packet type” is set to “Use specific length” this setting defines
the length of printable items in the data packet that the printer will look
for. The length is defined in bytes.
Data packet type Set if the start and end of items in the data packet will be marked with
start and end markers. Or, set if the printer will look for items of a
specific length.
Ack type Set the acknowledgement type:
• None - No acknowledgement will be sent.
• Default - The letters ACK (41 43 4B) will be sent.
RegExpression - A user defined acknowledgement will be sent (This
feature will be enabled in a later software update).
• DefaulSpecialChars - ACK (06) will be sent.
• BufferDepth - The number of items in the data buffer will be sent.
Ack/Nack buffer Select if an acknowledgment (ACK) or negative acknowledgement
depth (NAK) will be sent when the data buffer is full or empty.
Ack/Nack buffer Select the format of the returning ACK or NAK when the data buffer is
format full or empty.
• Text
• 1 byte
• 2 bytes (BE)
• 2 bytes (LE)

4-76 EPT026795 Issue 17 June 2020

INSTALLATION

Table 13: EDC Settings

Setting Name Description

Ack schedule Select when an acknowledgement is sent after a data packet has been
received:
• Immediately - The acknowledgment will be sent immediately after
the packet has been received.
• AfterParsing - The acknowledgment will be sent after the data has
been checked and verified as ok.
Ack regular Define a custom acknowledgment if “Ack type” is set to
expression filter “RegExpression”.
(This feature will be enabled in a later software update).
Ack regular Define a custom acknowledgment if “Ack type” is set to
expression format “RegExpression”.
(This feature will be enabled in a later software update).
Nack regular Define a custom negative acknowledgment if “Ack type” is set to
expression filter “RegExpression”.
(This feature will be enabled in a later software update).
Nack regular Define a custom negative acknowledgment if “Ack type” is set to
expression format “RegExpression”.
(This feature will be enabled in a later software update).
Data regular Define characters in the data packet that identify data for batch printing.
expression Default setting: , *
(This feature will be enabled in a later software update).
Persistence enabled Tick to repeatedly print data marked with a data regular expression
character.
Further notes about this setting are described on page 4-84.
History checked Check to see if the data has already been printed. The data can only be
checked against the last 1000 prints.
Maximum queue Define the maximum number of items that the data queue can store.
size
Expiry entries Delete items from the data queue if they have not been printed after the
enabled time specified in the “Expiry entries lifetime (s)” setting.
This setting is useful in the alcohol and tobacco industries. It can be
used to ensure tax codes are removed from the printer’s data queue if
they have not been printed after a specified time.
Expiry entries If “Expiry entries enabled” is enabled, define the time in seconds that
lifetime (s) EDC data can stay in the queue before it is deleted.

EPT026795 Issue 17 June 2020 4-77

INSTALLATION

Table 13: EDC Settings

Setting Name Description

Store ID enabled Tick the “Store ID enabled” box to enable the return of data packet IDs
that are in the buffer when the list of expired entries is queried.
The data packet IDs are returned, instead of the data so that space and
time are optimised.
(This feature will be enabled in a later software update).
Exp. entries report If “Store ID enabled” is enabled, define the format of the expired entries
format report.
(This feature will be enabled in a later software update).
Expired ID length If “Store ID enabled” is enabled, define the length of the data packet
identifier, maximum 10 characters. The identifier will be part of the data
packet (the total length of the EDC packet will be the ID length + Data
length).
(This feature will be enabled in a later software update).
Buffer low level Set the buffer low level value. When the number of EDC packets in the
buffer drops below this value an action defined by the “Buffer low level
action” setting will occur.
Buffer low level Choose the action that will occur when the number of EDC packets in
action the buffer drops below the “Buffer low level” value.
• None - No action will occur.
• Send message - A message written by the user will be sent.
• Pulse GPO - An output pin on the user port will be pulsed (This
feature is not currently enabled).
Buffer low level If the “Buffer low level action” setting is set to “Send message”. Define
message the message that will be shown when buffer drops below the “Buffer
low level” value.
Buffer high level Set the buffer high level value. When the number of data packets in the
buffer goes above this value an action defined by the “Buffer high level
action” setting will occur.
Buffer high level Choose the action when the number of data packets in the buffer goes
action above the “Buffer high level” value.
• None - No action will occur.
• Send message - A message written by the user will be sent.
• Pulse GPO - An output pin on the user port will be pulsed (This
feature is not currently enabled).
Buffer high level If the “Buffer high level action” setting is set to “Send message”. Define
message the message that will be shown when buffer goes above the “Buffer
high level” value.

4-78 EPT026795 Issue 17 June 2020

INSTALLATION

Table 13: EDC Settings

Setting Name Description

Buffer empty Choose the action when there is no data in the EDC buffer, but the label
behaviour requires data.
• Blank EDC element - The label will be printed, but the external data
element will not be printed.
• Blank label - The label will not be printed.
• Default EDC element - The external data element’s default value
will be printed.
Buffer overwrite Tick to enable data in the buffer to be overwritten.
This setting may be useful, if each product is printed with unique data
but a product has been removed from the production line. This setting
will allow the data buffer to be updated to make sure the correct data is
printed on the correct product. A longer example is described on
page 4-84.

(9) Tick the Protocol enabled tick box.

(10) To save the new settings, select Home > Setup > Production line setup > Power options >
Restart and wait for the printer to restart.
End of procedure

EPT026795 Issue 17 June 2020 4-79

INSTALLATION

Ethernet
To setup and enable EDC via Ethernet:
(1) On the TouchScreen, select Home > Setup > Printer network > Protocol settings.
(2) Select the Protocol Setting drop down setting and select EDC TCP.
(3) Un-tick the Protocol enabled tick box.
(4) EDC settings described in the table below can now be defined. After the settings have been
defined tick the Protocol Enabled tick box.

Table 14: EDC Settings

Setting Name Description

TCP Port Define the port that will be used for communication.
Default setting: 16000
Encoding Set the data packet encoding method:
• ASCII
• UTF-8
• Unicode(BE)
• Unicode(LE)
Start marker Define the start marker that is used to mark the start of printable items
in the data packet.

Default setting: <STX>

End marker Define the end marker that is used to mark the end of printable items in
the data packet.

Default setting: <ETX>

(5) Tick the Protocol enabled tick box.

Enable/Disable Essential Security

When essential security mode is active, only users with a valid password will be able to operate
the printer through the user interface.
Notes: (1) You will be immediately logged out of the printer when the security mode is enabled.
Make sure you have a valid password to log into the printer before enabling essential
security mode.
(2) Either a logged in admin level user, or an engineer with an engineer’s USB key can
disable essential security.
To enable/disable essential security mode:
(1) Select Home > Setup > Security.
(2) Select the Security mode drop down setting.
(3) Select Essential or Off.
End of procedure.

Log In
To log in:
(1) Select the Padlock icon in the bottom right corner of the user interface.
(2) Select Log in.
(3) Enter the password for the required user group. The default password for each user group is
defined in the table below:
Note: Passwords are case sensitive.

User Group Password Explanation

operator op Operator access to the basic settings required for

printer operation, including:
• Start/Stop printing.
• Print optimisation.
• Label select.
• Acknowledge alerts.
• Change printer state.
admin admin Administrator access to all printer settings.

End of procedure.

4-86 EPT026795 Issue 17 June 2020

INSTALLATION

Log Out
To log out:
(1) Select the Padlock icon in the bottom right corner of the user interface.
(2) Select Log out.
End of procedure.

EPT026795 Issue 17 June 2020 4-87

INSTALLATION

Enable Auto Log-in

To enable auto log-in:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security.
(3) Tick the Enable auto log-in tick box.
(4) Select the Auto login user drop down setting.
(5) Select the user that will automatically be logged in when the printer is turned on.
End of procedure.

Disable Auto Log-in

To disable auto log-in:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security.
(3) Untick the Enable auto log-in tick box.
End of procedure.

Change User Password

To change a user password:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security > Users.
(3) Select a user.
(4) Select Change password.
(5) Enter the following information:

Setting Name Explanation

Current password Note: Required to change admin password only.

Enter the current user password.
New password Enter the new password.
Retype password Retype the new password.

(6) Select Save.

End of procedure.

4-88 EPT026795 Issue 17 June 2020

INSTALLATION

TRAVERSER SETUP
Instructions for traverser installation and operation are supplied by the manufacturer of the
traverser unit. This section of the Ax-Series Engineer’s Reference Guide is intended to provide
further information about integrating an Ax-Series printer with a traverser unit.

Description
In a standard traverser installation, the traverser moves the print head on a linear slide to print
onto a temporarily stationary print surface. The printer normally receives print trigger signals and
encoder information from the traverser as it carries the print head across the print surface.

Modes of Operation
Traversers can operate in one of 4 different modes as described in the table below:

Mode Description

Traverser (Print FROM Home) Printing will occur as the print head is moved across a
stationary print surface from the traverser’s Home position.
On completion of the print, the print head will return to the
Home position.
Traverser (Print TO Home) Printing will occur as the print head is moved across a
stationary print surface towards the traverser’s Home
position. On completion of the print, the traverser will return
the print head to the Start position.
Traverser (Print BOTH Ways) Printing will occur as the print head is moved across a
stationary print surface from the traverser’s Home position.
The print head will also print as it moves back across a
stationary print surface towards the traverser’s Home
position.
Lane Changer Note: Typically used on an extrusion line where
multiple extrusions are produced parallel to each
other.
The print head is stationary as it prints on a moving print
surface. When the label is complete the traverser will move
the print head to another lane where it will print onto another
moving print surface.

EPT026795 Issue 17 June 2020 4-89

INSTALLATION

Setup
Product Detect Sensor/Shaft Encoder PNP/NPN Settings
To set the product detect/shaft encoder switches:
(1) Remove the product detect/shaft encoder switches cover.

Ax150i Ax350i/Ax550i

(2) Set the switches as illustrated below:

PD Switches: PNP (Up Position)

SE A Switches: NPN (Down Position)

(3) Replace the product detect/shaft encoder switches cover.

End of procedure.

4-90 EPT026795 Issue 17 June 2020

INSTALLATION

Print Reverse Input Signal Setup

Scottish Robotics Traverser’s can produce a “print reverse” signal to inform the printer which
direction the print head/traverser is moving. The print reverse signal allows the printer to print in
both directions.
To use this signal, the print reverse cable must be connected to one of the printer’s input pins,
either on one of the Extended GPIO Sockets or on the GPIO Socket. The jumpers on the input
PCB must be set to PNP and the printer’s software must also be setup.
PNP Print Reverse Input Setup (GPIO PCB)
WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Follow electrostatic discharge precautions when accessing the printer’s
electronics compartment. Wear an ESD wristband attached to ground. Avoid
wearing clothing which can build up electrostatic voltages.

Required tools: T10 torx driver.

To move the jumpers on the GPIO PCB to set inputs to PNP:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear electronics panel.
(4) Lower the rear electronics panel.
(5) Move the jumper on LK2 to PNP.

(6) Replace the printer’s rear electronics panel.

(7) Connect the power lead to the rear of the printer.
(8) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

EPT026795 Issue 17 June 2020 4-91

INSTALLATION

PNP Print Reverse Input Setup (Extended IO PCB)

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver.

To move the jumpers on the Extended IO PCB to set inputs to PNP:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear electronics panel.
(4) Lower the rear electronics panel.
(5) Move the jumper on LK6 to PNP.

(6) Replace the printer’s rear electronics panel.

(7) Connect the power lead to the rear of the printer.
(8) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

4-92 EPT026795 Issue 17 June 2020

INSTALLATION

Print Reverse Input Assignment

Note: Frequent navigation and configuration of the I/O settings can cause excessive memory
use. It is recommended to re-boot the printer after the I/O settings have been
configured.
To assign an input pin to print reverse:
(1) Select Home > Setup > I/O Port > Assignment.
(2) Select the Function drop down setting for the pin that the print reverse signal is connected
to and select Print Reversed.
(3) Select the Active level drop down setting for the pin that the print reverse signal is
connected to and select Low.
End of procedure.
Traverser/Print Surface Speed
It is recommended to use a quadrature shaft encoder for traverser applications. If a single ended
shaft encoder is used, there is data in the print queue and the print head stops at the exact point
that a shaft encoder signal is generated, false movement information will be sent to the printer.
This will cause any labels in the print queue to be printed unintentionally. A quadrature shaft
encoder, produces two output signals, output A and B. The signals are generated at different
points of the shaft encoder’s rotation. If the printer does not receive one signal after the other, the
printer will detect that there is not really any movement.
If the traverser/print surface speed doesn’t vary, an internal encoder can be setup according to
the procedure on page 4-40.
If the traverser/print surface speed does or can vary, an external quadrature shaft encoder can be
setup according to the procedure on page 4-45.
If a quadrature shaft encoder is not available, setup a single ended shaft encoder according to the
procedure on page 4-42. The Encoder persistence (ms) value can be increased, to reduce but not
completely eliminate the risk of detecting movement when the encoder stops at the point that a
signal is generated.

EPT026795 Issue 17 June 2020 4-93

INSTALLATION

Print Trigger
The recommended print trigger settings depend on the type of label data that will be printed and
if the distance between the lanes is evenly spaced.
Four different print trigger scenarios are described in the illustrations below. Table 15 contains a
key to the illustrations.
Note: If the alert “Print trigger occurred whilst printing” is displayed and there are missing
prints, it is recommended to print 1 large label that covers all lanes, as described in
Print Trigger Scenario 4.

Table 15: Key

Symbol Description Symbol Description

L1 = Label 1 L1 = Label 1
F = Direction Forward F = Direction Forward
Rp0 = Repeat Print 0 Rp0 = Repeat Print 0
T1 = Text Element 1
T2 = Text Element 2
Print Trigger Repeat Pitch

Traverser Direction Traverser Velocity

Print Trigger Scenario 1 The illustration below shows a print trigger provided for each label on
each lane. Each label is printed onto a different lane.

Print Trigger Scenario 1

4-94 EPT026795 Issue 17 June 2020

INSTALLATION

Print Trigger Scenario 2 The illustration below shows a single print trigger provided for the first
label. The label is then repeated on the next 3 lanes.
Note: This setup is not recommended if the space between each lane varies. It is not
possible to set different repeat pitch values. Instead, use a large label to print across
the lanes as shown in scenario 3 and 4.

Traverser Print Trigger Scenario 2

Print Trigger Scenario 3 The illustration below shows a print trigger provided for each label.
The labels have been designed so that one label is large enough to print across 2 lanes.

Traverser Print Trigger Scenario 3

EPT026795 Issue 17 June 2020 4-95

INSTALLATION

Print Trigger Scenario 4 The illustration below shows a print trigger provided for 1 label. The
label has been designed so it is large enough to print across all lanes.

Traverser Print Trigger Scenario 4

4-96 EPT026795 Issue 17 June 2020

INSTALLATION

EPT026795 Issue 17 June 2020 4-97

INSTALLATION

THIS PAGE INTENTIONALLY LEFT BLANK

4-98 EPT026795 Issue 17 June 2020

PART 5 : OPERATION

5-4 EPT026795 Issue 17 June 2020

OPERATION

QUICKSTEP INTERFACE
Home Screen
When starting the printer, the following Home Screen is displayed.

Start Stop
Information Bar Status Tab Information Bar

Label
Finder

Label
Creator

Lock

Home Printer Print Label Name Setup Time / Date

Name Optimisation

QuickStep Home Screen

EPT026795 Issue 17 June 2020 5-5

OPERATION

Setting Name Explanation

Start Select Start to sequence the ink jet on and enter the Ready state.
When the printer is in the Ready state, the ink jet will be running
and the printer will print when it receives the correct print trigger
and encoder signals.
Stop Sequence the printer to one of the following states:

Sequence off - The ink jet will stop running. The print head will be
flushed to prevent ink from drying and blocking the nozzle or
gutter. The printer will turn off.

Pause printing - The ink jet will continue running. Printing will be
paused. Power to the deflector plates will be stopped.

Fast shutdown - The printer will skip the flush sequence and
quickly turn off. Turn the printer back on as soon as possible to
prevent ink from drying and blocking the nozzle or gutter.

Jet running - The ink jet will continue running. Printing will be
paused. There will be no phasing or power to the deflector plates.

Phase locked - The ink jet will continue running. Printing will be
paused. Modulation and charging will be present, but no power to
the deflector plates.
Information Bar Displays printer information.
See “Information Screens” on page 5-15.
Status Tab Displays printer status and alerts. If more than one alert is present,
the highest priority alert is displayed.
If an alert is displayed, select the Status Tab to show more
information and to clear the alert.
See “STATUSES, ALERTS AND FAULT FINDING” on page 11-1.
Label Finder Find a saved label from the printer’s label store to preview, print or
edit.
Label Creator Open the Label Creator to create a new label.
Lock Log the user out from the printer.
Disconnect the TouchScreen from the printer.
Change the user’s password.
Lock the screen to prevent accidental changes.
Date / Time Displays the current system date / time.
Setup Open the Setup screen.
See “Setup Screen” on page 5-9.
Production Line Setup Open the Production Line Setup screen.
See “Production Line Setup Screen” on page 5-10.
Print Optimisation Open the Print Optimisation screen.
See “Print Optimisation Screen” on page 5-11.

5-6 EPT026795 Issue 17 June 2020

OPERATION

Setting Name Explanation

Label Name Displays the name of the label which is currently loaded.
Printer Name Displays the name of the printer that the user interface is
connected to.
The name can be changed by selecting Home > Setup > System
information and changing the Printer name setting.
Home Press the Home Button at any time to return to this Home Screen.

EPT026795 Issue 17 June 2020 5-7

OPERATION

Currently Printing Label View

The currently printing label can be displayed on the printer’s Home screen.
Select the background area of the Home screen to access this view.
The illustration below shows an example of the currently printing label view.

Current Printing Label View

5-8 EPT026795 Issue 17 June 2020

OPERATION

Setup Screen
The Setup screen contains advanced printer settings, diagnostic tools and wizards.
This screen is accessed by selecting Setup on the Home screen.
The following illustration shows the Setup screen.

Setup Screen

EPT026795 Issue 17 June 2020 5-9

OPERATION

Production Line Setup Screen

The Production Line Setup screen contains print trigger, encoder and power settings which
should be configured during printer installation. See “Production Line Setup” on page 4-39.
This screen is accessed by selecting Production Line Setup on the Home screen.
The following illustration shows the Production Line Setup screen.

Production Line Setup Screen

5-10 EPT026795 Issue 17 June 2020

OPERATION

Print Optimisation Screen

The Print Optimisation screen contains settings which are used to make everyday adjustments to
label appearance.
This screen is accessed by selecting Print Optimisation on the Home Screen.
The following illustration shows the Print Optimisation screen.

Invert Reverse

Print height
Print Delay (%)
(mm)

Jet Gap
(mm)
Stroke Pitch
(mm/stroke)

Print Optimisation Screen

Setting Name Explanation

Invert Note: Not available if the Continuous Printing Pack is

installed.
Invert the label.

Print Delay (mm) Note: Not available if the Continuous Printing Pack is
installed.
Set the delay between a product sensor detecting a product and
the label being printed.
Stroke Pitch (mm/stroke) Adjust the width of the label by increasing or decreasing the
distance between the lines of ink drops that make up each printed
character. The default value is 0.43.

EPT026795 Issue 17 June 2020 5-11

OPERATION

Setting Name Explanation

Reverse Note: Not available if the Continuous Printing Pack is

installed.
Reverse the label.

Print Height (%) Notes: (1) Jet 1 and Jet 2 settings are available for the Duo Print
Head only.
(2) Adjustment of this setting on a printer equipped with
an i-Pulse Duo Print Head will change the accuracy of
the Jet Gap (mm) setting.
Adjust the print height percentage.

Jet Gap (mm) Notes: (1) For i-Pulse Duo Print Head only.
(2) If the Print Height (%) is also adjusted, the accuracy of
the Jet Gap value will be effected.
Adjust the vertical gap between the two ink jet printing areas.

5-12 EPT026795 Issue 17 June 2020

OPERATION

Label Creator Screen

The Label Creator screen is used in label creation and label editing.
The following illustration shows the label creator screen.
Label Zoom Options

Label View Max print speed Save/Save as/Print

Element
Moving
Options
Undo/
Redo
Label Canvas
Area Side
Menu

Label Creator Screen

Setting Name Explanation

Label View Options The Label Creator contains three different viewing options:
• Standard - View, add and edit label elements.
• Segment - View, add and edit label segments (Professional
printing pack and 10" TouchScreen only).
• Preview - Preview how the label will look when printed.
Label Zoom Options Zoom in and out of the label design, or fit the label design to the
canvas area.
Max print speed Displays the maximum print speed of the current label design.
Save/Save As/Print Save the label design or send it to print.
Side Menu The Side Menu contains two tabs:
• Element - Add and edit label elements such as text, barcode
and graphics.
• Label - Edit the label layout. Edit label print settings such as
the label offset and label repeat. Manage label elements by
locking them.

EPT026795 Issue 17 June 2020 5-13

OPERATION

Setting Name Explanation

Element Moving Options Choose to move elements in the label design area by dragging
them. Or, choose to display arrow buttons to move elements more
precisely.
Undo/Redo Undo or redo the previous action.

5-14 EPT026795 Issue 17 June 2020

OPERATION

Information Screens
The Information Screens display detailed live information about the printer’s performance.
To open the Information Screens:
(1) Press the icon on the Information Bar.
(2) Swipe the screen left, or right to go to the next or previous screen.
(3) Press the icon to close the Information Screen.
Note: The Information Bar on the Home Screen will display summarised information from the
Information Screen which was closed.
The following Information Screens are available:
• Connection and Consumable, see page 5-16.
• Overall Equipment Efficiency, see page 5-18.
• Live Status, see page 5-20.

EPT026795 Issue 17 June 2020 5-15

OPERATION

Connections and Consumables Screen

The following illustration shows the Connections and Consumables screen.
Connection and Next Screen
Jet Information

Consumable
Details

Ink
Level

Make-up
Level

Information
Bar

Connection and Consumable Screen

Setting Name Explanation

Next Screen Proceed to the Overall equipment efficiency screen.

Consumable Details View details about the printer’s consumable items:
• Ink type that the printer is configured for and ink cartridge
expiry date.
• Make-up type that the printer is configured for and make-up
cartridge expiry date.
• ITM type that the printer is configured for and ITM expiry
date. For an ITM type 6, expiry is the number of remaining run
time hours, or a date (depending on the ITM’s state).
Connection and Shows connection and jet information about the printer:
Consumable Information • Jet running/stopped.
• USB device connected.
• Service key connected.
• Multiple network connected.

5-16 EPT026795 Issue 17 June 2020

OPERATION

Setting Name Explanation

Ink Level Shows the fluid level in the ink cartridge and ITM.

When the indicator is in the green area, no user action is required.

The indicator moves to amber when the ink cartridge is empty and
the printer is using only the fluid in the ITM.
Make-up Level Shows the fluid level in the make-up cartridge and MUM.

When the indicator is in the green area, no user action is required.

The indicator moves to amber when the make-up cartridge is

empty and the printer is using only the fluid in the MUM.
Information Bar Shows status icons which will be displayed on the Home Screen
when the Connections and Consumables screen is closed.

EPT026795 Issue 17 June 2020 5-17

OPERATION

Overall Equipment Efficiency Screen

The overall equipment efficiency screen (OEE) enables the user to monitor progress against user
set targets.
Printer efficiency information is displayed on the screen including the elapsed time of the current
print job, the estimated end of job time and the printer’s operational availability. The screen also
displays an estimate of when the next operator interaction is required and what the interaction will
be.
The following illustration shows the OEE screen.
Efficiency Data
Previous Print Next
Screen Rates Screen

Set
Targets
Settings

Next
Operator
Interaction

Information
Bar

Print and Apply Counts

Overall Equipment Efficiency Screen

Setting Name Explanation

Next Screen Proceed to the Live status screen.

Previous Screen Go back to the Connections and consumables screen.
Set Targets Set print rate and print count targets.
Settings Choose when to reset the OEE targets.
Print Rates Shows the targeted number of prints per minute against the
current number of prints per minute.

5-18 EPT026795 Issue 17 June 2020

OPERATION

Setting Name Explanation

Next Operator Interaction Shows the estimated time of future operator interactions.
Efficiency Data Printer efficiency data including elapsed time, estimated time to
end of job etc.
Print and Apply Counts The targeted number of prints shown against the actual number of
prints.
Information Bar Shows status icons which will be displayed on the Home Screen
when the Overall Equipment Efficiency screen is closed.

OEE Target Setup

To set the OEE targets:
(1) Press the icon on the Information Bar.
(2) Swipe the screen to navigate to Overall equipment efficiency.
(3) Select Set targets.
(4) Enter the Target run rate (target print speed/number of prints per minute).
(5) Enter the Target total prints (target number of prints for the production run/print job).
(6) Select Close.
(7) Select the Settings icon:
(8) Choose when the OEE targets are reset:

Setting Name Explanation

Lifetime Do not reset.

Power on Reset when printer is powered on.
Label change Reset when a new label is loaded for printing.
Shift change Reset when the shift changes.
Daily Reset at the start of every new day.
Cartridge change Reset when an ink or make-up cartridge is changed.

(9) Select Close.

End of procedure.

EPT026795 Issue 17 June 2020 5-19

OPERATION

Live Status Screen

The following illustration shows the Live Status screen.
Previous
Screen

Live Status
Information

Information
Bar

Live Status Screen

Setting Name Explanation

Previous Screen Go back to the Overall equipment efficiency screen.

Live Status Information Displays live status information about the printer.
Information Bar Shows status icons which will be displayed on the Home Screen
when the Live Status screen is closed.

5-20 EPT026795 Issue 17 June 2020

OPERATION

START-UP
Start-up to the Ready State
When the printer is in the Ready state, the ink jet will be running and the printer will print when it
receives the correct print trigger and encoder signals.
To start-up the printer and enter the Ready state:
(1) Ensure the power connector at the rear of the printer is connected to a power source.
Note: The red status light on the standby button will illuminate to indicate that the printer is
connected to a power source.
(2) Press and hold the Start/Stop button on the printer cabinet for 2 seconds.
(3) The printer will now sequence on in the following order:
(a) The green indicator lights on the standby button and start/stop button will begin
flashing to indicate that the printer is starting up.
(b) The TouchScreen screen will display the QuickStep start-up progress bar.
(c) The red indicator light on the standby button will turn off.
(d) The status tab will display the printer status and any faults that require attention.
(e) The printer is now ready to print labels.
End of procedure.

Start-up to the Idle State

When the printer is in the Idle state, the ink jet will not be running and the printer will not print.
Changes can be made to printer settings and labels can be created or edited in the label creator.
To start-up the printer and enter the Idle state:
(1) Ensure the power connector at the rear of the printer is connected to a power source.
Note: The red status light on the standby button will illuminate to indicate that the printer is
connected to a power source.
(2) Press and hold the standby button on the printer cabinet for 2 seconds.
(3) The printer will now sequence on in the following order:
(a) The green indicator light on the standby button will begin flashing to indicate that the
printer is starting up.
(b) The TouchScreen screen will display the QuickStep start-up progress bar.
(c) The red indicator light on the standby button will turn off.
(d) The status tab will display the printer status and any faults that require attention.
(e) The printer is now ready to perform non-printing functions such as creating a label.
End of procedure.

EPT026795 Issue 17 June 2020 5-21

OPERATION

Switch Between Ready State and Idle State

To switch the printer between the Ready state and Idle state:
(1) Press the Start/Stop button .
(2) Depending on the current printer status, the printer will enter one of the following two states:
• From the Ready state, the printer will enter the Idle state.
• From the Idle state, the printer will enter the Ready state.
End of procedure.

5-22 EPT026795 Issue 17 June 2020

OPERATION

SHUT DOWN
Controlled Shut Down
CAUTION: Wake-up mode disabled if power supply is disconnected. Risk of ink degradation.
If the printer is disconnected from the power supply after it has shut down, the
printer’s wake-up mode will not work. If the printer is left without power for a long
time and wake-up mode is required the ink quality will degrade, see page 19-13.

To shut down the printer in a controlled manner:

(1) Press and hold the standby button for 2 seconds.
(2) The printer will now begin shutting down in the following sequence:
(a) A progress bar will be displayed on the TouchScreen screen.
(b) The green indicator light on the standby button will begin flashing.
(c) The print head will run an auto-flush cycle to prevent ink from drying and blocking inside
the ink jet nozzle and print head gutter.
(d) The printer will shut down.
(e) The red status light on the standby button will illuminate to indicate that the printer is
connected to a power source.
End of procedure.

Fast Shut Down

CAUTION: Flush sequence will not be carried out. Risk of damage to nozzle assembly and
gutter.
Do not perform fast shut down unless the software locks up, or there is an
emergency.
The printer will shut down immediately without completing a flush sequence. If the
printer is left for a long period of time, ink will dry and block the nozzle assembly
and gutter.
Restart the printer as soon as possible to prevent damage.

CAUTION: Wake-up mode disabled if power supply is disconnected. Risk of ink degradation.
If the printer is disconnected from the power supply after it has shut down, the
printer’s wake-up mode will not work. If the printer is left without power for a long
time and wake-up mode is required the ink quality will degrade, see page 19-13.

To perform a fast shut down:

(1) Press and hold the standby button for 10 seconds.
(2) The printer will shut down immediately. The red status light on the standby button will
illuminate to indicate that the printer is connected to a power source.
End of procedure.

EPT026795 Issue 17 June 2020 5-23

OPERATION

Long Shut Down

Less Than 14 Days
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Depending on the ink type and the environment that the printer will be stored in, it’s generally ok
to shut down and store the printer for up to 14 days by following the procedure below.
However, some heavier ink types may need to be flushed out of the printer sooner than 14 days
by an engineer certified by Domino. Also, if the printer will be stored in an environment outside of
the recommended storage environment for the ink type, the ink will need to be flushed out of the
printer by an engineer certified by Domino. This prevents ink from degrading in the printer’s ink
system and causing faults when the printer is re-started. Contact your local support office for
more information.
To shut down and store the printer for less than 14 days:
(1) Clean the print head by following the print head cleaning procedure.
(2) Press and hold the standby button for 2 seconds.
(3) Flush the gutter with the correct wash during the gutter clearing cycle to ensure the gutter is
completely clean.
(4) Remove any factory air supply.
(5) Cover the print head gutter with masking tape or similar.
End of procedure.
Longer Than 14 Days
If the printer is to be shut down for longer than 14 days, or stored in an environment that could
degrade the ink the ink must be flushed out of the printer to protect the ink system. Follow the
procedure described on page 16-64.

5-24 EPT026795 Issue 17 June 2020

OPERATION

CREATING AND EDITING A LABEL

Create a New Label
To create a new label:
(1) From the TouchScreen’s Home Screen, select Label creator.
(2) Select Blank.
(3) Select the Label name text box.
(4) Use the on screen keyboard to enter a name which the label design will be saved as.
(5) Select the green Tick icon.
(6) Select the Layout settings to configure the label layout as described in the table below:
Note: Printers equipped with an i-Pulse Duo print head have label layout settings for each ink
jet.

Setting Name Explanation

Number of lines Select the required number of lines, 1, 2, 3, 4 or 5.

Line height (drops) Select the required height for each line in ink drops.
Type Select the required label quality.
Use default height (%) Tick the tick box to use the default print height setting.

Untick the tick box to display the Height (%) setting.

Height (%) Note: This setting is only valid if the Use default height (%)
tick box is not ticked.
Set the print height percentage.
Use default stroke pitch Tick the tick box to use the default stroke pitch setting.

Untick the tick box to display the stroke pitch (mm/stroke) setting.
Stroke pitch (mm/stroke) Note: This setting is only valid if the Use default stroke pitch
tick box is not ticked.
Set the distance between print strokes. A stroke is the line of ink
drops which is used to make up each printed character.

(7) Select Create label.

End of procedure.

EPT026795 Issue 17 June 2020 5-25

OPERATION

Edit a Label Layout

To edit a label layout:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55.
(2) In the label creator’s side menu, select the Label tab.
(3) Select the Edit menu.
(4) The layout settings as described in the table below can now be edited.

Setting Name Explanation

Number of lines Select the required number of lines, 1, 2, 3, 4 or 5.

Line height (drops) Select the required height for each line in ink drops.
Type Select the required label quality.
Use default height (%) Tick the tick box to use the default print height setting.

Untick the tick box to display the Height (%) setting.

(5) Select the Save icon to save the label layout.

End of procedure.

5-26 EPT026795 Issue 17 June 2020

OPERATION

Label Settings
Each individual label design can be created and saved with its own custom print settings.
To edit the label’s print settings:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55.
(2) In the label creator’s side menu, select the Label tab.
(3) Select the Settings menu.
(4) The settings described in the table below can now be edited.

Setting Name Explanation

Forward and Reverse Adjust the position of the label on the print surface in millimetres,
offset see page 5-28.
Inverse mode Invert the label design, see page 5-29.

Reverse mode Reverse the label design, see page 5-30.

Repeat mode Set the label design to print repeatedly, see page 5-31.
Max. print speed Set the unit of measurement that the maximum print speed will be
displayed in.
Name Displays the name the label is saved as. This value cannot be
changed.
Shift code tables Create a shift code table that can be inserted into the label design,
page 5-33.
Script variables Edit variables in LUA script elements that have been inserted in
the label.
Note: LUA scripts can only be used if the printer has the
Professional Printing Pack or Continuous Printing Pack
installed.

(5) Select the Save icon to save the settings.

End of procedure.

EPT026795 Issue 17 June 2020 5-27

OPERATION

Forward and Reverse Offset

Forward offset is used to adjust the position of the label on the print surface. If the print head is on
a traversing line the Reverse offset can also be set.
Note: A global offset setting is also available to adjust the offset for all label designs, see
page 5-65.
Print Print
Trigger Trigger

Reverse Forward
Offset Offset

Print Delay Print Delay

Direction of print Direction of print

Print Offset Diagram

To adjust the offset for an individual label design:

(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55.
(2) In the label creator’s side menu, select the Label tab.
(3) Select the Settings menu.
(4) Adjust the Forward offset (mm) or Reverse offset (mm) setting.
(5) Select the Save icon to save the setting.

End of procedure.

5-28 EPT026795 Issue 17 June 2020

OPERATION

Invert Mode
Invert mode is used to invert an individual label design as shown in the illustration below.

This setting can also be used on a traversing line to invert the label design for a specified number
of times before inverting the label back. If the printer is fitted with a GPIO pack or extended IO
pack, this setting can be configured to invert the label when an assigned input pin is activated.
Notes: (1) A global invert setting is available to invert all label designs. However, the global
setting does not allow the number of inverted prints to be counted. Also, the global
setting does not allow inverted prints to be triggered by a user port, see page 5-71.
(2) If required, the label can also be inverted on the Print optimisation screen, see
page 5-11.
To setup invert mode for an individual label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55.
(2) In the label creator’s side menu, select the Label tab.
(3) Select the Settings menu.
(4) Select the Invert mode drop down setting.
(5) Select and configure one of the options described in the table below:

Setting Name Explanation

On - Always The label design will be inverted at all times.

On - Counted The label design will be inverted for a specified number of prints.
When this option is selected, the settings described below will
also be displayed:

Invert: Initial orientation - Select the orientation of the first label

print.

Invert repeat count - Select the number of times the label will be
printed in an inverted orientation.
On - GPI / User port The label design will be inverted when an assigned input pin is
activated.
This setting can only be used if the printer is equipped with a
GPIO Pack (see page 7-42) or Extended IO Pack (see page 7-54).
To assign an input pin this function, see page 7-67.
Off The label design will not be inverted.

(6) Select the Save icon to save the setting.

End of procedure.

EPT026795 Issue 17 June 2020 5-29

OPERATION

Reverse Mode
Reverse mode is used to reverse an individual label design as shown in the illustration below.

This setting can be configured to reverse the label design for a specified number of prints, before
reversing the label back for the same number of prints. If the printer is fitted with a GPIO pack or
extended IO pack, this setting can be configured to reverse the label when an assigned input pin
is activated.
Notes: (1) A global invert setting is available to invert all label designs. However, the global
setting does not allow the number of inverted prints to be counted. Also, the global
setting does not allow inverted prints to be triggered by a user port, see page 5-71.
(2) If required, the label can also be inverted on the Print optimisation screen, see
page 5-11.
To setup reverse mode for an individual label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55.
(2) In the label creator’s side menu, select the Label tab.
(3) Select the Settings menu.
(4) Select the Reverse mode drop down setting.
(5) Select and configure one of the options described in the table below:

Setting Name Explanation

On - Always The label design will be reversed at all times.

On - Counted The label design will be reversed for a specified number of prints.
When this option is selected, the settings described below will
also be displayed:

Reverse: Initial orientation - Select the orientation of the first label

print.

Reverse repeat count - Select the number of times the label will
be printed in each orientation.
On - GPI / User port The label design will be reversed when an assigned input pin is
activated.
This setting can only be used if the printer is equipped with a
GPIO Pack (see page 7-42) or Extended IO Pack (see page 7-54).
To assign an input pin this function, see page 7-67.
Off The label design will not be reversed.

(6) Select the Save icon to save the setting.

End of procedure.

5-30 EPT026795 Issue 17 June 2020

OPERATION

Repeat Mode
Repeat mode can be configured to repeatedly print an individual label design for a specified
number of times after a single print trigger signal is received. Repeat mode can also be configured
to repeatedly print the label design when a continuous print trigger signal is received.
Note: A global repeat setting is available to repeat print all label designs, see page 5-66.
To setup repeat mode for an individual label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55.
(2) In the label creator’s side menu, select the Label tab.
(3) Select the Settings menu.
(4) Select the Repeat mode drop down setting.
(5) Select and configure one of the options described in the table below:

Setting Name Explanation

Off The label design will not be repeated.

Counted The label design will be repeated for a specified number of extra
prints. When this option is selected, the settings described below
will also be displayed:

Repeat count - Enter the number of times to repeat the current

label. The number of repeat counts is extra to the initial print, i.e. 6
will print 6 extra prints (7 in total).

Repeat spacing mode - Select how the distance between each

print is defined. Select, Space by pitch to define the distance
between the start of one print and the start of the next print in
mm. Or, select Space by gap to define the distance between the
end of one print to the start of the next print in mm.

Repeat spacing (mm) - Define the distance between prints.

5-34 EPT026795 Issue 17 June 2020

OPERATION

Edit a Text Element

To edit a text element in the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) Select the text element that requires editing.
(3) In the label creator’s side menu select the Element tab.
(4) Select the Edit menu.
(5) The following settings can now be used to edit the text element:

Setting Name Explanation

Name Edit the name of the element.

Font type Tower - Each character will be rotated by 90° anti clockwise.

Fixed - Each character will take up an equal amount of horizontal

space.

Proportional - Each character will take up the amount of horizontal

space required for that specific character only.
Font Change the height of the text in ink drops.
Bold Print text in bold.
Range: 0-3
Set to 1 in the example below.

Inter-character gap Vary the gap between text characters.

(strokes) Range: 1-50

Invert black/white Invert the printed and unprinted parts of the text element.

Invert Invert the text element.

EPT026795 Issue 17 June 2020 5-35

OPERATION

Setting Name Explanation

Reverse Reverse the text element.

Open the keyboard to edit the text.

Note: The keyboard type and language can be changed by
selecting the appropriate icon at the bottom of the text
entry screen.
Copy the text element.

Delete the text element.

(6) Select the Save icon to save the change.

End of procedure.

5-36 EPT026795 Issue 17 June 2020

OPERATION

Unicode
To add a Unicode character into a text element:
(1) When editing or creating a new text element, select the Unicode icon in the text entry
screen.

(2) Enter the Unicode value:

Common Unicode Characters

00A3 Pound (Sterling) 20AA Shekel (Israel)
0024 Dollar (US) 20AB Dong (Vietnam)
00A2 Cent (US) 20A2 Cruzeiro (Brazil)
00A5 Yen (Japan) 20A6 Naira (Nigeria)
20AC Euro 20A8 Rupee
20A1 Colon (Costa Rica) 20A9 Won (South Korea)

(3) Select the Tick icon in the top right of the screen to confirm the Unicode character.
(4) Select the green Tick icon to enter the Unicode character into the text element.
(5) Select the Save icon to save the label design.

End of procedure.
Input Method Editor (IME)
Entered in a similar manner to entering Unicode characters.
(1) When editing or creating a new text element, select the IME icon in the text entry screen.

(2) Enter the required characters.

(3) Select the green Tick icon to enter the IME character into the text element.
(4) Select the Save icon to save the label design.

End of procedure.

EPT026795 Issue 17 June 2020 5-37

OPERATION

Add a Barcode Element

Notes: (1) The printer can currently print 10x10, 12x12, 14x14, 16x16, 18x18, 20x20, 22x22,
24x24, 26x26, 32x32, 8x18, 8x32, 12x26, 12x36, 16x36, and 16x48 data matrix
symbols. The amount of data that can be contained within a data matrix symbol is
dependent on the data matrix size.
(2) The printer applies a limit of 64 characters to unrestricted codes.
To add a barcode element into the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the label creator’s side menu, select the Element tab.
(3) Select the Add menu.
(4) Select Barcode.
(5) Select the barcode type.
(6) Define any other barcode type specific settings.
(7) Select Add.
(8) Enter the required barcode data using the keyboard.
Note: The keyboard type can be changed by selecting the appropriate icon at the bottom of
the data entry screen.
(9) Select the green Tick icon to add the barcode data to the label design.
(10) In the label design area, select the barcode.
(11) In the side menu, select the Element tab.
(12) Select the Edit menu.
(13) The following barcode settings can now be defined:

Setting Name Explanation

Name Enter the name of the barcode element.

Type Select the barcode type.
Height (drops) Specify the height of the barcode in ink drops.
Module width Specify the barcode module width.
Range: 1-10
Show human readable Tick the Show human readable code tick box to display the
code barcode data in human readable text underneath the barcode.
Bearer bars Tick the Bearer bars tick box to add bearer bars above and below
the barcode.
Bearer box Tick the Bearer box tick box to add a bearer box around the
barcode.
Bar width ratios Specify the width ratio between the widest and thinnest bar in the
barcode.
Space width ratios Specify the width ratio between the widest and thinnest space in
the barcode.
Invert black/white Invert the printed and unprinted parts of the barcode element.

5-38 EPT026795 Issue 17 June 2020

OPERATION

Setting Name Explanation

Invert Flip the barcode upside down.

Reverse Reverse the barcode.
Rotation Rotate the barcode by 0° 90° 180° or 270°.
Check digit algorithm If required, select a check digit algorithm.
Quiet zone: Left Add an empty area to the left of the barcode.
Quiet zone: Right Add an empty area to the right of the barcode.

(14) Select the Save icon to save the change.

End of procedure.

EPT026795 Issue 17 June 2020 5-39

OPERATION

Add a QR Code Element

To add a QR Code element into the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the label creator’s side menu, select the Element tab.

(3) Select the Add menu.

5-40 EPT026795 Issue 17 June 2020

OPERATION

Notes: (1) To create and save an image file in the printer, see page 5-58.
(2) To import and save an image file in the printer from a USB flash drive, see page 5-59.
To insert a graphic element into the label:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the label creator’s side menu, select the Element tab.
(3) Select the Add menu.
(4) Select Graphics.
(5) Select the required graphic from the Images folder.
(6) Select the Save icon to save the change.

End of procedure.

5-44 EPT026795 Issue 17 June 2020

OPERATION

Variable Label Elements

Variable label elements are elements which contain variable data such as clocks, counters and
shift codes.
The following pages explain how to add and edit different variable label elements.
Add a Clock Element
To add a clock element into the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the Side-menu, select the Element tab.
(3) Select the Add menu.
(4) Select Text.
(5) Select +Variable at the top of the screen.
(6) Select Insert new...
(7) Select Clock.
(8) The following clock settings can now be defined:

Setting Name Explanation

Name Enter the name of the clock element.

Format Input the required date format:

HH - Hour with leading zero, 24 hour clock (00-23)

hh - Hour with leading zero. 12 hour clock (01-12)
H - Hour code
QQ - Quarter hour code (00-95)
mm - Minute with leading zero (00-59)
ss - (Second with leading zero (00-59)
AMPM - AM or PM
AP - A or P
DD - Day of the month with leading zero (01-31)
_D - Day of the month with leading space (1-31)
JJJ - Julian day of the year (001-366)
Y - Julian year of the decade (0-9)
YY - 2 digit year (00-99)
YYYY - 4 digit year (0000-9999)
MM - Month number with leading zero (01-12)
_M - Month number with leading space (1-12)
PGMM - Month name (January-December)
M - Mandatory alpha character (upper case only) A-Z
Q - Quarter year code (five year cycle)
QD - Day in the quarter
PGDDD - Day name (Monday-Sunday)
WW - Calendar week number (01-53)
D - Day of the week (1-7)
A7 - Day of week code
A31 - Day of month code

EPT026795 Issue 17 June 2020 5-45

OPERATION

Setting Name Explanation

Calendar Select the calendar type:

• Gregorian
• Hijri
• Jalali
Language Select the language:
• Western
• Arabic
• Farsi
Offset If required, an offset value can be set in years, months, weeks,
days, hours and minutes.
Roll over time This setting is a delay that adjusts time when the calendar date
will roll over to the next day. Only a positive value can be set. For
example, a value of [Link] will retain the previous calendar date
past midnight until 03:30.
Month offset rollover Note: Only visible when an offset month value is entered.
This setting defines the offset clocks behaviour, if the current
month is longer than the month that the clock will offset to. On the
last day of a longer month, the offset clock can display the next,
or previous month.
• Forwards - Display the next month on the last day of a long
month.
• Backwards - Display the previous month on the last day of a
long month.

(9) Select the green Tick icon to confirm the clock settings.
(10) Select the green Tick icon to add the clock element to the label design.
(11) Select the Save icon to save the change.

End of procedure.

5-46 EPT026795 Issue 17 June 2020

OPERATION

Add a Counter Element

To add a counter element to the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the label creator’s side menu, select the Element tab.
(3) Select the Add menu.
(4) Select Text.
(5) Select +Variable at the top of the screen.
(6) Select Insert new...
(7) Select Counter.
(8) The following counter settings can now be defined:

Setting Name Explanation

Name Enter the name of the counter element.

Format Input the required counter format:

0000 - Four mandatory numeric characters (0-9)

LLLL - Four mandatory alpha character (A-Z or a-z)
Start Value Input the counter start value.
Repeat count Enter the number of times the same counter value will be
repeated.
Show additional Tick the Show additional properties tick box to show more
properties counter settings.
Step Enter the number of steps and the direction that the counter will
count it, for example:

If the Start value is set to 00 and Step is set to 5, the counter will
count upwards from 00 in the following sequence: 00, 05, 10, 15,
etc. The counter will reset when it reaches the Upper limit value.

If the Start value is set to 20 and Step is set to -5, the counter will
count downwards from 20 in steps of 5 in the following sequence:
20, 15, 10, 05, etc. The counter will reset when it reaches the
Lower limit value.
Lower limit Enter the minimum counter value. When the counter reaches this
value it will reset.
Upper limit Enter the maximum counter value. When the counter reaches this
value it will reset.

EPT026795 Issue 17 June 2020 5-47

OPERATION

Setting Name Explanation

Rollover behaviour Rollover - When the counter reaches the upper limit, it will reset to
the lower limit. A counter with a lower limit of 0 and an upper limit
of 5 will print: 0, 1, 2, 3, 4, 5, 0, 1, 2, 3, 4, 5, 0, 1, 2, 3, 4, 5...

Reverse including limit - This setting is designed for traversing

applications. A counter with a lower limit of 0 and an upper limit of
5 will print: 0, 1, 2, 3, 4, 5, 5, 4, 3, 2, 1, 0, 0, 1, 2, 3, 4, 5...

Reverse excluding limit - This setting is designed for traversing

applications. A counter with a lower limit of 0 and an upper limit of
5 will print: 0, 1, 2, 3, 4, 5, 4, 3, 2, 1, 0, 1, 2, 3, 4, 5...
Leading zeros Tick the Leading zeros tick box to add padding characters to the
counter.
Padding character If the Leading zeros tick box has been ticked, this setting is used
to define the padding character that will be printed.
Trigger Note: To trigger counter updates from an external input only,
see page 4-37.
Specify what method will trigger the counter value to update.

Product Detect - The counter will be triggered each time a product

detect signal is received.

Another Counter - The counter will update when another selected

counter element reaches its Upper limit or Lower limit value.
Language Select the language:
• Western
• Arabic
• Farsi
Store persistent counter Select when the counter value is saved:
value • never
• on print start
• on print complete

(9) Select the green Tick icon to confirm the counter settings.
(10) Select the green Tick icon to add the counter element to the label design.
(11) Select the Save icon to save the change.

End of procedure.

5-48 EPT026795 Issue 17 June 2020

OPERATION

Add a Prompted Field Element

When a label containing a prompted field element is sent to print, the operator will be prompted to
update data in the prompted field element before printing can start.
The type of data that can be entered into a prompted field element can be Time, Date or Text.
To add a prompted field element into the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the Side menu select the Element tab.
(3) Select the Add menu.
(4) Select Text.
(5) Select +Variable at the top of the screen.
(6) Select Insert new...
(7) Select Prompted field.
(8) The following prompted field settings can now be defined:

Setting Name Explanation

Name Enter the name of the prompted field element.

Type Select the type of prompted field:

None - The user will be prompted to enter standard text.

Clock - The user will be prompted to enter a date or time.
Prompt Enter a prompt message which will be displayed to the operator to
prompt when the label is sent to print.
Input mask If Type is set to None, enter the number and type of characters
which the operator must input.

If Type is set to Clock or Time Conditional, enter the format the

operator must use to input the date or time.
Output format Note: This setting is only valid if Type is set to Clock.
Enter the format which the clock or time will be printed in.
Language Note: This setting is only valid if Type is set to Clock.
Select the clock or date language.

(9) Select the green Tick icon to confirm the prompted field settings.
(10) Select the green Tick icon to add the prompted field element to the label design.
(11) Select the Save icon to save the change.

End of procedure.

EPT026795 Issue 17 June 2020 5-49

OPERATION

Add a Reference Element

A reference element can be used to print data contained within a barcode as human readable text
elsewhere in the same label design.
Note: A reference element can only link to data from barcode elements.
To add a reference element into the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the Side menu select the Element tab.
(3) Select the Add menu.
(4) Select Text.
(5) Select +Variable at the top of the screen.
(6) Select Insert new...
(7) Select Reference.
(8) The following link settings can now be defined:

Setting Name Explanation

Source ID Select the name of the barcode element that will be referenced.
Source length Set the maximum length of the reference data.
Source offset Add an offset to the reference data.

(9) Select the green Tick icon to confirm the reference settings.
(10) Select the green Tick icon to add the link element to the label design.
(11) Select the Save icon to save the change.

End of procedure.

5-50 EPT026795 Issue 17 June 2020

OPERATION

Add a Script Element

Note: The Professional Printing Pack is required for this procedure.
Script elements written in LUA programming language can be imported into the printer using the
file manager, see page 8-22. Once imported, the script element can then be added into the label
design.
To add a script element into the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the Side menu select the Element tab.
(3) Select the Add menu.
(4) Select Text.
(5) Select +Variable at the top of the screen.
(6) Select Insert new...
(7) Select Script.
(8) Select Source.
(9) Navigate to the location of the script file and select it.
(10) Select the green Tick icon to confirm the correct script file has been selected.
(11) Select the Placeholder setting.
(12) Enter text that will act as a place holder for the script element on the label design area and
select the green Tick icon.
(13) Select the green Tick icon to add the script element to the label design.
(14) Select the Save icon to save the change.

End of procedure.

EPT026795 Issue 17 June 2020 5-51

OPERATION

Add an External Data Element

An external data element is a text field that allows data to be printed from an external source. Data
can be transmitted to the printer via Ethernet TCP or Serial connection.
To add an external data element into the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the Side menu select the Element tab.
(3) Select the Add menu.
(4) Select Text.
(5) Select +Variable at the top of the screen.
(6) Select Insert new...
(7) Select External data.
(8) The external data settings can now be defined:

Setting Name Explanation

Source Select the external data communication source.

Length Set the maximum length of the printed data.
For example, if the data received by the printer is 01234 and
length is set to 3, the printed data will be 012.
Offset The offset value specifies which part of the data will be printed.
For example, if the data received by the printer is 01234, the
length is set to 2 and offset is set to 3, the printed data will be 234.
Delimited Tick the delimited box to display the Delimiter and Index settings.
Example data Displays an illustration of the format the data will be printed in.
Default value Set a default that can be used in place of missing EDC data.
To enable this feature, select Home > Setup > Printer network
settings > Protocol settings. Set Buffer empty behaviour to Default
EDC element.

(9) Select the green Tick icon to confirm the external data settings.
(10) Select the green Tick icon to add the external data element to the label design.
(11) Select the Save icon to save the change.

End of procedure.

5-52 EPT026795 Issue 17 June 2020

OPERATION

Add a Shift Code Element

Note: A shift code table must be created before a shift code element can be added to the
label design. To create a shift code table see page 5-33.
A shift code element can be used to print data from a shift code table.
To add an shift code element into the label design:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the Side menu select the Element tab.
(3) Select the Add menu.
(4) Select Text.
(5) Select +Variable at the top of the screen.
(6) Select Insert new...
(7) Select Shift-code.
(8) Select the Shift-code table drop down menu.
(9) Select the required shift code table.
(10) Select the green Tick icon to confirm the shift code table selection.
(11) Select the green Tick icon to add the shift code element to the label design.
(12) Select the Save icon to save the change.

End of procedure.

EPT026795 Issue 17 June 2020 5-53

OPERATION

Lock Label Elements

Label elements can be locked to stop them from being accidentally edited or moved within the
label design.
To lock a label element:
(1) If the label is not already open in the label creator, open the label that requires editing, see
page 5-55. Or create a new label, page 5-25.
(2) In the label creator’s side menu, select the Element tab.
(3) Select the Manage menu.
(4) Select the element to be locked from the list of elements, or select the element in the label
design area.
(5) Select the Lock icon in the side menu to lock the selected element.
(6) Select the Save icon to save the setting.

End of procedure.

Preview Label
Select Preview at the top of the Label Creator to view a preview image of the label design.

5-54 EPT026795 Issue 17 June 2020

OPERATION

Open and Edit a Label

To edit an existing label:
(1) From the Home Screen, select Label finder.
(2) Open the label store.
(3) Select Edit icon next to the label which requires editing.

The label will open in the Label Creator. To edit the content within the Label Creator:
(1) Select an element to edit within the label design.
(2) Edit the item using the available settings in the side menu.
End of procedure.
Copy a Label Element
To copy an element within the label design:
(1) Select the element to copy.
(2) In the side menu, select the Element tab.
(3) Select the Edit menu.
(4) Select the Copy icon.

(5) Drag the new element to a suitable position in the label design area.
(6) Select the Save icon to save the change.

End of procedure.
Copy Multiple Label Elements
To copy multiple elements within the label design:
(1) In the label creator’s side menu, select the Element tab.
(2) Select the Manage menu.
(3) Select the tick box next to the name of each element to be copied.
Note: A square will be displayed around each selected element in the label design area.
(4) Select the Element tab.
(5) Select the Edit menu.
(6) Select the Copy icon.

(7) Drag the new elements to suitable positions in the label design area.
(8) Select the Save icon to save the change.

End of procedure.

EPT026795 Issue 17 June 2020 5-55

OPERATION

Delete a Label Element

To delete an element within the label design:
(1) Select the element to delete.
(2) In the side menu, select the Element tab.
(3) Select the Edit menu.
(4) Select the Delete icon.

(5) Select the Save icon to save the change.

End of procedure.
Delete Multiple Label Elements
To delete multiple label elements within the label design:
(1) In the label creator’s side menu, select the Element tab.
(2) Select the Manage menu.
(3) Select the tick box next to the name of each element which will be deleted.
Note: A square will be displayed around each selected element in the label design area.
(4) Select the Element tab.
(5) Select the Edit menu.
(6) Select the Delete icon.

(7) Select the Save icon to save the change.

End of procedure.

5-56 EPT026795 Issue 17 June 2020

OPERATION

Move a Label Element

To move an element within the label design:
(1) Select the element to move.
(2) Either:
(a) Select the Drag icon and drag the element to move it.

(b) Select the Arrows icon and use the arrows to move the selected element precisely.

(3) Select the Save icon to save the change.

End of procedure.
Zoom
Select the Fit to Screen, Zoom In or Zoom Out icon to change the magnification of the label area.

Fit to Screen Zoom In Zoom Out

Save Label
Once the label has been created:
(1) Select the Save as icon.

(2) Give the label a name and select a location.

(3) Select the Save icon.

End of procedure.

EPT026795 Issue 17 June 2020 5-57

OPERATION

IMAGES
Create an Image
Images are stored in the Images folder.
To create an image:
(1) Select Home > Setup > Tools.
(2) Use the Width and Height settings to specify the width and height of the design area.
Note: This will define the size occupied by the image even if the content is smaller than this
size.
(3) Use the Arrow icons to place the cursor in the required position.

(4) Click on the Paint Brush icon and draw the image by moving the brush using the Arrow
icons.

(5) Click on the Eraser icon to remove pixels where required.

(6) Select the Save As icon to save the image to the Images folder.

(7) Enter a filename for the image in the Name text box.
(8) Select Save.
End of procedure.

5-58 EPT026795 Issue 17 June 2020

OPERATION

Edit an Image
To edit an image:
(1) Select Home > Setup > Tools.
(2) Select the Folder icon.

(3) Select the image which requires editing.

(4) Edit the image as required.
(5) Save the image using the Save or Save As icons.

End of procedure.

Import an Image
To import images into the printer from a USB flash drive:
(1) Insert the USB flash drive containing the image files into the USB port on the TouchScreen.
(2) Wait until the USB icon on the information bar turns green.

(3) Select Home > Setup > File Manager.

(4) Open the USB folder.
(5) Open the folder that contains the image file.
(6) Select the tick box next to the image to be imported.

(7) Select either the Copy or Cut icon.

(8) Navigate to and open the Labels folder.

(9) Open the IMAGE folder.

EPT026795 Issue 17 June 2020 5-59

OPERATION

(10) Select the Paste icon.

(11) Remove the USB flash drive from the TouchScreen.

End of procedure.

5-60 EPT026795 Issue 17 June 2020

OPERATION

LABEL STORE AND FILE MANAGEMENT

Selecting an Existing Label
Note: Where no label is selected, “No label selected” will be displayed on the Home screen.
To open an existing label:
(1) On the Home Screen, select Label finder.
(2) Open the Labels folder.
(3) If the label name or part of the label name is known, select Filter labels... and enter the
label’s name. If the label name is not known, swipe the screen vertically to scroll through the
available the labels.
Note: Stored labels can be viewed by name, or by name and a preview image:

View labels by name.

View labels by name and preview image.

Refresh the label list.

(4) When the required label has been found, select either Print, Edit or Preview.
End of procedure.

File Manager
The File Manager is a useful tool for reviewing, organising and editing stored labels, images, fonts,
rasters, scripts and other file types. The File Manager can also copy files from USB memory
devices.
To access the file manager:
(1) Select Home > Setup > File Manager.
(2) Open a folder to view the files saved in that folder.
(3) Select the Tickbox next to a file to enable the settings listed below:
• Paste
• Copy
• Cut
• Rename
• Detail
• Delete
End of procedure.

EPT026795 Issue 17 June 2020 5-61

OPERATION

Import Label(s)
To import a label into the printer from a USB flash drive:
(1) Insert the USB flash drive containing the label files into the USB port on the TouchScreen.
(2) Wait until the USB icon on the information bar turns green.

(3) Select Home > Setup > File Manager.

(4) Open the USB folder.
(5) Open the folder that contains the label file.
(6) Select the tick box next to the label to be imported.

(7) Select either the Copy or Cut icon.

(8) Navigate to and open the Labels folder.

(9) Select the Paste icon.

(10) Remove the USB flash drive from the TouchScreen.

End of procedure.
Import Single Jet Labels into Duo Printers
Single jet Ax-Series labels can be imported into a Duo printer in the normal way as described
above. However, when the label is opened in the Editor a prompt will be appear to specify loading
it in the upper, lower or both regions.

5-62 EPT026795 Issue 17 June 2020

OPERATION

Export a Label(s)
To export a label from the printer to a USB flash drive:
(1) Insert the USB flash drive into the USB port on the TouchScreen.
(2) Wait until the USB icon on the information bar turns green.

(3) Select Home > Setup > File Manager.

(4) Open the Labels folder.

(5) Select the tick box next to the label to be exported.

(6) Select either the Copy or Cut icon.

(7) Navigate to and open the USB folder.

(8) Select the Paste icon.

(9) Remove the USB flash drive from the TouchScreen.

End of procedure.

EPT026795 Issue 17 June 2020 5-63

OPERATION

Delete a Label
To delete a label from the Labels folder:
(1) Select Home > Setup > File Manager.
(2) Open the Labels folder.

(3) Select the tick box next to the label to be deleted.

(4) Select the Delete icon.

End of procedure.

5-64 EPT026795 Issue 17 June 2020

OPERATION

EDITOR DEFAULTS
Set the default label settings. New labels will use these defaults.

Print Offset
Home > Setup> Editor Defaults > Properties
The Forward offset is used to adjust the position of the label on the print surface. If the print head
is on a traversing line the Reverse offset can also be set.
Note: This is a global print setting, label designs can also be saved with their own individual
print offset, see page 5-27.

Product Product
Detect Detect

Reverse Forward
Offset Offset

Print Delay Print Delay

Direction of print Direction of print

Print Offset Diagram

EPT026795 Issue 17 June 2020 5-65

OPERATION

Repeat Print
Labels can be repeat printed using one of two different methods. Or, repeat printing can be turned
off as described in the table below.
Note: This is a global print setting, label designs can also be saved with their own individual
print offset, see page 5-27.

Repeat Method Explanation

Off Repeat printing will not be enabled.

Counted Repeatedly print the same label for a specified number of times
after a single pulsed print trigger signal is received.
See page 5-67.
Typical application: Printing on lengths of extrusions of different
specification each requiring a different label.
Continuous Continuously print the same label when a constant print trigger
signal is received by the printer. The printer will stop printing when
the print trigger signal stops.
See page 5-68.
Typical application: Printing on cable.

5-66 EPT026795 Issue 17 June 2020

OPERATION

Counted
To setup Counted repeat printing:
(1) Select Home > Setup > Editor Defaults > Properties.
(2) Configure the settings described in the table below:

Setting Name Explanation

Repeat Select Counted.

Repeat count Enter the number of times to repeat the current label.
Note: The number of repeat counts is extra to the initial print,
i.e. 6 will print 6 extra prints (7 in total).
Repeat spacing type Select how the distance between prints is defined:

Space by pitch - The distance between the start of one print and
the start of the next print defined in mm.

Space by gap - The distance between the start of one print and
the start of the next print defined using the gap between
characters in mm.
Repeat Spacing (mm) Set the distance from the start of one print to the start of the next.
Repeat: Update each print Tick the Update each print tick box to update any clock and
counter information contained in the label with each print.

Alternatively, Untick the Update each print tick box to keep the
same information on each print.
Repeat: End of product Use the print trigger signal to set the behaviour of repeat printing:

Ignore - End of detected product will have no effect on repeat

printing.

Complete - If the end of product is detected between prints, one

more repeat label will be printed. If the end of product is detected
while printing a repeat, the print will complete and no further
repeats will be printed.

Cancel - If the end of product is detected between prints, no

further repeats will be printed (and the pending print will be
cancelled). If end of product is detected while printing a repeat,
the print will complete.

End of procedure.

EPT026795 Issue 17 June 2020 5-67

OPERATION

Continuous
To setup Continuous repeat printing:
(1) Select Home > Setup > Editor Defaults > Properties.
(2) Configure the settings described in the table below:

Setting Name Explanation

Repeat Select Continuous.

Repeat Spacing Type Select how the distance between prints is defined:

Space by pitch - The distance between the start of one print and
the start of the next print defined in mm.

Alternatively, untick the Update each print tick box to keep the
same information on each print.
Repeat: End of product Use the print trigger signal to set the behaviour of repeat printing:

Ignore - End of detected product will have no effect on repeat

printing.

Complete - If end of product is detected between prints, one more

repeat label will be printed. If the end of product is detected while
printing a repeat, the print will complete and no further repeats will
be printed.

Cancel - If the end of product is detected between prints, no

further repeats will be printed (and the pending print will be
cancelled). If end of product is detected while printing a repeat,
the print will complete.

End of procedure.

5-68 EPT026795 Issue 17 June 2020

OPERATION

Default Font Size

To set the default font size for label text elements:
(1) Select Home > Setup > Editor Defaults > Properties.
(2) Select the Default font size for text elements (drops) drop down setting.
(3) Select the a new default font size option.
End of procedure.

Prevent Duplicate Prompts

If a label containing a prompted field is sent to print on a printer equipped with a duo print head,
the prompt will be displayed for each ink jet. This setting wil stop the prompt being displayed
twice when the setting is enabled.
To enable or disable duplicate prompts:
(1) Select Home > Setup > Editor Defaults > Properties.
(2) Select or deselect the Prevent duplicate prompts for prompted fields tick box.
End of procedure.

Clocks/Dates
To view and change clock and date codes:
(1) Select Home > Setup > Editor defaults > Clocks / dates.
(2) View and change the settings listed below:
• Hour codes.
• Day of week codes.
• Day of month codes.
• Month codes.
• Calendar scheme.
• Day names.
• Month names.
End of procedure.

EPT026795 Issue 17 June 2020 5-69

OPERATION

REGIONAL SETTINGS
Set the Language and Keyboard
To set the user interface language and keyboard:
(1) Select Home > Setup > Regional > Language & keyboard.
(2) View and change the settings listed below:
• Language
• Keyboard layout
• IME Scheme
• Primary currency.
End of procedure.

Set the Master Clock

Note: The correct system date and system time values must be entered to print accurate
date or time elements within label designs.
To set the printer’s master clock:
(1) Select Home > Setup > Regional > Date and time.
(2) View and change the settings listed below:
• System date.
• System time (24 hour clock).
• Date format.
End of procedure.

5-70 EPT026795 Issue 17 June 2020

OPERATION

GLOBAL PRINT SETTINGS

Position / Orientation
Notes: (1) Everyday adjustments to print height, print delay, invert and reverse should be made
on the Print Optimisation screen, see page 5-11.
(2) These are global settings which will affect all label designs when printed. The Invert
and Reverse settings can also be configured and saved with individual label designs,
see page 5-27.
To adjust print position and orientation:
(1) Select Home > Setup > Global print settings > Position / orientation.
(2) View and change the settings listed below:

Setting Name Explanation

Calibrate Use the print height calibration wizard to set the print height, see
page 4-61.
Print delay (mm) Set the distance between a product sensor detecting a product
and the label being printed.
Internal stroke rate (mm/s) Note: This setting is only available if the Encoder input is set
to internal, see page 4-40.
If an internal encoder is used to set the print speed, this setting
defines the print speed in millimetres per second. This setting is
the same as the Speed (mm/s) setting on the Line movement
screen, see page 4-40.
Print height (%) Notes: (1) Jet 1 and Jet 2 settings are available for the Duo Print
Head only.
(2) Adjustment of this setting on a printer equipped with a
Duo Print Head will change the accuracy of the Jet
Gap (mm) setting.
Adjust the print height percentage.

Invert Invert the label.

Reverse Reverse the label.

EPT026795 Issue 17 June 2020 5-71

OPERATION

Setting Name Explanation

Bold Print text in bold.

Range: 0-3
Set to 1 in the example below.

Jet gap (mm) Notes: (1) For i-Pulse Duo Print Head only.
(2) If the Print Height (%) is also adjusted, the accuracy of
the Jet Gap value will be effected.
Adjust the vertical gap between the two ink jet printing areas.

Region offset Note: For i-Pulse Duo Print Head only.

Adjust the horizontal offset between the two ink jet printing areas.

End of procedure.

5-72 EPT026795 Issue 17 June 2020

OPERATION

Content
(1) Select Home > Setup > Global Print Settings > Content
(2) View and change the settings listed below:

Setting Name Explanation

Maximum active prints Note: It is recommended to leave this set to 2.

This setting defines the number of active buffered print labels.
2 = Default setting for most Domino applications.
1 = Not recommended for use, but maybe used in the future for
high speed applications.
Persistent script variables Select Reset All to reset all persistent script variables.
Raise good print on abort When this setting is enabled, a good print signal will be sent from
an assigned GPIO or user port output pin if a print is aborted.

End of procedure.

EPT026795 Issue 17 June 2020 5-73

OPERATION

THIS PAGE INTENTIONALLY LEFT BLANK

5-74 EPT026795 Issue 17 June 2020

PART 6 : CONSUMABLE REPLACEMENT

CONTENTS
Page
CONSUMABLE REPLACEMENT .............................................................................................. 6-3
Ink and Make-up Cartridge Replacement ............................................................................ 6-3
ITM Replacement ................................................................................................................. 6-7
Make-up Module Filter Replacement ................................................................................... 6-12
Make-up Module (MUM) Replacement ................................................................................ 6-14
Air Filter Replacement .......................................................................................................... 6-17

EPT026795 Issue 17 June 2020 6-1

CONSUMABLE REPLACEMENT

THIS PAGE INTENTIONALLY LEFT BLANK

6-2 EPT026795 Issue 17 June 2020

CONSUMABLE REPLACEMENT

CONSUMABLE REPLACEMENT
Ink and Make-up Cartridge Replacement
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Replace the make-up cartridge when prompted. Risk of damage to printer.
If the make-up cartridge is not replaced when required, the ink viscosity will go
outside the printer’s operating limits. Print head flushing will not be carried out
when the printer is shut down. Ink may be deposited on the print head
components and dry causing a blockage. Replace the make-up cartridge when
prompted.

CAUTION: Do not replace a cartridge until prompted. Risk of ink leak.

If the make-up or ink cartridge is replaced when it is not needed, the ink level in the
ITM could overfill. This will cause ink to leak out of the printer cabinet. Only replace
the ink or make-up cartridge when prompted by the user interface or status lights.

CAUTION: Hazardous chemicals. Risk of environmental damage.

Used ink and make-up cartridges contain residual chemicals which are hazardous
to the environment. Follow local waste disposal regulations to safely dispose of
used cartridges.

Note: Shake heavy duty ink cartridges for at least two minutes before fitting.
When the ink or make-up cartridges need to be replaced, the messages ‘Add Ink Cartridge’ or
‘Add Make-up Cartridge’ will appear on the TouchScreen status tab. If these messages are
ignored, the messages ‘Ink Level Below Minimum’ and ‘Make-up Level Below Minimum’ will
appear. Also, the amber alert light and the ink or make-up level alert light on the printer cabinet
will illuminate.
When the ink or make-up cartridges require replacing immediately, the messages ‘Change Ink
Cartridge - Empty’ or ‘Change Make-up Cartridge - Cartridge Empty’ will appear on the
TouchScreen status tab. Also, the red alert light will illuminate and the ink or make-up light on the
printer cabinet will start flashing. If the ink or make-up cartridge is not replaced at this stage, the
printer will stop working and will not continue printing until a new cartridge is fitted.
Tools required: 6mm Hex Key.

EPT026795 Issue 17 June 2020 6-3

CONSUMABLE REPLACEMENT

To replace the ink or make-up cartridge:

(1) Open the access door to the printer’s ink compartment.
(2) Remove the old cartridges by rotating the ink cartridge anti-clockwise and the make-up
cartridge clockwise to free them before lifting the cartridge away.

Make-up Ink Cartridge

Cartridge

Removal of Ink and Make-up Cartridges

(3) Before breaking the tab on the new cartridge and inserting it, hold the cartridge near the
Quality Management Module (QMM) to check that the ink or make-up type is correct. The
lights on the QMM will flash amber to indicate that the RFID tags are being read. When the
RFID tags have successfully been read and validated, the lights will turn green. See “QMM
(Quality Management Module) Status Lights” on page 2-24.
Notes: (1) If a fault is detected, the QMM lights will turn red and an alert will be displayed on the
Status tab.
(2) If the RFID tag cannot be read, or an RFID tag is not present, the QMM lights will turn
solid amber.

6-4 EPT026795 Issue 17 June 2020

CONSUMABLE REPLACEMENT

(4) Insert a 6mm hex key into the top of the new cartridge, twist to break the sealing tab and
remove the sealing tab.

Breaking the Make-up Breaking the Ink Cartridge

Cartridge Sealing Tab Sealing Tab

(5) Push the ink cartridge onto the ITM, or push the make-up cartridge onto the make-up
module.

Make-up Cartridge Ink Cartridge

Replacement Replacement

EPT026795 Issue 17 June 2020 6-5

CONSUMABLE REPLACEMENT

(6) Rotate the ink cartridge clockwise and the make-up cartridge anti-clockwise. Ensure that
the label is facing towards you.

Ink and Make-up Cartridge Replacement

(7) Check for leaks inside the printer.

(8) Close the access door to the printer ink compartment.
(9) Dispose of empty cartridges by following local waste disposal regulations.
End of procedure.

6-6 EPT026795 Issue 17 June 2020

CONSUMABLE REPLACEMENT

ITM Replacement
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

WARNING: Pressurised ink system. Risk of ink spray.

When replacing the ITM, ensure the retaining clips are fully engaged.

CAUTION: Risk of damage to printer’s ink system.

Do not allow foreign objects to enter the ITM or ink block. Observe good
cleanliness procedures.

CAUTION: Hazardous chemicals. Risk of environmental damage.

The used ITM and paper towels contain residual chemicals which are hazardous to
the environment. Follow local waste disposal regulations to safely dispose of the
used ITM and paper towels.

The main ink and gutter filters are situated in the ITM and are an integral part of the printer’s ink
system. Replacement of these filters therefore occurs automatically during scheduled ITM
replacement.
The messages, ‘The ITM life is soon to expire. Ensure a replacement ITM is available’ and
‘Intelligent Ink System is in depletion mode to prepare for ITM change’ will appear near the end of
the ITM life. Printing will not continue beyond the expiry of the ITM life.
The ink system will automatically run down the level of ink in the ink cartridge to a minimum level,
so it is usual to replace the ink cartridge at the same time.
Required equipment: Paper towels (or similar) and wash.
To replace the ITM:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access door to the printer ink compartment.
(4) If an ink cartridge is attached to the ITM, remove it by twisting the cartridge anti-clockwise
and lifting it out of the printer.

EPT026795 Issue 17 June 2020 6-7

CONSUMABLE REPLACEMENT

(5) Pull the two ITM retaining clips upwards away from the ITM.

Removing the ITM

(6) Pull the ITM backwards, withdrawing the connecting manifold from the ink block and
remove the old ITM.
Notes: (1) If the ITM does not withdraw with moderate pressure, push the ITM fully forward
(which will break any seal caused by dry ink) and try again.
(2) The manifold pipes will contain residual ink. Take care when removing the ITM to avoid
spillage.
(7) Unpack the new ITM and remove the sealing strip that protects the ITM manifold.

Removing the ITM Sealing Strip

(8) Re-use the sealing strip to seal the manifold on the old ITM.

6-8 EPT026795 Issue 17 June 2020

CONSUMABLE REPLACEMENT

(9) Place paper towel or similar on top of the level sensor modules to catch excess fluid and
using wash, remove any dried residual ink from the ink block valve face.

CAUTION: Important step. Risk of fluid leak

Ensure you clean the ink block valve face. If you do not clean the ink block valve
face of dried ink, it may be difficult to create a good seal between the ink block and
ITM. A bad seal between the ink block and ITM could cause fluid to leak.

Wash Ink Block Valve Face

(10) Place paper towel or similar under the ITM manifold pipes and lubricate the pipes with
wash.

CAUTION: Important step. Risk of fluid leak

Ensure you lubricate the ITM manifold pipes. If you do not lubricate the ITM
manifold pipes, it may be difficult to create a good seal between the ink block and
ITM. A bad seal between the ink block and ITM could cause fluid to leak.

Wash ITM Manifold Pipes

EPT026795 Issue 17 June 2020 6-9

CONSUMABLE REPLACEMENT

(11) Insert the ITM between the retaining clips and push the manifold pipes into the ink block.

Insert the ITM

WARNING: Pressurised ink system. Risk of ink spray.

When replacing the ITM, ensure the retaining clips are fully engaged.

(12) Continue pushing until the retaining clips engage with a click.

Retaining Clip Engaged Retaining Clip Not Engaged

(13) Re-connect the power lead to the rear of the printer.

(14) Press and hold the standby button for 2 seconds and wait for the printer to start.
(15) Attach a new ink cartridge to the ITM or re-use the existing ink cartridge. See, “Ink and
Make-up Cartridge Replacement” on page 6-3.

6-10 EPT026795 Issue 17 June 2020

CONSUMABLE REPLACEMENT

(16) Check the ink compartment for leaks.

(17) The status lights on the Quality Management Module (QMM) will flash amber to indicate that
the RFID tags on the ITM, Ink Cartridge and Make-up Cartridge are being read. When the
RFID tags have successfully been read and validated, the status lights will turn green.
Notes: (1) If a fault is detected, the QMM status lights will turn red and an alert will be displayed
on the Status tab.
(2) If the RFID tag cannot be read, or an RFID tag is not present, the QMM status lights
will turn solid amber.

Make-up Ink Cartridge

Cartridge

ITM

Quality Management Module Status Lights

(18) Shut the ink compartment access door.

(19) Dispose of contaminated paper towels and the old ITM by following local waste disposal
regulations.
Note: If a new ITM has been fitted, the printer will recognise the new ITM and automatically
prime the ink system when the ink jet is next sequenced on. If the same ITM has been
removed and replaced, the printer will not recognise that the ITM has been replaced
and the ink system will need to be primed manually. To prime the ink system, select
Home > Setup > Diagnostics > Tests and run the ITM replacement sequence.
End of procedure.

EPT026795 Issue 17 June 2020 6-11

CONSUMABLE REPLACEMENT

Make-up Module Filter Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of damage to printer’s ink system.

Do not allow foreign objects to enter the ITM or ink block. Observe good
cleanliness procedures.

CAUTION: Hazardous chemicals. Risk of environmental damage.

The used ITM and paper towels contain residual chemicals which are hazardous to
the environment. Follow local waste disposal regulations to safely dispose of the
used ITM and paper towels.

The make-up module filter is situated in the top of the make-up module. As a user replaceable
part it is coloured yellow.
Required tools: 6mm hex key.
To replace the make-up module filter:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Open the access door to the printer ink compartment.
(3) If a make-up cartridge is attached to the make-up module, remove it by twisting the
cartridge in a clockwise direction and lifting it out of the printer (refer to “Ink and Make-up
Cartridge Replacement” on page 6-3).

6-12 EPT026795 Issue 17 June 2020

CONSUMABLE REPLACEMENT

(4) Remove the old make-up module filter from the make-up module by inserting a 6mm hex
key into the yellow filter top and unscrewing the filter from the make-up module.

Make-up
Filter

Make-Up
Module

MUM Filter Replacement

(5) Use the 6mm hex key to screw the new make-up module filter into the make-up module.
(6) Replace the make-up cartridge (if fitted).
(7) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(8) Check inside the printer cabinet for leaks.
(9) Shut the ink compartment access door.
(10) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(11) Select Start and follow the on screen instructions to prime the ink system.
(12) Dispose of the old make-up filter by following local waste disposal regulations.
End of procedure.

EPT026795 Issue 17 June 2020 6-13

CONSUMABLE REPLACEMENT

Make-up Module (MUM) Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the Make-up Module.

CAUTION: Risk of damage to printer’s ink system.

Do not allow foreign objects to enter the make-up module or ink block. Observe
good cleanliness procedures.

CAUTION: Hazardous chemicals. Risk of environmental damage.

The used ITM and paper towels contain residual chemicals which are hazardous to
the environment. Follow local waste disposal regulations to safely dispose of the
used ITM and paper towels.

Required equipment: Paper towels (or similar) and wash.

To replace the make-up module (MUM):
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access door to the printer ink compartment.
(4) If a make-up cartridge is attached to the MUM, remove it by twisting the cartridge
anti-clockwise and lifting it out of the printer.

6-14 EPT026795 Issue 17 June 2020

CONSUMABLE REPLACEMENT

(5) Undo and remove the thumb screw that secures the MUM to the printer cabinet.

Remove MUM Securing Screw

(6) Remove the MUM from the printer cabinet, take care to remove the make-up recovery tube.

MUM Removal

(7) Place paper towel or similar on top of the level sensor modules to catch excess fluid and
use wash to clean the valve face.

EPT026795 Issue 17 June 2020 6-15

CONSUMABLE REPLACEMENT

(8) Place paper towel or similar under the manifold pipes on the new MUM and lubricate the
pipes with wash.
(9) Insert the MUM into the printer cabinet, insert the make-up recovery tube into the MUM and
push the MUM’s manifold pipes into the ink block.
(10) Tighten the thumb screw that secures the MUM to the printer cabinet.
(11) Re-connect the power lead to the rear of the printer.
(12) Press and hold the standby button for 2 seconds and wait for the printer to start.
(13) Attach a new make-up cartridge to the MUM. See, “Ink and Make-up Cartridge
Replacement” on page 6-3.
(14) The status lights on the Quality Management Module (QMM) will flash amber to indicate that
the RFID tags on the ITM, Ink Cartridge and Make-up Cartridge are being read. When the
RFID tags have successfully been read and validated, the status lights will turn green.
Notes: (1) If fault is detected, the QMM status lights will turn red and an alert will be displayed on
the Status tab.
(2) If the RFID tag cannot be read, or an RFID tag is not present, the QMM status lights
will turn solid amber.

Make-up Ink Cartridge

Cartridge

ITM

Quality Management Module Status Lights

(15) Check the ink compartment for leaks.

(16) Shut the ink compartment access door.
(17) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(18) Select Start and follow the on screen instructions to prime the ink system.
(19) Dispose of contaminated paper towels, the old make-up cartridge and the old MUM by
following local waste disposal regulations.
End of procedure.

6-16 EPT026795 Issue 17 June 2020

CONSUMABLE REPLACEMENT

Air Filter Replacement

WARNING: Hazardous Air Particles. Risk of eye and skin damage.

The used air filter may contain particles which cause skin or eye irritation. Wear
appropriate protective equipment such as gloves and glasses.

Air filter replacement is recommended after every 2000 hours of operation but may need to be
replaced sooner depending on the operating environment.
Note: The air filter is not designed to be cleaned, it must be replaced.
A new air filter can be ordered through [Link]
The air filter is located in a slot at the back of the printer. As a user replaceable part it is coloured
yellow.

Air filter

Air Filter Location

EPT026795 Issue 17 June 2020 6-17

CONSUMABLE REPLACEMENT

To replace the air filter:

(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Remove the air filter by holding the yellow exposed part of the filter and pulling it gently out
of the filter housing.
(3) Replace the air filter with a new unit.
Note: Ensure the new air filter is correctly orientated by confirming the arrow symbols on the
yellow filter moulding are pointing up. If the filter is inserted upside-down it will get
stuck in the printer cabinet.

Filter Orientation

(4) Press and hold the standby button for 2 seconds to start up the printer.
(5) Select Home > Setup > Adjustment > Inspection > Add...
(6) Select the Replaced part drop down menu and select Air filter.
(7) Select Operator name and enter your name.
(8) If necessary, select Notes and enter any notes which may be useful.
(9) Select Save.
End of procedure.

6-18 EPT026795 Issue 17 June 2020

PART 7 : CONNECTIVITY PACKS

7-4 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

CONNECTIVITY PACK OVERVIEW

As standard, Ax-Series printers are equipped with a power connector and two print detect / shaft
encoder connectors. Ax350i/Ax550i printers are also equipped with a connector to provide
communication with a Domino TouchScreen.
Connectivity packs can be added to the printer to equip it with additional external connectors.
Connectivity packs can be fitted to the printer at the time of manufacture or fitted at a later date as
an upgrade.
The table below lists the connectivity pack options:

Table 1: Connectivity Pack Options

Pack Name and Printer

Description
Part Number Compatibility

Status Pack - Ax150i The status pack adds the following external
EPT022072SP Ax350i connections:
Ax550i • Beacon connector: 5-Way Socket
• Alarm connector: 7-Way Socket, 1A, 30V
maximum
RS232 Pack - Ax150i The RS232 pack adds the following external
EPT022073SP Ax350i connections:
Ax550i • Serial RS232 Port: 8-Way Socket
GPIO Pack - Ax150i The Basic GPIO pack adds the following external
EPT022074SP Ax350i connections:
Ax550i • Basic GPIO Port
Comms Pack - Ax150i The comms pack adds the following external
EPT022075SP Ax350i connections:
Ax550i • Ethernet Port
• USB Port
Extended Comms Ax350i Note: Not available if the printer is equipped with
Pack - Ax550i a Safeguard DCI.
EPT022070SP The extended comms pack adds the following
external connections:
• Powered HMI Port: 7-way Socket
• Control Port: 8-way Socket
• USB port
Extended GPIO Ax350i The extended GPIO pack adds the following external
Pack - Ax550i connections:
EPT022071SP • User Port: 25-Way D-Sub Socket
• User Port: 37-Way D-Sub Socket

EPT026795 Issue 17 June 2020 7-5

CONNECTIVITY PACKS

Ax150i Connectivity Pack PCBA Layout

The diagram below illustrates the location of the connectivity pack PCBAs as they are mounted
inside the Ax150i cabinet.

Ax150i Connectivity Pack Layout

7-6 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Ax350i/Ax550i Connectivity Pack PCBA Layout

The diagram below illustrates the location of the connectivity pack PCBAs as they are mounted to
the Ax350i/Ax550i rear electronics panel.

Ax350i/Ax550i Connectivity Pack Layout

EPT026795 Issue 17 June 2020 7-7

CONNECTIVITY PACKS

Connectivity Pack Mounting

The connectivity pack PCBs are mounted using panel mount connectors and T10 torx screws. Do
not over tighten the panel mount connectors as this will put pressure on the connector pin solder
joints.
To preserve the printer cabinet’s IP rating use the supplied plugs to seal the printer cabinet where
connectivity pack connectors have not been fitted.
The illustration below shows an example of the connectivity pack PCB mounting method.

Lumberg
Connector

PCB

IP68 D
Connector

EMC GND Stand-offs

(welded to rear panel)

Rear
Panel

Connectivity Pack PCB Mounting

7-8 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

EXTENDED COMMS PACK

Introduction
Notes: (1) The extended comms pack is not available for the Ax150i.
(2) The extended comms pack cannot be fitted if the printer is equipped with a Safeguard
DCI socket.
The extended comms pack adds two communication ports (J5 and J6) to the rear of the printer
cabinet. A USB Type A socket (J12) is also added to the printer cabinet.
The powered HMI port (J5) provides a 24V power supply and Ethernet communication for a
remote user interface such as a Domino TouchPanel Type 1 or Type 2.
The External Control Port (J6) enables a customer equipment to control basic printer functions
and receive printer status information.
The USB Type A socket (J12) enables data to be transferred to and from the printer. For example.
label file transfer, software updates, software backups and pack installation/migration can be
performed through the USB socket.
The items listed in the table below are contained in the extended comms pack:

Table 2: Extended Comms Pack Contents

Quantity Item Description

1 Powered HMI / Control PCBA

2 Sealing Cap
1 Cable, Powered HMI
1 Cable, Ethernet
1 USB PCBA
1 Cable, USB
1 Cap, Plastic for C4 Screw Panel
3 Screw M3x5 Torx T10 SS Captive Washer

Extended Comms Pack Contents

EPT026795 Issue 17 June 2020 7-9

CONNECTIVITY PACKS

Installation
WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver.

To install the extended comms pack:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear electronics panel.
(4) Lower the rear electronics panel.
(5) Mount the two PCBAs onto the back of the electronics panel.
(6) Connect the Ethernet cable to connector J7 on the powered HMI / control PCBA and
connector J1001 on the printer’s main PCB
(7) Connect the HMI power cable to connector J8 on the powered HMI / control PCBA and
connector J173 on the printer’s main PCB.
(8) Connect the USB cable to connector J13 on the USB PCBA and connector J25 on the
printer’s main PCB.
(9) Replace the printer’s rear electronics panel.
(10) Connect the power lead to the rear of the printer.
(11) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

7-10 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Powered HMI / Control PCBA Layout

Powered HMI / Control PCBA Powered HMI / Control PCBA

Top View Bottom View

EPT026795 Issue 17 June 2020 7-11

CONNECTIVITY PACKS

Powered HMI Port (J5)

The powered HMI port provides a 24V power supply and Ethernet communication for a remote
user interface such as a Domino TouchPanel Type 1 or Type 2.
Connector type: 7 way Din Socket IEC60130-9 (Lumberg 0307 07).
Mating cable connector type: 7 way Din Plug IEC60130-9 (Lumberg 0332 07).
Pin Description

Table 3: Powered HMI Port (J5) Pin Description

Pin Signal Description

1 +24V 24V supply at 500mA 1 6

nominal
2 0V Power GND 2 7 5

3 TX1+ Transmit +
3 4
4 TX1- Transmit -
5 RX1+ Receive +
J5 Connections
6 RX1- Receive - (external view)

7 NC Not Connected
Shell EMC_GND Ground via panel
mounting

7-12 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

TouchPanel Type 1/2 Connection

WARNING: Electricity. Risk of injury from electric shock.

Disconnect the printer from mains power in the event of a TouchPanel failure.

A 5 meter Domino TouchPanel interface cable is required to connect the printer to a TouchPanel
Type 1 or Type 2. The part number for this cable is L015211.
A TouchPanel Type 1 or Type 2 can be powered from two different power sources. Both power
sources can be used individually or at the same time. The two power sources are illustrated and
described below.
Mains AC Mains AC Power Supply and
Power Supply Power Supply Ethernet via Printer’s
Connector Switch Powered HMI Port

TouchPanel Type 1 Power Sources

Mains AC Mains AC Power Supply and

Power Supply Power Supply Ethernet via Printer’s
Connector Switch Powered HMI Port

TouchPanel Type 2 Power Sources

EPT026795 Issue 17 June 2020 7-13

Powered HMI Port Connection Schematic
7-14

Printer Customer

+ 12V 2018 0805

M F- S M D F0 50 M HC 2 0 1 2 S 5 1 Q
F1 L1

0805
M HC 2 0 1 2 S 5 1 Q C1
L2 1 n F /2 k V /1 2 0 6

C2 E M C _G ND 2
1 n F /2 k V /1 2 0 6

E M C _G ND 2 0 30 7 0 7
V+

CONNECTIVITY PACKS
T X1 A 1
H1 1 0 2 L
T M 2 1 - C - 8 8 ( 51 )
0V
2
TouchPanel
1
E T H_T X + 1 T D+ T X+ 16 T X1 +
3
Type 1/2
2
E T H_T X -
2 T CT T CMT 15
T X1 -
4
Via Domino
3
E T H_R X + RX1 +
5
TouchPanel
3 T D- T X- 14
4
B IAS RX1 - Cable
6
B IAS NC
5 7
E T H_R X - T X1 B
6 H1 1 0 2 L J5
B IAS
7
6 T D+ RX+ 11
B IAS
8
S HE I L D 1 R2 7 T CT RX- 9
S HI E L D 1 R1
S HI E L D 2 7 5R
S HI E L D 2 7 5R 8 T D- RCT 10 R3 7 5R R4 7 5R
EPT026795 Issue 17 June 2020

J7 R5
D NF
0R C7
C8 C5 C6 C4 0805 1 n F /2 k V /1 2 0 6
1 n /2 k V /1 2 0 6 1 n F /2 k V /1 2 0 6 1 0 0 p F /5 0 V 1 0 0 p F /5 0 V M HC 2 0 1 2 S 5 1 Q
L3
Powered HMI Port Connection Schematic E M C _G ND 2
CONNECTIVITY PACKS

External Control Port (J6)

The external control port enables customer equipment to monitor printer status and power the
printer on or off.
Connector type: 8 way Din Socket IEC60130-9 (Lumberg 0307 08).
Mating cable connector type: 8 way Din Plug IEC60130-9 (Lumberg 0332 08).
Pin Description
CAUTION: Risk of printer damage.

Input voltages above 5V will damage the printer’s main PCB.

If voltage free contacts are used to activate the inputs, pin 7 (5V+ OUT) can be used as the high
voltage level.
The signals described below are 3V3 TTL compatible. Inputs are 5V TTL compatible.

Table 4: External Control Port (J6) Pin Description

Pin Signal Description

1 PWR_ON_IN Remote Power On Input.

A high pulse will turn the printer on. 8 7
2 PWR_OFF_IN Remote Power Off Input. 6
3 1
A high pulse will request that the
printer is turned off.
5 4
3 PWR_STAT_OUT Power Status Output. 2
0V output when the printer is off.
3V3 output when the printer is on.
J6 External Control Port
4 PRINT_EN_IN This input is for future use.
(external view)
5 PRINT_STATUS_ This output is for future use.
OUT
6 CUSTOM_OUT This output is for future use.
7 5V+ OUT +5V STANDBY (<100mA)
8 0V Signal Ground
Shell NC Ground via panel mounting

EPT026795 Issue 17 June 2020 7-15

CONNECTIVITY PACKS

External Control Port Wiring Schematic

7-16 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Internal Interface to Main PCB (J7)

This connector provides internal communication between the main printer PCB and the powered
HMI / control PCBA. Use the correct cable from the pack to connect it to socket J1001 on the
printer’s main PCB.
Connector type: Straight shielded RJ45 (cat 5e).
Pin Description

J7 Connections
(external view)

Table 5: J7 Internal Interface to Main PCB (J7) Pin Description

Powered HMI /
Pin Main PCB Signal Description
Control PCBA Signal

1 TX+_D ETH_TX2+ Transmit Data+

2 TX-_D ETH_TX2- Transmit Data-
3 RX+_D ETH_RX2+ Receive Data+
4 Bias Bias Bias (EMC)
5 Bias Bias Bias (EMC)
6 RX-_D ETH_RX2- Receive Data-
7 Bias Bias Bias (EMC)
8 Bias Bias Bias (EMC))
SH1 SHEILD1 SHEILD1 1nF 2kV to EMC GND
SH2 SHEILD2 SHEILD2 1nF 2kV to EMC GND

EPT026795 Issue 17 June 2020 7-17

CONNECTIVITY PACKS

Internal Interface to Main PCB (J8)

This connector provides internal power and communication between the main PCB and the
powered HMI / control PCBA. Use the correct cable from the pack to connect it to socket J173 on
the printer’s main PCB.
Connector type: 22W Vertical SMT Micro-Fit.
Pin Description

2 4 6 8 10 12 14 16 18 20 22

This connector provides internal communication between the main printer PCB and the USB
PCBA. Use the correct cable from the connectivity pack to connect it to socket J25 or J26 on the
printer’s main PCB.
Connector type: USB type A.
Pin Description
7 6

1 2 3 4

J13 Connections
(external view)

Table 8: Internal Interface to Main PCB (J13) Pin Description

Pin USB PCBA Signal Main PCB Signal Description

1 USB_PWR USB_PWR USB Power

2 USB_Data - USB_HUB - USB Data
3 USB_Data + USB_HUB + USB Data
4 USB_GND GND_USB USB Ground
5 SHEILD_USB SHEILD_USB SHEILD_USB
6 SHEILD_USB SHEILD_USB SHEILD_USB
7 SHEILD_USB SHEILD_USB SHEILD_USB

EPT026795 Issue 17 June 2020 7-21

CONNECTIVITY PACKS

STATUS PACK
Introduction
The status pack contains a single PCBA which adds the following external connections:
• 5 way socket for a beacon.
• 7 way plug for an alarm (Requires: L014981 Cable X29 Interlock 9m BCP7).
The beacon connector is designed for use with the Domino beacon assembly, see page 10-3.
The items listed in the table below are contained in the status pack:

Table 9: Status Pack Contents

Quantity Item Description

1 Status PCBA
1 Cable, Status
1 Male Socket Sealing Cap
1 Female Socket Sealing Cap
2 Screw M3x5 Torx T10 SS Captive Washer

Status Pack Contents

7-22 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Installation
WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver.

To install the status pack:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear electronics panel.
(4) Lower the rear electronics panel.
(5) Mount the status PCBA in the printer cabinet.
(6) Connect the status cable to connector J16 on the status PCBA and connector J15 on the
printer’s main PCB
(7) Replace the printer’s rear electronics panel.
(8) Connect the power lead to the rear of the printer.
(9) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

EPT026795 Issue 17 June 2020 7-23

CONNECTIVITY PACKS

Status PCBA Layout

PCBA Top View PCBA Bottom View

7-24 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Internal Interface to Main PCB (J16)

This connector provides internal communication between the main printer PCB and the status
PCBA. Use the correct cable from the connectivity pack to connect it to socket J15 on the
printer’s main PCB.
Connector type: 16-way vertical box header (SMT).
Pin Description

2 4 6 8 10 12 14 16

1 3 5 7 9 11 13 15

J16 Connections
(external view)

Table 10: Internal Interface to Main PCB (J16) Pin Description

Pin Status PCBA Signal Main PCB Signal

1 +24V +24V_INT_A
2 +24V +24V_INT_A
3 ALARM_1 ALARM_1
4 ALARM_2 ALARM_2
5 ALARM_3 ALARM_3
6 GND GND
7 GND GND
8 GREEN_BEACON GREEN_BEACON
9 RED_BEACON RED_BEACON
10 AMBER_BEACON AMBER_BEACON
11 BLUE_BEACON BLUE_BEACON
12 GND GND
13 GND GND
14 ICTP14 TP1510
15 +24V +24V_INT_A
16 +24V +24V_INT_A

EPT026795 Issue 17 June 2020 7-25

CONNECTIVITY PACKS

External Beacon Socket (J17)

The beacon socket provides an external 24V DC FET switched output to drive each of the lamps
in a standard Domino beacon (P/N L014934).
For information on beacon installation, see page 10-3.
Connector type: 5 way DIN socket IEC60130-9 (Lumberg 030705-1)
Mating cable connector type: 5 way DIN plug (Lumberg 033205-1)
Pin Description
The beacon connector pin assignments are shown below.

Table 11: External Beacon Socket (J17) Pin Description

Pin Signal Description

1 Blue Lamp driver 24V FET - switched

5 1
2 Amber Lamp driver 24V FET - switched
3 Green Lamp driver 24V FET - switched 4 2

4 Red Lamp driver 24V FET - switched 3

5 0V Ground
J17 Beacon Socket Connections
Shell NC EMC Ground via panel mounting (external view)

Outputs
Voltage: 24V floating
Max current: 170mA
The beacon indicators are illuminated in a solid state as described in the table below.

Table 12: Beacon Colour Description

Beacon Colour Description

Green The printer is ready or ready to print.

Red There is a fault, an alert is displayed on the user interface, the printer has
stopped.
Amber The printer requires attention, an alert is displayed on the user interface,
the printer is still printing.
Blue The printer is on but in an idle state. The printer is not ready for printing.

7-26 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Beacon Connection Diagram

Beacon

External Beacon
Socket (J17)

5 1

4 2
3

Beacon Connection Wiring Diagram

EPT026795 Issue 17 June 2020 7-27

CONNECTIVITY PACKS

External Alarm Connector (J18)

The alarm connector provides an external port to trigger a customer supplied alarm.
Connector type: 7 way DIN plug IEC60160-9 (Lumberg 0317 07)
Mating cable connector type: 7 way DIN socket (Lumberg 0322 07)
Pin Description

Table 13: External Alarm Connector (J18) Pin

Description

Pin Signal Description

6 1
1 ALARM1_NC Green Beacon
(normally closed)
5 7 2
2 ALARM1_NO Green Beacon
(normally open)
4 3
3 ALARM2_NC Red Beacon
(normally closed)
J18 Alarm Plug Connections
4 ALARM2_NO Red Beacon
(external view)
(normally open)
5 ALARM3_NC Amber Beacon
(normally closed)
6 ALARM3_NO Amber Beacon
(normally open)
7 COM Externally supplied
common
Shell NC Ground via panel
mounting

7-28 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

RS232 PACK
Introduction
The RS232 pack adds an 8-Way RS232 port to the printer cabinet. The RS232 port can be used
to send information to the printer, such as labels and variable information from an external control
system. Information can also be sent to the external control system from the printer. Basic printer
control can also be performed using the RS232 port.

Table 14: RS232 Pack Contents

Quantity Item Description

1 RS232 PCBA
1 Cable, RS232
1 RS232 Port Sealing Cap
1 Screw M3x5 Torx T10 SS Captive Washer
1 8-Way Cable Socket Connector

RS232 Pack Contents

EPT026795 Issue 17 June 2020 7-29

CONNECTIVITY PACKS

Installation
WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver.

To install the RS232 pack:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear electronics panel.
(4) Lower the rear electronics panel.
(5) Mount the extended RS232 PCBA in the printer cabinet.
(6) Connect the RS232 cable to connector J11 on the RS232 PCBA and connector J22 on the
printer’s main PCB
(7) Replace the printer’s rear electronics panel.
(8) Connect the power lead to the rear of the printer.
(9) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

7-30 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

RS232 PCBA Layout

RS232 PCBA RS232 PCBA

Top View Bottom View

EPT026795 Issue 17 June 2020 7-31

CONNECTIVITY PACKS

External RS232 Connector (J10)

The RS232 connector provides external RS232 level serial connection to user equipment.
Connector type: 8 way DIN plug IEC60160-9 (Lumberg 031708-1)
Mating cable connector type: 8 way DIN socket (Lumberg 032208-1)
Pin Description

Table 15: External RS232 Connector (J10) Pin Description

Pin Signal Description

1 RS232_DCD Data Carrier Detect

2 RS232_TXD Transmit Data Output 6 7
8
3 RS232_RXD Receive Data Input 1 3

4 RS232_DSR Data Set Ready Input 4 5

2
5 0V Signal GND
6 RS232_DTR Data Terminal Ready Output
8-Way RS232 Port Connections
7 RS232_CTS Clear To Send Input (External View)
8 RS232_RTS Request To Send Output
Shell NC EMC_GND via panel mounting

7-32 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

RS232 Connection Diagram

Customer
RS232 Connector (J10) Equipment

DCD
Pin 1 Data Carrier Detect

TXD
Pin 2 Transmit Data

RXD
Pin 3 Receive Data

DSR
Pin 4 Data Set Ready

GND
Pin 5 Ground

DTR
Pin 6 Data Terminal Ready

CTS
Pin 7 Clear to Send

RTS
Pin 8 Request to Send

RS232 Connection Diagram

EPT026795 Issue 17 June 2020 7-33

CONNECTIVITY PACKS

Internal Interface to Main PCB (J11)

This connector provides internal communication between the main printer PCB and the RS232
PCBA. Use the correct cable from the connectivity pack to connect it to socket J22 on the
printer’s main PCB.
Connector type: 12-way Grid vertical box header (SMT).
Pin Description

2 4 6 8 10 12

1 3 5 7 9 11

J11 Connections
(external view)

Table 16: Internal Interface to Main PCB (J11) Pin Description

RS232 PCBA Main PCB

Pin Description
Signal Signal

1 TTL_DSR UART0_DSR Data Set Ready

2 TTL_DCD UART0_DCD Data Carrier Detect
3 TTL_RTS UART0_RTS Request To Send
4 TTL_RXD UART0_RXD Receive Data
5 TTL_CTS UART0_CTS Clear To Send
6 TTL_TXD UART0_TXD Transmit Data
7 ICTP2 TP1303 Test Point
8 TTL_DTR UART0_DTR Data Terminal Ready
9 GND GND Ground
10 GND GND Ground
11 +5V +5V_FUSED +5V
12 +5V +5V_FUSED +5V

7-34 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

COMMS PACK
The comms pack is recommended for system integration involving Ethernet or USB.
The comms pack adds the following external connections to the printer cabinet:
• USB Port (J12)
• Ethernet Port (J14)
The items listed in the table below are contained in the comms pack:

Table 17: Comms Pack Contents

Quantity Item Description

1 USB PCBA
1 Cable, USB
1 Ethernet PCBA
1 Cable Ethernet
1 Dust Cover for RJ45 & USB Waterproof Connector
1 Cap, Plastic for C4 Screw Panel
1 Screw M3x5 Torx T10 SS Captive Washer

Comms Pack Contents

EPT026795 Issue 17 June 2020 7-35

CONNECTIVITY PACKS

Installation
WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver.

To install the comms pack:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear electronics panel.
(4) Lower the rear electronics panel.
(5) Mount the USB PCBA and Ethernet PCBA in the printer cabinet.
(6) Connect the USB cable to connector J13 on the USB PCBA and connector J26 on the
printer’s main PCB
(7) Connect the Ethernet cable to connector J15 on the Ethernet PCBA and connector J1002
on the printer’s main PCB
(8) Replace the printer’s rear electronics panel.
(9) Connect the power lead to the rear of the printer.
(10) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

7-36 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

USB PCBA Layout

USB PCBA USB PCBA

Top View Bottom View

External USB Port (J12)

This connector is an external USB type A port which can be used to transfer files such as software
upgrades or label designs to the printer.
Connector type: Panel mounted metal USB type A with straight PCB pins.
Pin Description
6 5

1 2 3 4
J12 Connections
(external view)

Table 18: External USB Port (J12) Pin Description

Pin Signal

1 USB_PWR
2 USB Data -
3 USB Data +
4 USB_GND
5 USB_GND
6 USB_PWR

EPT026795 Issue 17 June 2020 7-37

CONNECTIVITY PACKS

Internal Interface to Main PCB (J13)

1 2 3 4

J13 Connections
(external view)

Table 19: Internal Interface to Main PCB (J13) Pin Description

Pin USB PCBA Signal Main PCB Signal Description

1 USB_PWR USB_PWR USB Power

2 USB_Data - USB_HUB - USB Data
3 USB_Data + USB_HUB + USB Data
4 USB_GND GND_USB USB Ground
5 SHEILD_USB SHEILD_USB SHEILD_USB
6 SHEILD_USB SHEILD_USB SHEILD_USB
7 SHEILD_USB SHEILD_USB SHEILD_USB

7-38 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Ethernet PCBA Layout

Ethernet PCBA Ethernet PCBA

Top View Bottom View

EPT026795 Issue 17 June 2020 7-39

CONNECTIVITY PACKS

External Ethernet Port (J14)

This connector adds an external Ethernet interface to the printer cabinet.
Connector type: IP68 Panel mounted metal shell RJ45 with straight PCB pins.
Pin Description

J14 Connections
(external view)

Table 20: External Ethernet Port (J14) Pin Description

Pin Name Description

1 TX1+ Transmit Data+

2 TX1- Transmit Data-
3 RX1+ Receive Data+
4 Bias (EMC) Bias (EMC)
5 Bias (EMC) Bias (EMC)
6 RX1- Receive Data-
7 Bias (EMC) Bias (EMC)
8 Bias (EMC) Bias (EMC)
SH1 SHEILD1 1nF 2kV to EMC GND
SH2 SHEILD2 1nF 2kV to EMC GND

7-40 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Internal Interface to Main PCB (J15)

This connector provides internal communication between the main printer PCB and the Ethernet
PCBA. Use the correct cable from the connectivity pack to connect it to socket J1002 on the
printer’s main PCB.
Connector type: Straight shielded RJ45 (cat 5e)
Pin Description

J15 Connections
(external view)

Table 21: Internal Interface to Main PCB (J15) Pin Description

Pin Ethernet PCBA Signal Main PCB Signal Description

1 ETH_TX1+ ETH_TX1+ Transmit Data+

2 ETH_TX1- ETH_TX1- Transmit Data-
3 ETH_RX1+ ETH_RX1+ Receive Data+
4 Bias Bias Bias (EMC)
5 Bias Bias Bias (EMC)
6 ETH_RX1- ETH_RX1- Receive Data-
7 Bias Bias Bias (EMC)
8 Bias Bias Bias (EMC)
SH1 SHIELD1 SHIELD1 1nF 2kV to EMC
GND
SH2 SHIELD2 SHIELD2 1nF 2kV to EMC
GND

EPT026795 Issue 17 June 2020 7-41

CONNECTIVITY PACKS

GPIO PACK
The GPIO pack adds a 14 way GPIO port to the printer cabinet. The GPIO port can be connected
to customer supplied equipment to enable control of basic printer functions and output of printer
acknowledgements. Additionally, up to 15 labels can be selected from the printer’s internal
memory and sent to print.
To setup the GPIO port functions, see page 7-65.
The items listed in the table below are contained in the GPIO pack:

Table 22: GPIO Pack Contents

Quantity Item Description

1 Basic GPIO PCBA

1 Cable, Basic GPIO
1 Female Socket Sealing Cap
2 Screw M3x5 Torx T10 SS Captive Washer
1 14-Way Cable Plug Connector

Installation
WARNING: High voltage electricity. Risk of death or injury.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage.

Required tools: T10 torx driver.

To install the GPIO pack:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear electronics panel.
(4) Lower the rear electronics panel.
(5) Mount the basic GPIO PCBA in the printer cabinet.
(6) Connect the basic GPIO cable to connector J20 on the GPIO PCBA and connector J1502
on the printer’s main PCB.
(7) Replace the printer’s rear electronics panel.
(8) Connect the power lead to the rear of the printer.

7-42 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

(9) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

EPT026795 Issue 17 June 2020 7-43

CONNECTIVITY PACKS

GPIO PCBA
CAUTION: Sensitive components. Risk of damage.
If jumpers LK1 or LK3 are fitted in the wrong orientation, the 24V supply will short
to ground and blow the fuse.

Note: The input and output functions are configured on the printer’s user interface, see
page 7-65.
The GPIO PCBA provides four inputs and four outputs through a 14-way Lumberg connector
(J19):
• One pair of inputs for sourcing (PNP mode), sinking (NPN mode) or differential input signals.
• Three single ended inputs for sourcing (PNP mode, sinking (PNP mode) but not differential.
• Four single ended outputs capable of sinking (NPN and sourcing (PNP)

LK3
Output Power
System or User

LK1
Input Power
System or User

LK2 Input
Differential I/P

LK4 Output I.P LK2 Input I.P 1-3

0-3 PNP/NPN PNP/NPN

GPIO PCBA Layout and Jumper Positions

7-44 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

External Basic GPIO Connector

The GPIO connector provides general purpose input and output connectivity that enables external
devices to control basic printer functions.
Connector type: 14 way Din Socket IEC60130-9 (Lumberg 0307 14)
Mating cable connector type: 14 way Din Plug IEC60130-9 (Lumberg 0332 14)
Pin Description

B A K

L N
C J

D M H
O

E F G

CAUTION: Sensitive components. Risk of damage.
If jumpers LK1 or LK3 are fitted in the wrong orientation, the 24V supply will short
to ground and blow the fuse.

Input 0+ and input 0- (pins B and C on the GPIO connector) can be used together as a single
ended input. For operation in any configuration, connect pin B and C together. The green
highlights on the illustration below indicate the jumper positions for single ended, printer powered
NPN configuration.
Printer Side External Source

7-48 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Inputs 1, 2, 3
CAUTION: Sensitive components. Risk of damage.
If jumpers LK1 or LK3 are fitted in the wrong orientation, the 24 V supply will short
to ground and blow the fuse.

The green highlights on the illustration below show the jumper positions for printer 24 V (System)
and user +24 V selection for inputs 1 to 3 (pins D, E and F on the GPIO connector). There is no
option to take the printer +24 V to the connector.
Printer Side External Source

EPT026795 Issue 17 June 2020 7-49

CONNECTIVITY PACKS

Outputs 0, 1, 2 and 3
CAUTION: Sensitive components. Risk of damage.
If jumpers LK1 or LK3 are fitted in the wrong orientation, the 24V supply will short
to ground and blow the fuse.

The green highlights on the illustration below show the jumper positions for user powered PNP
configuration for outputs 0 to 3 (pins J, K, L and M on the GPIO connector). There is no option to
take the printer +24V to the connector.
Printer Side External Source

7-50 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

GPIO Test Box

The image below illustrates a test box that has been locally produced by a Domino engineer. The
box is designed to activate inputs and observe outputs on the GPIO connector J19.
The input trigger switches are DPST, this allows an LED to be illuminated from a 9V battery inside
the box when an input is triggered. The box also features LEDs that enable outputs to be
observed when each output is triggered. The output LEDs are powered from the printer.
As default, inputs on the GPIO connector are activated by a high input signal. Also by default,
outputs from the GPIO connector produce a high output when triggered. However, this
functionality can be reversed by changing the Active level settings, see page 7-65.
Note: A wiring diagram for this box is shown on the next page of this document.

GPIO Input/Output Box Example

EPT026795 Issue 17 June 2020 7-51

CONNECTIVITY PACKS

GPIO Test Box Wiring Schematic

Note: The wiring schematic below is valid if the GPIO PCBA jumpers LK3 and LK1 are set to
System. If the jumpers are set to User, the ground will need to be connected to the
user’s ground source.

GPIO Test Box

9V
J19 Inputs
B1

J1 9 P in B

4 70 Ω
R1 S1

L1
J1 9 P in C

4 70 Ω
R2 S2

L2
J1 9 P in D

4 70 Ω
R3 S3

L3
J1 9 P in E

4 70 Ω
R4 S4

L4
J1 9 P in F

J19 Outputs
1.56 k Ω
R5
J1 9 P in J
L5

1.56 k Ω
R6
J1 9 P ink K
L6

1.56 k Ω
R7
J1 9 P in L
L7

1.56 k Ω
R8
J1 9 P in M
L8

J19 Ground

J1 9 P in A

7-52 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Internal Interface to Main PCB (J20)

This connector provides internal communication between the main printer PCB and the GPIO
PCBA. Use the correct cable from the connectivity pack to connect it to socket J1502 on the
printer’s main PCB.
Connector type: 20-way vertical box header (SMT).
Pin Description

2 4 6 8 10 12 14 16 18 20

1 3 5 7 9 11 13 15 17 19

J20 Connections
(external view)

Table 24: Internal Interface to Main PCB (J20) Pin Description

GPIO PCBA
Pin Main PCB Signal Direction
Signal

1 GND GND From main

2 INPUT_0 BASIC_GPIO_IN0 To main
3 INPUT_1 BASIC_GPIO_IN1 To main
4 INPUT_2 BASIC_GPIO_IN2 To main
5 INPUT_3 BASIC_GPIO_IN3 To main
6 GND GND From main
7 OUTPUT_0 BASIC_GPIO_OUT0 From main
8 OUTPUT_1 BASIC_GPIO_OUT1 From main
9 OUTPUT_2 BASIC_GPIO_OUT2 From main
10 OUTPUT_3 BASIC_GPIO_OUT3 From main
11 GND GND From main
12 ICTP1 TP1512 From main
13 GND GND From main
14 GND GND From main
15 GND GND From main
16 +5V +5V_FUSED From main
17 +5V +5V_FUSED From main
18 +5V +5V_FUSED From main
19 +24V +24V_INT_A From main
20 +24V +24V_INT_A From main

EPT026795 Issue 17 June 2020 7-53

CONNECTIVITY PACKS

EXTENDED IO PACK
Introduction
Notes: (1) The expended IO pack is not available for the Ax150i.
(2) If replacing an A-Series or an A-Series Classic installation, a 37-Way D type to 25-Way
type 1 socket adapter cable is required, Domino part number EAS002903.
The extended IO pack adds two user ports to the printer cabinet. The user ports can be
connected to customer supplied equipment to enable control of basic printer functions and
output of printer acknowledgements. Additionally, up to 255 labels can be selected from the
printer’s internal memory and sent to print.
To setup the user port functions, see page 7-65.
The items listed in the table below are contained in the extended IO pack:

Table 25: Extended IO Pack Contents

Quantity Item Description

Internal Interface to Main PCB (J22)

This connector provides internal communication between the main printer PCB and the extended
IO PCBA. Use the correct cable from the connectivity pack to connect it to connector J1502 on
the printer’s main PCB.
Connector type: 20W vertical box header (SMT).
Pin Description

2 4 6 8 10 12 14 16 18 20

1 3 5 7 9 11 13 15 17 19

J22 Connection
(external view)

Table 26: Internal Interface to Main PCB (J22) Pin Description

Extended IO
Pin Main PCB Signal Direction
PCBA Signal

1 0V 0V From Main
2 INPUT_0 BASIC_GPIO_IN0 To Main
3 INPUT_1 BASIC_GPIO_IN1 To Main
4 INPUT_2 BASIC_GPIO_IN2 To Main
5 INPUT_3 BASIC_GPIO_IN3 To Main
6 0V 0V From Main
7 OUTPUT_0 BASIC_GPIO_OUT0 From Main
8 OUTPUT_1 BASIC_GPIO_OUT1 From Main
9 OUTPUT_2 BASIC_GPIO_OUT2 From Main
10 OUTPUT_3 BASIC_GPIO_OUT3 From Main
11 0V 0V From Main
12 ICTP1 TP1512 From Main
13 0V 0V From Main
14 0V 0V From Main
15 0V 0V From Main
16 5V 5V From Main
17 5V 5V From Main
18 5V 5V From Main
19 24V 24V From Main
20 24V 24V From Main

7-58 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Internal Interface To Main PCB (J21)

This connector provides communication between the main printer PCB and the extended IO
PCBA. Use the correct cable from the connectivity pack to connect it to socket J171 on the
printer’s main PCB.
Connector type: 34W vertical box header (SMT).
Pin Description

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33

J21 Connections
(external view)

Table 27: Internal Interface to Main PCB (J21) Pin Description

Extended IO PCBA
Pin Main PCB Signal Direction
Signal

1 EXP_TTL_TXD PL_UART2_TXD From Main

2 EXP_TTL_RXD PL_UART2_RXD To Main
3 EXP_TTL_CTS PL_UART2_CTS To Main
4 EXP_TTL_RTS PL_UART2_RTS From Main
5 EXP_TTL_DTR PL_UART2_DTR From Main
6 EXP_TTL_DSR PL_UART2_DSR To Main
7 DGND DGND To Main
8 EXP__GPIO_OUT0 EXTENDED_GPIO_OUT0 From Main
9 EXP__GPIO_OUT1 EXTENDED_GPIO_OUT1 From Main
10 EXP__GPIO_OUT2 EXTENDED_GPIO_OUT2 From Main
11 EXP__GPIO_OUT3 EXTENDED_GPIO_OUT3 From Main
12 EXP__GPIO_OUT4 EXTENDED_GPIO_OUT4 From Main
13 EXP__GPIO_OUT5 EXTENDED_GPIO_OUT5 From Main
14 EXP__GPIO_OUT6 EXTENDED_GPIO_OUT6 From Main
15 EXP__GPIO_OUT7 EXTENDED_GPIO_OUT7 From Main
16 EXP__GPIO_OUT8 EXTENDED_GPIO_OUT8 From Main
17 EXP__GPIO_OUT9 EXTENDED_GPIO_OUT9 From Main
18 EXP__GPIO_OUT10 EXTENDED_GPIO_OUT10 From Main
19 EXP__GPIO_OUT11 EXTENDED_GPIO_OUT11 From Main
20 EXP_GPIO_IN0 EXTENDED_GPIO_IN0 To Main

EPT026795 Issue 17 June 2020 7-59

CONNECTIVITY PACKS

Table 27: Internal Interface to Main PCB (J21) Pin Description

Extended IO PCBA
Pin Main PCB Signal Direction
Signal

21 EXP_GPIO_IN1 EXTENDED_GPIO_IN1 To Main

22 EXP_GPIO_IN2 EXTENDED_GPIO_IN2 To Main
23 EXP_GPIO_IN3 EXTENDED_GPIO_IN3 To Main
24 EXP_GPIO_IN4 EXTENDED_GPIO_IN4 To Main
25 EXP_GPIO_IN5 EXTENDED_GPIO_IN5 To Main
26 EXP_GPIO_IN6 EXTENDED_GPIO_IN6 To Main
27 EXP_GPIO_IN7 EXTENDED_GPIO_IN7 To Main
28 EXP_GPIO_IN8 EXTENDED_GPIO_IN8 To Main
29 EXP_GPIO_IN9 EXTENDED_GPIO_IN9 To Main
30 EXP_GPIO_IN10 EXTENDED_GPIO_IN10 To Main
31 EXP_GPIO_IN11 EXTENDED_GPIO_IN11 To Main
32 0V GND From Main
33 +24V +24V_INT_A From Main
34 +5V +5V_FUSED From Main

7-60 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

External User Port 37W Connector (J23)

J23 provides the following external connections to user equipment:
• Configurable opto-isolated inputs.
• Configurable opto-isolated outputs.
• Isolated and non-isolated power and ground reference.
Connector type: 37 Way D-Type Socket
Mating cable connector type: 37 Way D-Type Plug
Pin Description

19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20

37 Way Socket Connections

(external view)

Note: See page 7-67 to assign configurable input and output pins to functions.

Table 28: External User Port 37W Connector (J23) Pin Description

Pin Signal Name

1 CONFIGURABLE INPUT
2 CONFIGURABLE INPUT
3 CONFIGURABLE INPUT
4 CONFIGURABLE INPUT
5 CONFIGURABLE INPUT
6 CONFIGURABLE INPUT
7 CONFIGURABLE INPUT
8 CONFIGURABLE INPUT
9 CONFIGURABLE INPUT
10 CONFIGURABLE INPUT
11 CONFIGURABLE INPUT
12 CONFIGURABLE INPUT
13 ISOLATED GROUND
14 CONFIGURABLE OUTPUT
15 CONFIGURABLE OUTPUT
16 CONFIGURABLE OUTPUT
17 CONFIGURABLE OUTPUT

EPT026795 Issue 17 June 2020 7-61

CONNECTIVITY PACKS

Table 28: External User Port 37W Connector (J23) Pin Description

Pin Signal Name

18 OUTPUT COMMON
19 ISOLATED +24V OUTPUT
20 ISOLATED +24V OUTPUT
21 NOT USED
22 NOT USED
23 ISOLATED GROUND
24 DIGITAL GROUND
25 SCREEN (EMC) GROUND
26 NOT USED
27 RS232 CTS INPUT
28 RS232 RTS OUTPUT
29 NOT USED
30 NOT USED
31 NOT USED
32 RS232 TX OUTPUT
33 RS232 RX INPUT
34 RS232 DTR OUTPUT
35 DIGITAL GROUND
36 RS232 DSR INPUT
37 NOT USED

7-62 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

External User Port 25W Connector (J24)

J24 provides the following external connections to user equipment:
• Configurable opto-isolated inputs.
• Configurable opto-isolated outputs.
• Isolated and non-isolated power and ground reference.
Connector type: 25 Way D-Type Socket
Mating cable connector type: 25 Way D-Type Plug
Pin Description

13 12 11 10 9 8 7 6 5 4 3 2 1

25 24 23 22 21 20 19 18 17 16 15 14

25 Way Socket Connections

(external view)

Note: See page 7-67 to assign configurable input and output pins to functions.

Table 29: External User Port 25W Connector (J24) Pin Description

Pin Signal Name

1 DIGITAL GROUND
2 CONFIGURABLE INPUT
3 CONFIGURABLE INPUT
4 CONFIGURABLE INPUT
5 CONFIGURABLE INPUT
6 CONFIGURABLE OUTPUT
7 CONFIGURABLE OUTPUT
8 CONFIGURABLE OUTPUT
9 NOT USED
10 NOT USED
11 NOT USED
12 NOT USED
13 ISOLATED GROUND
14 NOT USED
15 NOT USED
16 NOT USED
17 NOT USED

EPT026795 Issue 17 June 2020 7-63

CONNECTIVITY PACKS

Table 29: External User Port 25W Connector (J24) Pin Description

Pin Signal Name

18 OUTPUT COMMON (OPTO)

19 ISOLATED +24V OUTPUT
20 ISOLATED +24V OUTPUT
21 NOT USED
22 NOT USED
23 ISOLATED GROUND
24 DIGITAL GROUND
25 NOT USED

7-64 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

USING IO PACKS
The following pages in this chapter explain the printer settings that are available to setup and use
the GPIO Pack and Extended IO Pack.

Set Up
Note: Frequent navigation and configuration of the I/O settings can cause excessive memory
use. It is recommended to re-boot the printer after the I/O settings have been
configured.
To view and configure the settings available on the set up screen:
(1) Select Home > Setup > I/O Port > Set up.
(2) The settings available on the Set up screen are described in the three tables below.

Table 30: Input Settings

Setting Explanation

GPI debounce Define the input debounce time.

time (us)
GPI queue depth Define the maximum number of data packets allowed in the input queue.
Range 4 - 1023
GPI queue empty Tick the tick box to raise a printer alert when the external data queue is
alert empty.
GPI queue first Tick the box to raise a printer alert when the first data packet enters the
element received external data queue.
alert
GPI queue Tick the box to raise a printer alert when there are too many entries in the
overflow alert external data queue.

Table 31: Other Settings

Setting Explanation

EDC history External data packets sent to the printer can be saved in a history queue.
queue depth The history queue allows the printer to check if duplicate data is received
and to raise an alert if required.
This setting defines the maximum number of data packets that can be
saved in the history queue.
Range: 0 - 2048
EDC history Define the number of duplicate data packets allowed before a printer alert
queue maximum is triggered. For example, if this setting is set to ten, then ten duplicate data
duplicates packets will be allowed before the alert is triggered.
Range: 0 - 100

EPT026795 Issue 17 June 2020 7-65

CONNECTIVITY PACKS

Table 31: Other Settings

Setting Explanation

EDC history Define the printers action when the EDC history queue becomes full:
queue full action
Reset - Clear the history queue and start again.

Overwrite - Overwrite the history queue.

EDC history Tick the box to preserve the EDC history queue when the printer is
queue preserve powered off.
over power off
If the box is not ticked, the EDC history queue will be deleted when the
printer is powered off.
Label select: alert Tick the box to show an alert when a empty label slot is selected. See
on empty slot “External Label Selection” on page 7-72.
selection
Custom shift Note: The custom shift register is a data transfer feature used in
register: alert on special applications such as Tetrapak.
invalid bit count Tick the box to show an amber alert when the number of bits read by the
custom shift register since the last product detect is not a multiple of 16.

End of procedure.

7-66 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Assignment
Inputs
Assign a function to each input pin to ensure the correct function is triggered.
Notes: (1) Inputs and Outputs that are labelled “B-Pin” are valid for the GPIO port J19 (if fitted),
see page 7-51.
(2) The inputs and outputs that are labelled “Ext25” are valid for the 25 way user port J24
(if fitted), see page 7-63.
(3) The inputs and outputs that are labelled “Ext37” are valid for the 37 way user port J23
(if fitted), see page 7-61.
(4) Frequent navigation and configuration of the I/O settings can cause excessive memory
use. It is recommended to re-boot the printer after the I/O settings have been
configured.
To assign pins to specific input functions:
(1) Select Home > Setup > I/O Port > Assignment.
(2) Select the Active level drop down setting for each input pin and select if a High or Low
signal will activate the input function.
(3) Select the Function drop down setting for each pin and select a function as described in the
table below.

Table 32: Input Functions

Function Explanation

Unassigned The pin will not be assigned to any function.

Label selection The pin will be assigned to external label selection.
When selecting Label selection for the first time, the alert “no message is
selected for printing” will be displayed.
Select only the minimum number of pins required for external label
selection. See page page 7-72 for more information about external label
selection.
Reset statistics Reset Resettable Counter 1 on the printer’s Statistics menu.
counter 1 Resettable Counter 1 can be viewed on the printer’s user interface by
selecting Home > Setup > Printer status > Statistics
Reset statistics Reset Resettable Counter 2 on the printer’s Statistics menu.
counter 2 Resettable Counter 2 can be viewed on the printer’s user interface by
selecting Home > Setup > Printer status > Statistics
Print inverted Invert the current printing label.
Print reversed Reverse the current printed label.
Global print Invert all labels that are sent to print until this input is triggered again.
inverted
Global print Reverse all labels that are sent to print until this input is triggered again.
reversed
Jet control Sequence the ink jet on or off.

EPT026795 Issue 17 June 2020 7-67

CONNECTIVITY PACKS

Table 32: Input Functions

Function Explanation

Reset all print Reset all counter elements in the currently printing label. All counters will
counters reset to the value that was specified when the counters were created.
Reset print Reset counter element 1 in the currently printing label. The counter will
counter 1 reset to the value that was specified when the counter was created.
Reset print Reset counter element 2 in the currently printing label. The counter will
counter 2 reset to the value that was specified when the counter was created.
Reset print Reset counter element 3 in the currently printing label. The counter will
counter 3 reset to the value that was specified when the counter was created.
Reset print Reset counter element 4 in the currently printing label. The counter will
counter 4 reset to the value that was specified when the counter was created.
Update print Note: To set the printer to only update counter elements using inputs,
counter 1 enable the GPI counter updates only setting, see page 4-37.
Update counter element 1 in the currently printing label. The counter will
updated by the step size that was specified when the counter was created.
Update print Note: To set the printer to only update counter elements using inputs,
counter 2 enable the GPI counter updates only setting, see page 4-37.
Update counter element 2 in the currently printing label. The counter will
updated by the step size that was specified when the counter was created.
Update print Note: To set the printer to only update counter elements using inputs,
counter 3 enable the GPI counter updates only setting, see page 4-37.
Update counter element 3 in the currently printing label. The counter will
updated by the step size that was specified when the counter was created.
Update print Note: To set the printer to only update counter elements using inputs,
counter 4 enable the GPI counter updates only setting, see page 4-37.
Update counter element 4 in the currently printing label. The counter will
updated by the step size that was specified when the counter was created.
Print abort Notes: (1) In printer software version 01.40.0407 and earlier, this input can
only be set on pins 0, 1, 2 or 3. This is resolved in software
version 01.40.0428 onwards.
(2) Do not trigger the print abort input more than once in
succession, during printing of the same single label. This can
cause unexpected printer behaviour.
The printer will stop printing the label at the end of the current print stroke.
The next label will be printed when the next print trigger is received.

7-68 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Table 32: Input Functions

Function Explanation

Suppress print This input will stop the next print. Dynamic data such as counter elements
will continue to increment/decrement during print suppress.

This input is useful for traversing applications when using a bidirectional

counter. This input can also be used to suppress printing onto a damaged
product without loosing the traverser lane identification.

To enable print suppress, the input must switch to the active level and
back to the inactive level before the print trigger occurs. Do not hold the
input active during the print. The correct timing is illustrated below. In this
example, label 1 will be suppressed, label 2 will be printed.

Print Trigger

Suppress Print
Label 1 Label 2

Print enable Enable or disable printing, this input will not turn the ink jet on or off.
CSR clock This interrupt is for the Custom Shift Register (CSR) feature used in
conjunction with the CSR data input. This is used in special applications
such as Tetrapak.
CSR data This input is for the custom shift register feature mainly used in special
applications like Tetrapak.
Reset backlash Reset the encoder backlash count to zero. See “Encoder Mode Setup” on
page 4-49.

(3) The number for each pin will turn green to indicate when an input is received.

Input Received Input NOT Received

End of procedure.

EPT026795 Issue 17 June 2020 7-69

CONNECTIVITY PACKS

Outputs
Assign a function to each output pin to ensure the correct function is triggered.
Notes: (1) Inputs and Outputs that are labelled “B-Pin” are valid for the GPIO port J19 (if fitted),
see page 7-51.
(2) The inputs and outputs that are labelled “Ext25” are valid for the 25 way user port J24
(if fitted), see page 7-63.
(3) The inputs and outputs that are labelled “Ext37” are valid for the 37 way user port J23
(if fitted), see page 7-61.
(4) Frequent navigation and configuration of the I/O settings can cause excessive memory
use. It is recommended to re-boot the printer after the I/O settings have been
configured.
To assign pins to specific output functions:
(1) Select Home > Setup > I/O Port > Assignment.
(2) Scroll down the screen to the list of Output functions.
(3) Select the Active level drop down setting for each output pin and select if a High or Low
signal will be sent when the output function is active.
(4) Adjust the Pulse time (ms) value for each pin to set the length of the output pulse.
(5) Select the Function drop down setting for each output pin and select a function as
described in the table below.

Table 33: Output Functions

Function Explanation

Unassigned The pin will not be assigned to any function.

Printer ready The output will be switched when the printer has compiled/rendered the
label for printing.
Good print The output will be switched when printing is good.
Bad print The output will be switched when an alert that could affect printing the
right message on the right product occurs. Examples of alerts that will
trigger the output include, Print stretch detected, Long print, Check print
quality, Detected too Many Products, Some Ignored, Print Trigger
Occurred Too Early, and Print GO occurred While Printing.
EDC buffer low The output will be switched when the amount of data in the EDC (external
data capture) starts to run low.
EDC buffer high The output will be switched when the amount of data in the EDC (external
data capture) is high.
External comms The output will be switched to confirm when an EDC or Codenet command
ack is acknowledged.
Print complete The output will be switched after a label has finished printing.
Print Counter 1 The output will be switched when the rollover of counter element 1 in the
Rollover currently printing label occurs.
Print Counter 2 The output will be switched when the rollover of counter element 2 in the
Rollover currently printing label occurs.

7-70 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Table 33: Output Functions

Function Explanation

Print Counter 3 The output will be switched when the rollover of counter element 3 in the
Rollover currently printing label occurs.
Print Counter 4 The output will be switched when the rollover of counter element 4 in the
Rollover currently printing label occurs.
Reset print The output will be switched when the command to reset counter element 1
counter 1 output in the currently printing label is sent.
Reset print The output will be switched when the command to reset counter element 2
counter 2 output in the currently printing label is sent.
Reset print The output will be switched when the command to reset counter element 3
counter 3 output in the currently printing label is sent.
Reset print The output will be switched when the command to reset counter element 4
counter 4 output in the currently printing label is sent.

(6) To send a test output signal press the Test button for each output.

Test Button

(7) The number next to each output will turn green to indicate when the output is active.

Active Not Active

End of procedure.

EPT026795 Issue 17 June 2020 7-71

CONNECTIVITY PACKS

External Label Selection

An external device can be connected to the user ports (if fitted) or GPIO port (if fitted) to select
labels for printing. External label selection uses assigned input pins as a binary reference to select
labels from the printers internal memory and send them to print.
Notes: (1) Up to four input pins on the GPIO port (J19) can be assigned to label selection. If all
four input pins are assigned to label selection, up to 15 labels can be selected.
(2) Up to eight input pins using the 25-way (J23) and 37-way (J24) user ports combined
can be assigned to label selection. If all eight input pins are assigned to label selection,
up to 255 labels can be selected.
(3) The number of pins available for label selection will be reduced if input pins are
assigned to other functions.
(4) Frequent navigation and configuration of the I/O settings can cause excessive memory
use. It is recommended to re-boot the printer after the I/O settings have been
configured.
Assign Input Pins to Label Selection
To assign pins to label selection:
(1) Select Home > Setup >IO Port > Assignment.
(2) Select each required input pin and select Label selection.
End of procedure.
Allocate Labels to Slot Numbers
Allocate each label a slot number to make the label available for external label selection. When a
binary signal is received via the assigned input pins, the number received will select the label that
is assigned to that slot number and send the label to print.
To allocate a label to a slot number:
(1) Select Home > Setup > I/O Port > Assignment.
(2) Assign the required number of input pins to Label selection.
(3) Select Label select.
(4) Either select the icon to automatically populate the label slots with labels. Or, select
each label slot and select specific labels to assign to each slot.
(5) Select ON.
End of procedure.
Disable External Label Selection
To disable external label selection:
(1) Select Home > Setup > I/O Port > Label select
(2) Select the icon at the top of the screen to clear the label slots.
(3) Select Assignment.
(4) Un-assign the input pins, or assign the input pins to different functions.
End of procedure.

7-72 EPT026795 Issue 17 June 2020

CONNECTIVITY PACKS

Binary Inputs for Label Selection via GPIO Port or 25-Way User Port
The table below lists the maximum number of valid binary inputs for label selection using the
GPIO Port or 25-Way User Port. These binary inputs are valid if all four input pins are assigned to
label selection, see page 7-72.

Table 34: GPIO Port Binary Inputs for Label Selection

B-PinB-
B-PinD / B-PinE / B-PinF /
GPIO Port or 25-Way C/
Ext25- Ext25- Ext25-
User Port Connector Pin Ext25-
Pin3 Pin4 Pin5
Pin2

Input Binary Value 1 2 4 8

Slot Number Printing Inputs Selected

No Label Selected 0 0 0 0
Slot 1 1 0 0 0
Slot 2 0 1 0 0
Slot 3 1 1 0 0
Slot 4 0 0 1 0
Slot 5 1 0 1 0
Slot 6 0 1 1 0
Slot 7 1 1 1 0
Slot 8 0 0 0 1
Slot 9 1 0 0 1
Slot 10 0 1 0 1
Slot 11 1 1 0 1
Slot 12 0 0 1 1
Slot 13 1 0 1 1
Slot 14 0 1 1 1
Slot 15 1 1 1 1

EPT026795 Issue 17 June 2020 7-73

Binary Inputs for Label Selection via 37-Way User Port
7-74

The table below lists the maximum number of valid binary inputs for label selection via the 37-Way user port. These binary inputs are valid if eight
input pins are assigned to label selection, see page 7-72.

Table 35: 37-Way User Port Binary Inputs for Label Selection

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

No Label Selected 0 0 0 0 0 0 0 0

CONNECTIVITY PACKS
Slot 1 1 0 0 0 0 0 0 0
Slot 2 0 1 0 0 0 0 0 0
Slot 3 1 1 0 0 0 0 0 0
Slot 4 0 0 1 0 0 0 0 0
Slot 5 1 0 1 0 0 0 0 0
Slot 6 0 1 1 0 0 0 0 0
Slot 7 1 1 1 0 0 0 0 0
EPT026795 Issue 17 June 2020

Slot 8 0 0 0 1 0 0 0 0
Slot 9 1 0 0 1 0 0 0 0
Slot 10 0 1 0 1 0 0 0 0
Slot 11 1 1 0 1 0 0 0 0
Slot 12 0 0 1 1 0 0 0 0
Slot 13 1 0 1 1 0 0 0 0
Table 35: 37-Way User Port Binary Inputs for Label Selection
EPT026795 Issue 17 June 2020

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 14 0 1 1 1 0 0 0 0
Slot 15 1 1 1 1 0 0 0 0
Slot 16 0 0 0 0 1 0 0 0
Slot 17 1 0 0 0 1 0 0 0

CONNECTIVITY PACKS
Slot 18 0 1 0 0 1 0 0 0
Slot 19 1 1 0 0 1 0 0 0
Slot 20 0 0 1 0 1 0 0 0
Slot 21 1 0 1 0 1 0 0 0
Slot 22 0 1 1 0 1 0 0 0
Slot 23 1 1 1 0 1 0 0 0
Slot 24 0 0 0 1 1 0 0 0
Slot 25 1 0 0 1 1 0 0 0
Slot 26 0 1 0 1 1 0 0 0
Slot 27 1 1 0 1 1 0 0 0
Slot 28 0 0 1 1 1 0 0 0
Slot 29 1 0 1 1 1 0 0 0
Slot 30 0 1 1 1 1 0 0 0
7-75
Table 35: 37-Way User Port Binary Inputs for Label Selection
7-76

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 31 1 1 1 1 1 0 0 0
Slot 32 0 0 0 0 0 1 0 0
Slot 33 1 0 0 0 0 1 0 0
Slot 34 0 1 0 0 0 1 0 0

CONNECTIVITY PACKS
Slot 35 1 1 0 0 0 1 0 0
Slot 36 0 0 1 0 0 1 0 0
Slot 37 1 0 1 0 0 1 0 0
Slot 38 0 1 1 0 0 1 0 0
Slot 39 1 1 1 0 0 1 0 0
Slot 40 0 0 0 1 0 1 0 0
Slot 41 1 0 0 1 0 1 0 0
EPT026795 Issue 17 June 2020

Slot 42 0 1 0 1 0 1 0 0
Slot 43 1 1 0 1 0 1 0 0
Slot 44 0 0 1 1 0 1 0 0
Slot 45 1 0 1 1 0 1 0 0
Slot 46 0 1 1 1 0 1 0 0
Slot 47 1 1 1 1 0 1 0 0
Table 35: 37-Way User Port Binary Inputs for Label Selection
EPT026795 Issue 17 June 2020

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 48 0 0 0 0 1 1 0 0
Slot 49 1 0 0 0 1 1 0 0
Slot 50 0 1 0 0 1 1 0 0
Slot 51 1 1 0 0 1 1 0 0

CONNECTIVITY PACKS
Slot 52 0 0 1 0 1 1 0 0
Slot 53 1 0 1 0 1 1 0 0
Slot 54 0 1 1 0 1 1 0 0
Slot 55 1 1 1 0 1 1 0 0
Slot 56 0 0 0 1 1 1 0 0
Slot 57 1 0 0 1 1 1 0 0
Slot 58 0 1 0 1 1 1 0 0
Slot 59 1 1 0 1 1 1 0 0
Slot 60 0 0 1 1 1 1 0 0
Slot 61 1 0 1 1 1 1 0 0
Slot 62 0 1 1 1 1 1 0 0
Slot 63 1 1 1 1 1 1 0 0
Slot 64 0 0 0 0 0 0 1 0
7-77
Table 35: 37-Way User Port Binary Inputs for Label Selection
7-78

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 65 1 0 0 0 0 0 1 0
Slot 66 0 1 0 0 0 0 1 0
Slot 67 1 1 0 0 0 0 1 0
Slot 68 0 0 1 0 0 0 1 0

CONNECTIVITY PACKS
Slot 69 1 0 1 0 0 0 1 0
Slot 70 0 1 1 0 0 0 1 0
Slot 71 1 1 1 0 0 0 1 0
Slot 72 0 0 0 1 0 0 1 0
Slot 73 1 0 0 1 0 0 1 0
Slot 74 0 1 0 1 0 0 1 0
Slot 75 1 1 0 1 0 0 1 0
EPT026795 Issue 17 June 2020

Slot 76 0 0 1 1 0 0 1 0
Slot 77 1 0 1 1 0 0 1 0
Slot 78 0 1 1 1 0 0 1 0
Slot 79 1 1 1 1 0 0 1 0
Slot 80 0 0 0 0 1 0 1 0
Slot 81 1 0 0 0 1 0 1 0
Table 35: 37-Way User Port Binary Inputs for Label Selection
EPT026795 Issue 17 June 2020

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 82 0 1 0 0 1 0 1 0
Slot 83 1 1 0 0 1 0 1 0
Slot 84 0 0 1 0 1 0 1 0
Slot 85 1 0 1 0 1 0 1 0

CONNECTIVITY PACKS
Slot 86 0 1 1 0 1 0 1 0
Slot 87 1 1 1 0 1 0 1 0
Slot 88 0 0 0 1 1 0 1 0
Slot 89 1 0 0 1 1 0 1 0
Slot 90 0 1 0 1 1 0 1 0
Slot 91 1 1 0 1 1 0 1 0
Slot 92 0 0 1 1 1 0 1 0
Slot 93 1 0 1 1 1 0 1 0
Slot 94 0 1 1 1 1 0 1 0
Slot 95 1 1 1 1 1 0 1 0
Slot 96 0 0 0 0 0 1 1 0
Slot 97 1 0 0 0 0 1 1 0
Slot 98 0 1 0 0 0 1 1 0
7-79
Table 35: 37-Way User Port Binary Inputs for Label Selection
7-80

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 99 1 1 0 0 0 1 1 0
Slot 100 0 0 1 0 0 1 1 0
Slot 101 1 0 1 0 0 1 1 0
Slot 102 0 1 1 0 0 1 1 0

CONNECTIVITY PACKS
Slot 103 1 1 1 0 0 1 1 0
Slot 104 0 0 0 1 0 1 1 0
Slot 105 1 0 0 1 0 1 1 0
Slot 106 0 1 0 1 0 1 1 0
Slot 107 1 1 0 1 0 1 1 0
Slot 108 0 0 1 1 0 1 1 0
Slot 109 1 0 1 1 0 1 1 0
EPT026795 Issue 17 June 2020

Slot 110 0 1 1 1 0 1 1 0
Slot 111 1 1 1 1 0 1 1 0
Slot 112 0 0 0 0 1 1 1 0
Slot 113 1 0 0 0 1 1 1 0
Slot 114 0 1 0 0 1 1 1 0
Slot 115 1 1 0 0 1 1 1 0
Table 35: 37-Way User Port Binary Inputs for Label Selection
EPT026795 Issue 17 June 2020

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 116 0 0 1 0 1 1 1 0
Slot 117 1 0 1 0 1 1 1 0
Slot 118 0 1 1 0 1 1 1 0
Slot 119 1 1 1 0 1 1 1 0

CONNECTIVITY PACKS
Slot 120 0 0 0 1 1 1 1 0
Slot 121 1 0 0 1 1 1 1 0
Slot 122 0 1 0 1 1 1 1 0
Slot 123 1 1 0 1 1 1 1 0
Slot 124 0 0 1 1 1 1 1 0
Slot 125 1 0 1 1 1 1 1 0
Slot 126 0 1 1 1 1 1 1 0
Slot 127 1 1 1 1 1 1 1 0
Slot 128 0 0 0 0 0 0 0 1
Slot 129 1 0 0 0 0 0 0 1
Slot 130 0 1 0 0 0 0 0 1
Slot 131 1 1 0 0 0 0 0 1
Slot 132 0 0 1 0 0 0 0 1
7-81
Table 35: 37-Way User Port Binary Inputs for Label Selection
7-82

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 133 1 0 1 0 0 0 0 1
Slot 134 0 1 1 0 0 0 0 1
Slot 135 1 1 1 0 0 0 0 1
Slot 136 0 0 0 1 0 0 0 1

CONNECTIVITY PACKS
Slot 137 1 0 0 1 0 0 0 1
Slot 138 0 1 0 1 0 0 0 1
Slot 139 1 1 0 1 0 0 0 1
Slot 140 0 0 1 1 0 0 0 1
Slot 141 1 0 1 1 0 0 0 1
Slot 142 0 1 1 1 0 0 0 1
Slot 143 1 1 1 1 0 0 0 1
EPT026795 Issue 17 June 2020

Slot 144 0 0 0 0 1 0 0 1
Slot 145 1 0 0 0 1 0 0 1
Slot 146 0 1 0 0 1 0 0 1
Slot 147 1 1 0 0 1 0 0 1
Slot 148 0 0 1 0 1 0 0 1
Slot 149 1 0 1 0 1 0 0 1
Table 35: 37-Way User Port Binary Inputs for Label Selection
EPT026795 Issue 17 June 2020

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 150 0 1 1 0 1 0 0 1
Slot 151 1 1 1 0 1 0 0 1
Slot 152 0 0 0 1 1 0 0 1
Slot 153 1 0 0 1 1 0 0 1

CONNECTIVITY PACKS
Slot 154 0 1 0 1 1 0 0 1
Slot 155 1 1 0 1 1 0 0 1
Slot 156 0 0 1 1 1 0 0 1
Slot 157 1 0 1 1 1 0 0 1
Slot 158 0 1 1 1 1 0 0 1
Slot 159 1 1 1 1 1 0 0 1
Slot 160 0 0 0 0 0 1 0 1
Slot 161 1 0 0 0 0 1 0 1
Slot 162 0 1 0 0 0 1 0 1
Slot 163 1 1 0 0 0 1 0 1
Slot 164 0 0 1 0 0 1 0 1
Slot 165 1 0 1 0 0 1 0 1
Slot 166 0 1 1 0 0 1 0 1
7-83
Table 35: 37-Way User Port Binary Inputs for Label Selection
7-84

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 167 1 1 1 0 0 1 0 1
Slot 168 0 0 0 1 0 1 0 1
Slot 169 1 0 0 1 0 1 0 1
Slot 170 0 1 0 1 0 1 0 1

CONNECTIVITY PACKS
Slot 171 1 1 0 1 0 1 0 1
Slot 172 0 0 1 1 0 1 0 1
Slot 173 1 0 1 1 0 1 0 1
Slot 174 0 1 1 1 0 1 0 1
Slot 175 1 1 1 1 0 1 0 1
Slot 176 0 0 0 0 1 1 0 1
Slot 177 1 0 0 0 1 1 0 1
EPT026795 Issue 17 June 2020

Slot 178 0 1 0 0 1 1 0 1
Slot 179 1 1 0 0 1 1 0 1
Slot 180 0 0 1 0 1 1 0 1
Slot 181 1 0 1 0 1 1 0 1
Slot 182 0 1 1 0 1 1 0 1
Slot 183 1 1 1 0 1 1 0 1
Table 35: 37-Way User Port Binary Inputs for Label Selection
EPT026795 Issue 17 June 2020

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 184 0 0 0 1 1 1 0 1
Slot 185 1 0 0 1 1 1 0 1
Slot 186 0 1 0 1 1 1 0 1
Slot 187 1 1 0 1 1 1 0 1

CONNECTIVITY PACKS
Slot 188 0 0 1 1 1 1 0 1
Slot 189 1 0 1 1 1 1 0 1
Slot 190 0 1 1 1 1 1 0 1
Slot 191 1 1 1 1 1 1 0 1
Slot 192 0 0 0 0 0 0 1 1
Slot 193 1 0 0 0 0 0 1 1
Slot 194 0 1 0 0 0 0 1 1
Slot 195 1 1 0 0 0 0 1 1
Slot 196 0 0 1 0 0 0 1 1
Slot 197 1 0 1 0 0 0 1 1
Slot 198 0 1 1 0 0 0 1 1
Slot 199 1 1 1 0 0 0 1 1
Slot 200 0 0 0 1 0 0 1 1
7-85
Table 35: 37-Way User Port Binary Inputs for Label Selection
7-86

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 201 1 0 0 1 0 0 1 1
Slot 202 0 1 0 1 0 0 1 1
Slot 203 1 1 0 1 0 0 1 1
Slot 204 0 0 1 1 0 0 1 1

CONNECTIVITY PACKS
Slot 205 1 0 1 1 0 0 1 1
Slot 206 0 1 1 1 0 0 1 1
Slot 207 1 1 1 1 0 0 1 1
Slot 208 0 0 0 0 1 0 1 1
Slot 209 1 0 0 0 1 0 1 1
Slot 210 0 1 0 0 1 0 1 1
Slot 211 1 1 0 0 1 0 1 1
EPT026795 Issue 17 June 2020

Slot 212 0 0 1 0 1 0 1 1
Slot 213 1 0 1 0 1 0 1 1
Slot 214 0 1 1 0 1 0 1 1
Slot 215 1 1 1 0 1 0 1 1
Slot 216 0 0 0 1 1 0 1 1
Slot 217 1 0 0 1 1 0 1 1
Table 35: 37-Way User Port Binary Inputs for Label Selection
EPT026795 Issue 17 June 2020

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 218 0 1 0 1 1 0 1 1
Slot 219 1 1 0 1 1 0 1 1
Slot 220 0 0 1 1 1 0 1 1
Slot 221 1 0 1 1 1 0 1 1

CONNECTIVITY PACKS
Slot 222 0 1 1 1 1 0 1 1
Slot 223 1 1 1 1 1 0 1 1
Slot 224 0 0 0 0 0 1 1 1
Slot 225 1 0 0 0 0 1 1 1
Slot 226 0 1 0 0 0 1 1 1
Slot 227 1 1 0 0 0 1 1 1
Slot 228 0 0 1 0 0 1 1 1
Slot 229 1 0 1 0 0 1 1 1
Slot 230 0 1 1 0 0 1 1 1
Slot 231 1 1 1 0 0 1 1 1
Slot 232 0 0 0 1 0 1 1 1
Slot 233 1 0 0 1 0 1 1 1
Slot 234 0 1 0 1 0 1 1 1
7-87
Table 35: 37-Way User Port Binary Inputs for Label Selection
7-88

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 235 1 1 0 1 0 1 1 1
Slot 236 0 0 1 1 0 1 1 1
Slot 237 1 0 1 1 0 1 1 1
Slot 238 0 1 1 1 0 1 1 1

CONNECTIVITY PACKS
Slot 239 1 1 1 1 0 1 1 1
Slot 240 0 0 0 0 1 1 1 1
Slot 241 1 0 0 0 1 1 1 1
Slot 242 0 1 0 0 1 1 1 1
Slot 243 1 1 0 0 1 1 1 1
Slot 244 0 0 1 0 1 1 1 1
Slot 245 1 0 1 0 1 1 1 1
EPT026795 Issue 17 June 2020

Slot 246 0 1 1 0 1 1 1 1
Slot 247 1 1 1 0 1 1 1 1
Slot 248 0 0 0 1 1 1 1 1
Slot 249 1 0 0 1 1 1 1 1
Slot 250 0 1 0 1 1 1 1 1
Slot 251 1 1 0 1 1 1 1 1
Table 35: 37-Way User Port Binary Inputs for Label Selection
EPT026795 Issue 17 June 2020

37-Way User Port Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37- Ext37-
Connector Pin Pin1 Pin2 Pin3 Pin4 Pin5 Pin6 Pin7 Pin8

Input Value 1 2 4 8 16 32 64 128

Slot Number Printing Inputs Selected

Slot 252 0 0 1 1 1 1 1 1
Slot 253 1 0 1 1 1 1 1 1
Slot 254 0 1 1 1 1 1 1 1
Slot 255 1 1 1 1 1 1 1 1

CONNECTIVITY PACKS
7-89
CONNECTIVITY PACKS

Monitor
The Monitor screen is used to monitor input and output statistics. The External Data Capture
(EDC) queues and the product detect queue can also be cleared on this screen. The settings and
information available on the Monitor screen are explained in the table below.
To view the IO Port monitor screen:
(1) Select Home > Setup > I/O Port > Monitor.
(2) The settings described in the table below can now be changed:

Function Explanation

'EdcSerial' queue Displays the number of data packets transmitted over serial connection
state that are stored in the external data queue.
Select Clear to clear the external data queue.
'Edc TcpSink' Displays the number of data packets transmitted over Ethernet TCP/IP
Queue state connection that are stored in the external data queue.
Select Clear to clear the external data queue.
Current PD Displays the product detect sensor frequency as also displayed on the line
frequency movement graph. To view the line movement graph select Home > Setup >
Production line setup > Line movement.
EDC history reset Data packets received by the printer can be stored in the historic log. This
allows new data to be checked against historic data to avoid printing
duplicate information.
This setting displays the number of historic logs stored in the printer.
Select Clear to clear the historic log.
Encoder count Displays the number of shaft encoder pulse counts.
Encoder Displays the shaft encoder pulse count frequency in Khz as also displayed
frequency on the line movement graph. To view the line movement graph select
Home > Setup > Production line setup > Line movement.
PD queue state Displays the number of print trigger signals that are queued. Select Clear
to clear the queue.

End of procedure.

7-90 EPT026795 Issue 17 June 2020

PART 8 : PERFORMANCE PACKS

CONTENTS
Page
PERFORMANCE PACKS OPTIONS ......................................................................................... 8-3
EXTENDED RASTER PACK ...................................................................................................... 8-4
Installation ............................................................................................................................ 8-4
Migration .............................................................................................................................. 8-4
Additional Rasters ................................................................................................................ 8-5
PROFESSIONAL PRINTING PACK ........................................................................................... 8-7
Installation ............................................................................................................................ 8-7
Migration .............................................................................................................................. 8-7
Additional Rasters ................................................................................................................ 8-8
i-Pulse Print Head with 40μm Nozzle ................................................................................... 8-8
i-Pulse Print Head with 50μm Nozzle ................................................................................... 8-9
i-Pulse Print Head with 60μm Nozzle ................................................................................... 8-11
i-Pulse Print Head with 75μm Nozzle ................................................................................... 8-14
i-Pulse RS Print Head with 60μm Nozzle ............................................................................. 8-15
i-Pulse RS Print Head with 75μm Nozzle ............................................................................. 8-18
Segmented Labels ............................................................................................................... 8-20
Segmented Label Example .............................................................................................. 8-20
Add a Segment................................................................................................................. 8-21
LUA Script ............................................................................................................................ 8-22
Import LUA Script Files ................................................................................................... 8-22
Behavioural Configuration ............................................................................................... 8-22
Reset Script Variables ..................................................................................................... 8-22
OPERATOR ASSISTANCE PACK ............................................................................................. 8-23
Installation ............................................................................................................................ 8-24
Migration .............................................................................................................................. 8-24
Barcode Scanner ................................................................................................................. 8-25
Barcode Scanner Setup .................................................................................................. 8-25
Barcode Scanner Login ................................................................................................... 8-25
Work Order Sheet Example .............................................................................................. 8-26
Label Creation Example ................................................................................................... 8-27
Label Selection Example .................................................................................................. 8-28

EPT026795 Issue 17 June 2020 8-1

PERFORMANCE PACKS

ADVANCED SECURITY PACK ..................................................................................................8-29

Installation .............................................................................................................................8-29
Migration ...............................................................................................................................8-29
Security Manager ..................................................................................................................8-30
Enable Advanced Security Mode .....................................................................................8-30
Disable Security Mode .....................................................................................................8-30
Log In.................................................................................................................................8-31
Log Out..............................................................................................................................8-32
Enable Auto Log-in ...........................................................................................................8-32
Disable Auto Log-in ..........................................................................................................8-32
Change Current User Password .......................................................................................8-32
Reset Forgotten Password................................................................................................8-33
Set Password Policy..........................................................................................................8-34
Add New User ...................................................................................................................8-35
Change User Settings .......................................................................................................8-36
Delete User ........................................................................................................................8-37
Add New User Group .......................................................................................................8-37
Delete User Group ............................................................................................................8-37
Change User Group Access to Specific Printer Settings .................................................8-37
GREEN PACK ............................................................................................................................8-38
Installation .............................................................................................................................8-38
Make-up Loss Graph ............................................................................................................8-43
Energy Save Options ............................................................................................................8-44
Auto Jet Off ......................................................................................................................8-44
Auto Sleep ........................................................................................................................8-44
Action for Power Button (Standby Button) ........................................................................8-45

8-2 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

PERFORMANCE PACKS OPTIONS

Performance packs are additional packs which can be installed at the time of manufacture or
installed at a later date to increase the printers functionality.
One performance pack is available for the Ax150i and three performance packs are available for
the Ax350i/Ax550i.
The table below lists the performance pack options:

Table 1: Performance Pack Options

Printer
Pack Name Description
Compatibility

Extended Raster Ax150i The extended raster pack adds an extended range of
Pack - rasters to the printer which cover a broader range of
EPT030749SP general purpose applications.
Professional Printing Ax350i The professional printing pack adds advanced
Pack - Ax550i features for complex labels, high speed applications
EPT030750SP and best quality 2D coding.
Advanced Security Ax350i The advanced security pack adds security features to
Pack - Ax550i the printer.
EPT035038SP
Operator Assistance Ax350i The operator assistance pack adds security features
Pack - Ax550i and a barcode scanner for data entry. These features
EPT030751SP minimise the risk of operator error on the production
line.
Green Pack - Ax350i The green pack adds a Peltier condenser to reduce
EPT030753SP Ax550i make-up consumption by up to 20%. Power
consumption is also lowered with the addition of a
customisable power save mode.
Continuous Printing Ax350i The continuous printing pack adds features for
Pack - Ax550i printing long labels on high speed continuous print
EPT035039SP surfaces such as cable, wire and extrusion
applications.

EPT026795 Issue 17 June 2020 8-3

PERFORMANCE PACKS

EXTENDED RASTER PACK

Note: Available for Ax150i printers only.
Hardware requirements: An available USB Type A port on the printer cabinet.
Software requirements: Version 01.00.20 or higher.
The extended raster pack extends the range of rasters to cover a broader range of general
purpose applications.

Installation
To install the extended raster pack:
(1) Insert the extended raster pack USB into a USB port on the printer cabinet or TouchScreen.
(2) On the TouchScreen select, Setup > Packs management.
(3) Select the appropriate Install button.
(4) Follow the on screen instructions.
(5) Remove the extended raster pack USB.
(6) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

Migration
To migrate the extended raster pack to a different printer:
(1) Insert the extended raster pack USB into a USB port on the printer cabinet or TouchScreen.
(2) On the TouchScreen select, Setup > Packs management > Migrate Packs.
(3) Select the appropriate Migrate button.
(4) Follow the on screen instructions.
(5) Remove the extended raster pack USB.
(6) Insert the extended raster pack USB into a USB port on the printer cabinet or TouchScreen
that the pack is being migrated to.
(7) On the TouchScreen select, Setup > Packs management.
(8) Select the appropriate Install button.
(9) Follow the on screen instructions.
(10) Remove the extended raster pack USB.
(11) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

8-4 EPT026795 Issue 17 June 2020

Additional Rasters
EPT026795 Issue 17 June 2020

After the extended raster pack has been installed, the rasters described in the table below will be available for creating or editing label designs.
A full and updated list of rasters is maintained on Agile under document number DOC-0011071. The information in this manual is based on
information from DOC-0011071 v8 r3.

Speed at Standard DPI Speed at Max DPI Optimum

Raster Short (60dpi, 10 chars/inch) (82dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

1L05HQ60025 1L05HQ 5x 309 1012 514 226 741 3.76 8

1L07HQ60025 1L07HQ 5x, 7x 144 472 2.40 105 346 1.76 8

PERFORMANCE PACKS
1L07HQ60036 1L07HQ 5x, 7x 216 709 3.60 158 518 2.63 8
1L09HQ60030 1L09HQ 5x, 7x, 9x 114 373 1.89 83 273 1.39 8
1L09HQ60046 1L09HQ 5x, 7x, 9x 144 472 2.40 105 346 1.76 8
1L11HQ60057 1L11HQ 5x, 7x, 9x, 10x, 11x 114 373 1.89 83 273 1.39 8
1L12HQ60062 1L12HQ 5x, 7x, 9x, 10x, 11x, 12x 98 322 1.64 72 2.36 1.20 8
1L15HQ60079 1L15HQ 5x, 7x, 9x, 10x, 11x, 12x, 15x 70 229 1.16 51 167 0.85 8
1L16HQ60053 1L16HQ 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 58 192 0.97 4 140 0.71 8
1L16HQ60084 1L16HQ 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 65 215 1.09 48 157 0.80 8
1L18HQ60072 1L18HQ 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 35 116 0.59 26 85 0.43 8
1L21HQ60084 1L21HQ 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 30 100 0.51 22 73 0.37 8
21x
1L24HQ60084 1L24HQ 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 23 75 0.38 17 55 0.28 8
21x, 23x, 24x
8-5
8-6

Speed at Standard DPI Speed at Max DPI Optimum

Raster Short (60dpi, 10 chars/inch) (82dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

1L25HQ60084 1L25HQ 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 22 71 0.36 16 52 0.26 8
21x, 23x, 24x
1L29HQ60084 1L29HQ 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 15 50 0.26 11 37 0.19 8
21x, 23x, 24x
1L32HQ60084 1L32HQ 5x, 7x, 9x, 10x,11x, 12x, 15x, 16x, 18 59 0.30 13 43 0.22 8
21x, 23x, 24x, 31x, 32x
2L05HQ60062 2L0HQ 5x 108 354 1.80 79 259 1.32 8

PERFORMANCE PACKS
2L07HQ60053 2L07HQ 5x, 7x 62 202 1.03 45 148 0.75 8
2L07HQ60084 2L07HQ 5x, 7x 77 253 1.29 56 185 0.94 8
2L09HQ60066 2L09HQ 5x, 7x, 9x 48 157 0.80 35 115 0.59 8
2L09HQ60084 2L09HQ 5x, 7x, 9x 60 197 1.00 44 144 0.73 8
2L12HQ60084 2L12HQ 5x, 7x, 9x, 10x, 11x, 12x 30 98 0.50 22 72 0.37 8
2L16HQ60084 2L16HQ 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 30 100 0.51 22 73 0.37 8
3L05HQ60084 3L05HQ 5x 62 202 1.03 45 148 0.75 8
EPT026795 Issue 17 June 2020

3L07HQ60084 3L07HQ 5x, 7x 51 169 0.86 38 123 0.63 8

3L09HQ60084 3L09HQ 5x, 7x, 9x 34 112 0.57 25 82 0.42 8
4L05HQ60084 4L05HQ 5x 54 177 0.90 40 130 0.66 8
4L07HQ60084 4L07HQ 5x, 7x 34 111 0.56 25 81 0.41 8
5L05HQ60084 5L05HQ 3x 29 94 0.48 21 69 0.35 8
PERFORMANCE PACKS

PROFESSIONAL PRINTING PACK

Note: Available for Ax350i/Ax550i printers only.
Hardware requirements: An available USB Type A port on the printer cabinet or TouchScreen.
Software requirements: Version 01.00.20 or higher.
The professional printing pack adds advanced features for complex labels, high speed
applications and high quality 2D coding:
• High speed (ST and HQ) rasters.
• Label segmentation enables multiple rasters, print heights and stroke pitches to be used
within a single label. Due to screen space limitations, this feature can only be used if the
printer is equipped with a 10 inch TouchScreen. This enables the user to optimise print
quality, ink consumption and printing speed when both text and 2D codes are in use in the
same label.
• Lua script engine.

Installation
To install the professional printing pack:
(1) Insert the professional printing pack USB into a USB port on the printer cabinet or
TouchScreen.
(2) On the TouchScreen select, Setup > Packs management.
(3) Select the appropriate Install button.
(4) Follow the on screen instructions.
(5) Remove the professional printing pack USB.
(6) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

Migration
To migrate the professional printing pack to a different printer:
(1) Insert the professional printing pack USB into a USB port on the printer cabinet or
TouchScreen.
(2) On the TouchScreen select, Setup > Packs management > Migrate Packs.
(3) Select the appropriate Migrate button.
(4) Follow the on screen instructions.
(5) Remove the professional printing pack USB.
(6) Insert the professional printing pack USB into a USB port on the printer cabinet or
TouchScreen that the pack is being migrated to.
(7) On the TouchScreen select, Setup > Packs management.
(8) Select the appropriate Install button.
(9) Follow the on screen instructions.
(10) Remove the professional printing pack USB.
(11) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

EPT026795 Issue 17 June 2020 8-7

Additional Rasters
8-8

After the professional printing pack has been installed, the rasters described on the next few pages will be available for creating or editing label
designs.
A full and updated list of rasters is maintained on Agile under document number DOC-0011071. The information in this manual is based on
information from DOC-0011071 v8 r3.

i-Pulse Print Head with 40μm Nozzle

Speed at Standard DPI Speed at Max DPI Optimum

Raster Short (82dpi, 14 chars/inch) (110dpi, 18 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

PERFORMANCE PACKS
1L03HS40006 1L03HS 3 tower 443 1452 7.38 330 1082 5.50 4
1L05ST40012 1L05ST 5x 316 1037 5.27 236 773 3.93 4
1L07ST40016 1L07ST 5x, 7x 246 807 4.10 183 601 3.05 4
1L09ST40020 1L09ST 5x, 7x, 9x 148 484 2.64 110 361 1.83 4
1L16ST40037 1L16ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 71 234 1.19 53 175 0.89 4
1L21ST40048 1L21ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 40 132 0.67 30 98 0.50 4
21x
1L25ST40061 1L25ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 29 96 0.49 22 71 0.36 4
EPT026795 Issue 17 June 2020

21x, 23x, 24x

1T25HT40058 1T25HT 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 18 58 0.30 13 43 0.22 4
21x, 23x, 24x
2L05ST40030 2L05ST 5x 130 427 2.17 97 318 1.62 4
2L07ST40030 2L07ST 5x, 7x 105 346 7.76 79 258 1.31 4
3L07ST40048 3L07ST 5x, 7x 45 148 0.75 34 110 0.56 4
4L07ST40061 4L07ST 5x, 7x 39 127 0.65 29 95 0.48 4
i-Pulse Print Head with 50μm Nozzle
EPT026795 Issue 17 June 2020

Speed at Standard DPI Speed at Max DPI Optimum

Raster Short (82dpi, 14 chars/inch) (98dpi, 16 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

1L03HS50007 1L03HS 3 tower 440 1444 7.33 368 1208 6.14 6

1L05HS50013 1L05HS 5x 352 1155 5.87 295 966 4.91 6
1L05ST50013 1L05ST 5x 251 825 4.19 210 690 3.51 6
1L07HS50019 1L07HS 5x, 7x 251 825 4.19 210 690 3.51 6

PERFORMANCE PACKS
1L07ST50019 1L07ST 5x, 7x 196 642 3.26 164 537 2.73 6
1L09HS50035 1L09HS 5x, 7x, 9x 196 642 3.26 164 537 2.73 6
1L09ST50035 1L09ST 5x, 7x, 9x 135 444 2.26 113 372 1.89 6
1L12HS50038 1L12HS 5x, 7x, 9x, 10x, 11x, 12x 147 481 2.44 123 403 2.05 6
1L16HS50050 1L16HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 84 275 1.40 70 230 1.17 6
1L21ST50062 1L21ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 34 111 0.56 28 93 0.47 10
21x
1L24ST50071 1L24ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 24 79 0.40 20 66 0.34 10
21x, 23x, 24x
1L25ST50074 1L25ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 23 76 0.39 19 64 0.32 10
21x, 23x, 24x
1L29ST50074 1L29ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 23 74 0.38 19 62 0.31 10
21x, 23x, 24x
2L05HS50046 2L05HS 5x 147 481 2.44 123 403 2.05 6
8-9
8-10
2L0HS50050 2L07HS 5x, 7x 110 361 1.83 92 302 1.53 6
3L07HS50058 3L07HS 5x, 7x 63 206 1.05 53 173 0.88 6
3L07ST50058 3L07ST 5x, 7x 49 160 0.81 41 134 0.68 6
4L07ST50074 4L07ST 5x, 7x 42 137 0.70 35 115 0.58 10

PERFORMANCE PACKS
EPT026795 Issue 17 June 2020
i-Pulse Print Head with 60μm Nozzle
EPT026795 Issue 17 June 2020

Speed at Standard DPI Speed at Max DPI Optimum

Raster Short (60dpi, 10 chars/inch) (82dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

1L03HS60010 1L03HS 3 tower 540 1772 9.00 395 1296 6.58 8

1L05ST60025 1L05ST 5x 432 1417 7.20 316 1037 5.27 8
1L07ST60036 1L07ST 5x, 7x 309 1012 5.14 226 741 3.76 8
1L09ST60045 1L09ST 5x, 7x, 9x 240 787 4.00 176 576 2.93 8

PERFORMANCE PACKS
1L11ST60057 1L11ST 5x, 7x, 9x, 10x, 11x 166 545 2.77 122 399 2.03 8
1L12ST60062 1L12ST 5x, 7x, 9x, 10x, 11x, 12x 154 506 2.57 113 370 1.88 8
1L15ST60079 1L15ST 5x, 7x, 9x, 10x, 11x, 12x, 15x 108 354 1.80 79 259 1.32 8
1L16ST60084 1L16ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 103 337 1.71 75 247 1.25 8
1L21HS60084 1L21HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 51 169 0.86 38 123 0.63 8
21x
1L21ST60084 1L21ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 43 142 0.72 32 104 0.53 8
21x
1L23HS60084 1L23HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 51 169 0.86 38 123 0.63 8
21x, 23x
1L24HS60084 1L24HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 40 131 0.67 29 96 0.49 8
21x, 23x, 24x
1L24ST60084 1L24ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 30 100 0.51 22 73 0.37 8
21x, 23x, 24x
1L25HS60084 1L25HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 39 127 0.64 28 93 0.47 8
21x, 23x, 24x
8-11
8-12

Sped at Standard DPI Sped at Max DPI Optimum

Raster Short (60dpi, 10 chars/inch) (82dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

1L25ST60080 1L25ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 29 94 0.48 21 69 0.35 8
21x, 23x, 24x
1L29ST60084 1L29ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 24 78 0.40 17 57 0.29 8
21x, 23x, 24x
1O07ST60036 1O07ST 5x, 7x 196 644 3.27 144 471 2.39 8
1O09ST60046 1O09ST 5x, 7x, 9x 144 472 2.40 105 346 1.76 8
1T16HS60052 1T16HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 135 443 2.25 99 324 1.65 8

PERFORMANCE PACKS
2L05HS60062 2L05HS 5x 216 709 3.60 158 518 2.63 8
2L05ST60062 2L05ST 5x 180 591 3.00 132 432 2.19 8
2L07HS60084 2L07HS 5x, 7x 135 443 2.25 99 324 1.65 8
2L07ST60053 2L07ST 5x, 7x 127 417 2.12 93 305 1.55 8
2L07ST60084 2L07ST 5x, 7x 120 394 2.00 88 288 1.46 8
2L09ST60084 2L09ST 5x, 7x, 9x 80 262 1.33 59 192 0.98 8
2O05ST60062 2O05ST 5x 154 506 2.57 113 370 1.88 8
EPT026795 Issue 17 June 2020

3L05HS60084 3L05HS 5x 108 354 1.80 79 259 1.32 8

3L05ST60084 3L05ST 5x 86 283 1.44 63 207 1.05 8
3L07HS60084 3L07HS 5x, 7x 77 253 1.29 56 185 0.94 8
3L07ST60084 3L07ST 5x, 7x 62 202 1.03 45 148 0.75 8
4L07HS60084 4L07HS 5x, 7x 64 208 1.06 46 152 0.77 8
4L07ST60084 4L07ST 5x, 7x 50 165 0.84 37 121 0.61 8
EPT026795 Issue 17 June 2020

Sped at Standard DPI Sped at Max DPI Optimum

Raster Short (60dpi, 10 chars/inch) (82dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

5L05ST60084 5L05ST 5x 43 142 0.72 32 104 0.53 8

PERFORMANCE PACKS
8-13
i-Pulse Print Head with 75μm Nozzle
8-14

Speed at Standard DPI Speed at Max DPI Optimum

Raster Short (48dpi, 8 chars/inch) (64dpi, 11 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

1L03HS75013 1L03HS 3 tower 509 1669 8.48 382 1252 6.36 14

1L05ST75027 1L05ST 5x 407 1335 6.78 305 1002 5.09 14
1L07ST75033 1L07ST 5x, 7x 291 954 4.85 218 715 3.63 14
1L09ST75045 1L09ST 5x, 7x, 9x 226 742 3.77 170 556 2.83 14

PERFORMANCE PACKS
1L12ST75086 1L12ST 5x, 7x, 9x, 10x, 11x, 12x 120 393 2.00 90 295 1.50 14
1L16HS75086 1L16HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 127 417 2.12 95 313 1.59 14
1L16ST75087 1L16ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 88 290 1.47 66 218 1.11 14
1L24ST75086 1L24ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 34 113 0.57 26 85 0.43 14
21x, 23x, 24x
2L05HS75063 2L05HS 5x 204 668 3.39 153 501 2.54 14
2L05ST75063 2L05ST 5x 136 445 2.26 102 334 1.70 14
2L07HS75086 2L07HS 5x, 7x 113 371 1.88 85 278 1.41 14
EPT026795 Issue 17 June 2020

2L09HS75086 2L09HS 5x, 7x, 9x 75 247 1.26 57 185 0.94 14

3L05ST75086 3L05ST 5x 81 267 1.36 61 200 1.02 14
3L07ST75086 3L07ST 5x, 7x 58 191 0.97 44 143 0.73 14
i-Pulse RS Print Head with 60μm Nozzle
EPT026795 Issue 17 June 2020

Speed at Standard DPI Speed at Max DPI Optimum

Raster Short (60dpi, 10 chars/inch) (82dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

1R05HT60018 1R05HT 5x 154 506 2.57 113 370 1.88 8 (up to 50)
1R07HT60025 1R07HT 5x, 7x 98 322 1.64 72 236 1.20 8 (up to 50)
1R09HT60033 1R09HT 5x, 7x, 9x 70 229 1.16 51 167 0.85 8 (up to 50)
1R11HT60040 1R11HT 5x, 7x, 9x, 10x, 11x 50 165 0.84 37 121 0.61 8 (up to 50)

PERFORMANCE PACKS
1R15HT60056 1R15HT 5x, 7x, 9x, 10x, 11x, 12x, 15x 32 104 0.53 23 76 0.39 8 (up to 50)
1R23HT60088 1R23HT 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 17 56 0.29 13 41 0.21 8 (up to 50)
21x, 23x
1R03HS60008 1R03HS 3 tower 540 1772 9.00 3.95 1296 6.58 4
1R03HS60010 1R03HS 3 tower 720 2362 12.00 527 1728 8.78 8
1R05ST60018 1R05ST 5x 432 1417 7.20 316 1037 5.27 8
1R05ST60024 1R05ST 5x 432 1417 7.20 316 1037 5.27 8
1R07ST60025 1R07ST 5x, 7x 309 1012 5.14 226 741 3.76 8
1R07ST60037 1R07ST 5x, 7x 309 1012 5.14 226 741 3.76 8
1R09ST60032 1R09ST 5x, 7x, 9x 240 787 4.00 176 576 2.93 8
1R09ST60053 1R09ST 5x, 7x, 9x 240 787 4.00 176 576 2.93 8
1R11ST60039 1R11ST 5x, 7x, 9x, 10x, 11x 196 644 3.27 144 471 2.39 8
1R11ST60063 1R11ST 5x, 7x, 9x, 10x, 11x 196 644 3.27 144 471 2.39 8
1R12ST60062 1R12ST 5x, 7x, 9x, 10x, 11x, 12x 154 506 2.57 113 370 1.88 8
8-15
8-16

Sped at Standard DPI Sped at Max DPI Optimum

Raster Short (60dpi, 10 chars/inch) (82dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

1R15ST60083 1R15ST 5x, 7x, 9x, 10x, 11x, 12x, 15x 108 354 1.80 79 253 1.32 8
1R16ST60084 1R16ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 103 337 1.71 75 247 1.25 8
1R21HS60084 1R21HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 60 197 1.00 44 144 0.73 8
21x
1R21ST60084 1R21ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 49 161 0.82 36 118 0.60 8
21x
1R23HS60084 1R23HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 51 169 0.86 38 123 0.63 8

PERFORMANCE PACKS
21x, 23x
1R23ST60084 1R23ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 42 139 0.71 31 102 0.52 8
21x, 23x
1R24HS60084 1R24HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 44 145 0.73 32 106 0.54 8
21x, 23x, 24x
1R24ST60084 1R24ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 36 118 0.60 26 86 0.44 8
21x, 23x, 24x
2R26HS60084 1R26HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 39 127 0.64 28 93 0.47 8
21x, 23x, 24x
EPT026795 Issue 17 June 2020

1R26HS60084 1R26ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 33 109 0.55 24 80 0.41 8
21x, 23x, 24x
2R05ST60062 2R05ST 5x 180 591 3.00 132 432 2.19 8
2R05HS60062 2R05HS 5x 216 709 3.60 158 518 2.63 8
2R07ST60084 2R07ST 5x, 7x 120 394 2.00 88 288 1.46 8
2R07HS60084 2R07HS 5x, 7x 144 472 2.40 105 346 1.76 8
EPT026795 Issue 17 June 2020

Sped at Standard DPI Sped at Max DPI Optimum

Raster Short (60dpi, 10 chars/inch) (82dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

2R09ST60084 2R09ST 5x, 7x, 9x 80 262 1.33 59 192 0.98 8

3R05HS60074 3R05HS 5x 108 354 1.80 79 259 1.32 8
3R05ST60074 3R05ST 5x 86 283 1.44 63 207 1.05 8
3R07HS60084 3R07HS 5x, 7x 77 253 1.29 56 185 0.94 8
3R07ST60084 3R07ST 5x, 7x 62 202 1.03 45 148 0.75 8
4R07HS60084 4R07HS 5x, 7x 62 202 1.03 45 148 0.75 8

PERFORMANCE PACKS
4R07ST60084 4R07ST 5x, 7x 50 165 0.84 37 121 0.61 8
1R08US60031 1R08US only 3of8 Fonts (5x5S/5x5SV) 720 2362 12.00 527 1728 8.87 5
1R08US60037 1R08US only 3of8 Fonts (5x5S/5x5SV) 432 1417 7.20 316 1037 5.27 5
8-17
i-Pulse RS Print Head with 75μm Nozzle
8-18

Sped at Standard DPI Sped at Max DPI Optimum

Raster Short (48dpi, 10 chars/inch) (64dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

1R05HT75020 1R05HT 5x, 7x 145 477 2.42 109 358 1.82 14 (up to 50)
1R07HT75026 1R07HT 5x, 7x 93 304 1.54 69 228 1.16 14 (up to 50)
1R09HT75034 1R09HT 5x, 7x, 9x 66 215 1.09 49 162 0.82 14 (up to 50)
1R11HT75041 1R11HT 5x, 7x, 9x, 10x, 11x 47 155 0.79 35 116 0.59 14 (up to 50)

PERFORMANCE PACKS
1R15HT75056 1R15HT 5x, 7x, 9x, 10x, 11x, 12x, 15x 30 98 0.50 22 74 0.37 14 (up to 50)
1R23HT75086 1R23HT 3x, 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 16 53 0.27 12 40 0.20 14 (up to 50)
21x, 23x
1R05ST75025 1R05ST 5x 407 1335 6.78 305 1002 5.09 14
1R07ST75032 1R07ST 5x, 7x 291 954 4.85 218 715 3.63 14
1R09ST75057 1R09ST 5x, 7x, 9x 226 742 3.77 170 556 2.83 14
1R11ST75070 1R11ST 5x, 7x, 9x, 10x, 11x 170 556 2.83 127 417 2.12 14
1R15ST75086 1R15ST 5x, 7x, 9x, 10x, 11x, 12x, 15x 102 334 1.70 76 250 1.27 14
EPT026795 Issue 17 June 2020

1R16HS75086 1R16HS 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 120 393 2.00 90 295 1.50 14
1R16ST75086 1R16ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x 88 290 1.47 66 218 1.11 14
1R23ST75090 1R23ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 40 131 0.67 30 98 0.50 14
21x, 23x
1R24ST75086 1R24ST 5x, 7x, 9x, 10x, 11x, 12x, 15x, 16x, 34 113 0.57 26 85 0.43 14
21x, 23x, 24x
2R05HS75063 2R05HS 5x 204 668 3.39 153 501 2.54 14
EPT026795 Issue 17 June 2020

Sped at Standard DPI Sped at Max DPI Optimum

Raster Short (48dpi, 10 chars/inch) (64dpi, 14 chars/inch) Throw
Available Fonts
Reference Name Distance
m/min ft/min m/s m/min ft/min m/s (mm)

2R05ST75063 2R05ST 5x 136 445 2.26 102 334 1.70 14

3R05ST75086 3R05ST 5x 81 267 1.36 61 200 1.02 14
2R07HS75086 2R07HS 5x, 7x 136 445 2.26 102 334 1.70 14
2R09HS75086 2R09HS 5x, 7x, 9x 75 247 1.26 57 185 0.94 14
3R07ST75086 3R07ST 5x, 7x 58 191 0.97 44 143 0.73 14

PERFORMANCE PACKS
8-19
PERFORMANCE PACKS

Segmented Labels
Note: Due to limitations of space on the screen, segmented labels can only be used on
printers equipped with a 10 inch TouchScreen. This feature cannot be used with a 7
inch TouchScreen.
Label segmentation enables multiple rasters, print heights and stroke pitches to be used within a
single label. This enables the user to optimise print quality when both text and 2D barcode
elements are used in the same label.
Segmented Label Example
The illustration below shows an example of a label design with a barcode element and a text
element in two different segments.
Segment 1 contains a data matrix barcode that requires a high density print to ensure the code
can be properly scanned. To achieve this the Height (%) and Stroke pitch (mm/stroke) settings for
segment 1 have been adjusted to move the ink drops closer together.
Segment 2 contains a text element that does not require a high density print. The Height (%) and
Stroke pitch (mm/stroke) settings for segment 2 have been left at the default values to reduce ink
consumption and optimise the label print speed.

Segment 1 Segment 2

Segment Example

8-20 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

Add a Segment
To add a segment into a label design:
(1) In the Label Creator, select Segment at the top of the screen.
(2) In the side menu, select the Segment tab.
(3) Select the Add menu.
(4) Select the Add Segment icon.

(5) The following segment settings can now be defined:

Setting Name Description

Number of lines Select the required number of lines.

Line height (drops) Select the required line height in ink drops.
Type Select the required segment quality.
Use default height (%) Tick the tick box to use the default print height setting.

Untick the tick box to display the Height (%) setting.

Untick the tick box to display the stroke pitch (mm) setting.
Stroke pitch (mm/stroke) Note: This setting is only valid if the Use default stroke pitch
tick box is not ticked.
Set the distance between print strokes. A stroke is the line of ink
drops which is used to make up each printed character.

End of procedure.

EPT026795 Issue 17 June 2020 8-21

PERFORMANCE PACKS

LUA Script
Import LUA Script Files
Script elements written in LUA programming language can be imported into the printer using the
file manager. Once imported, the script element can then be added into the label design, see
page 5-51.
To import a script:
(1) Save the script file to a USB drive.
(2) Insert the USB drive into a USB slot on the TouchScreen or printer cabinet.
(3) On the TouchScreen, select Home > Setup > File manager.
(4) Open the USB folder.
(5) Copy the script file and navigate to the Scripts folder.
(6) Select Paste.
End of procedure.
Behavioural Configuration
The settings on the behavioural configuration screen define the loop time of specific scripts.
To set the loop time of a specific script:
(1) Select Home > Setup > Global print settings > Behavioural configuration
(2) Select Add new script
(3) Configure the following settings:

Table 2: Behavioural Configuration Settings

Setting Name Description

Script path Enter the location of the script file.

Instance name Enter the name of the script file.
Loop time (ms) Define the loop time.

(4) Select Add script.

End of procedure.
Reset Script Variables
To reset scripts:
(1) Select Home > Setup > Global Print Settings > Content.
(2) Select Reset All to reset persistent script variables.
End of procedure.

8-22 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

OPERATOR ASSISTANCE PACK

Note: Available for Ax350i/Ax550i printers only.
Hardware requirements: An available USB Type A port on the printer cabinet or TouchScreen.
The operator assistance pack is a performance pack that adds the following features to minimise
the risk of operator error on the production line:
• Barcode scanner user profile for essential security manager.
• Barcode scanning for label selection and data entry.
• Label templates for consistent code appearance.

EPT026795 Issue 17 June 2020 8-23

PERFORMANCE PACKS

Installation
To install the operator assistance pack:
(1) Insert the operator assistance pack USB into a USB port on the printer cabinet or
TouchScreen.
(2) On the TouchScreen select, Setup > Packs management.
(3) Select the appropriate Install button.
(4) Follow the on screen instructions.
(5) Remove the operator assistance pack USB.
(6) Connect the barcode scanner to a USB port on the printer cabinet or TouchScreen.
(7) Ensure the barcode scanner is active (scanner beeps and green light illuminates).
(8) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

Migration
To migrate the operator assistance pack to a different printer:
(1) Insert the operator assistance pack USB into a USB port on the printer cabinet or
TouchScreen.
(2) On the TouchScreen select, Setup > Packs management > Migrate Packs.
(3) Select the appropriate Migrate button.
(4) Follow the on screen instructions.
(5) Remove the operator assistance pack USB.
(6) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
(7) Insert the operator assistance pack USB into a USB port on the printer cabinet or
TouchScreen that the pack is being migrated to.
(8) On the TouchScreen select, Setup > Packs management.
(9) Select the appropriate Install button.
(10) Follow the on screen instructions.
(11) Remove the operator assistance pack USB.
(12) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

8-24 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

Barcode Scanner
The Operator Assistance Pack contains a barcode scanner and a dedicated scanner user profile.
When the operator is logged into the barcode scanner user profile, the operator will not be able to
search the full printer library for labels. To select a label and send it to print, the operator must
scan a barcode that contains the label name. The barcode containing the label name can be
provided to the operator on a work order sheet created by the customer. Labels can also contain
prompted field elements to prompt the operator to scan further barcodes to update prompted
data elements in the label.
Barcode Scanner Setup
To setup the barcode scanner:
(1) Enable essential security mode, see page 4-86.
(2) Login as an admin level user:
(3) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
(4) Plug the barcode scanner into a USB port on the printer cabinet or TouchScreen.
(5) Ensure the barcode scanner is active (scanner beeps and green light illuminates).
End of procedure.
Barcode Scanner Login
To log in as a barcode scanner user:
(1) Select the Padlock icon in the bottom right corner of the user interface.
(2) Select Log in.
(3) Enter the password:
Note: Passwords are case sensitive.

User Group: barcodescanner

Password: scanner

Note: Available for Ax350i/Ax550i printers only.
Hardware requirements: An available USB Type A port on the printer cabinet or TouchScreen.
The advanced security pack is a performance pack that adds the advanced mode to the printer’s
user interface.

Installation
To install the advanced security pack:
(1) Insert the advanced security pack USB into a USB port on the printer cabinet or
TouchScreen.
(2) On the TouchScreen select, Setup > Packs management.
(3) Select the appropriate Install button.
(4) Follow the on screen instructions.
(5) Remove the advanced security pack USB.
(6) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

EPT026795 Issue 17 June 2020 8-29

PERFORMANCE PACKS

Security Manager
Enable Advanced Security Mode
When advanced security mode is active, only users with a valid user name and password will be
able to operate the printer through the user interface. Users who are part of the admin group will
also have the capability to set password policy, create new user and group profiles and edit user
and group profiles.
Note: You will be immediately logged out of the printer when the security mode is enabled.
Before enabling advanced security mode, ensure you have a valid password to log into
the printer, see “Log In” on page 8-31.
To enable the advanced security mode:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security.
(3) Select the Security mode drop down setting.
(4) Select Advanced.
End of procedure.
Disable Security Mode
To disable security mode:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security.
(3) Select the Security mode drop down setting.
(4) Select Off.
End of procedure.

8-30 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

Log In
To log in:
(1) Select the Padlock icon in the bottom right corner of the user interface.
(2) Select Log in.
(3) Enter the log in details for the required user. The default usernames and passwords are
defined in the table below:
Note: Usernames and passwords are case sensitive.

Username Password Explanation

admin admin Access to all printer settings and functions.

supervisor sv Access to the following printer functions:
• Start/Stop printing
• Label finder
• Label creator
• Edit current label
• Print optimisation
• Printer status
• Label select
• Prompted data entry via UI keyboard
• Acknowledge alerts
operator op Access to the following printer functions:
• Start/Stop printing
• Print optimisation
• Printer status
• Label select
• Prompted data entry via UI keyboard
• Acknowledge alerts

End of procedure.

EPT026795 Issue 17 June 2020 8-31

PERFORMANCE PACKS

Log Out
To log out:
(1) Select the Padlock icon in the bottom right corner of the user interface.
(2) Select Log out.
End of procedure.
Enable Auto Log-in
To enable auto log-in:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security.
(3) Tick the Enable auto log-in tick box.
(4) Select the Auto login user drop down setting.
(5) Select the user that will automatically be logged in when the printer is turned on.
End of procedure.
Disable Auto Log-in
To disable auto log-in:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security.
(3) Untick the Enable auto log-in tick box.
End of procedure.
Change Current User Password
To change the current user’s password:
(1) Select the Padlock icon in the bottom right corner of the user interface.
(2) Select Change password.
(3) Enter the following information:

Setting Name Explanation

Current password Enter the current user password.

New password Enter the new password.
Retype password Retype the new password.

(4) Select Save.

End of procedure.

8-32 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

Reset Forgotten Password

If a user profile password is forgotten, an admin level user can reset the password.
If the admin level user password is forgotten, contact your local Domino support office.
To reset a forgotten password:
(1) Log in as an admin level user, page 8-31.
(2) Select Home > Setup > Security > Users.
(3) Select the user profile that requires a new password.
(4) Select Change password.
(5) Enter the following information:

Setting Name Explanation

New password Enter the new password.

Retype password Retype the new password.

Note: This procedure is possible in Advanced Security mode only.
To change a user’s settings:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security > Users.
(3) Select the user that requires changing.
(4) To change the user’s password, select Change password at the bottom of the screen.
(5) The settings described in the table below can also be changed:

Setting Name Explanation

User name Displays the user name, this name cannot be changed.
Groups Select which user groups the user belongs to.
Status Select the user’s status:
• Active
• Dormant
• Locked
Must change Select the tick box to force a new user to change their password the
password first time they log in.
Forename Enter the user’s first name (optional).
Surname Enter the user’s last name (optional).
Department Enter the user’s department (optional).
Inactivity timeout Define the number of minutes the printer will be inactive for before the
(minutes) user is logged out.
Account expiry Select the tick box to enable the account expiry date.
enabled
Account expiry date Enter the date on which the user account will expire on if Account expiry
date is enabled.
Password expiry Enter the number of days the current password can be used before it
(days) expires.

(6) Select Save.

End of procedure

8-36 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

Delete User
Note: This procedure is possible in Advanced Security mode only.
To delete or change a user:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security > Users.
(3) Select the red Bin icon next to the user to be deleted.
End of procedure.
Add New User Group
Note: This procedure is possible in Advanced Security mode only.
To add a new user group:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security > Groups.
(3) Select the Add new group icon.
(4) Select the Group name entry box and enter a name for the user group.
(5) Select Save.
(6) Select which printer functions and settings members of the user group will be allowed
access to.
(7) Select Save.
End of procedure.
Delete User Group
Note: This procedure is possible in Advanced Security mode only.
To delete a user group:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security > Groups.
(3) Select the user group to be deleted.
(4) Select Delete Group.
End of procedure.
Change User Group Access to Specific Printer Settings
Each user group can be customised to allow or block the user group’s access to specific printer
settings.
To customise what printer features a user group has access to:
(1) Log into the printer as an admin level user.
(2) Select Home > Setup > Security > Groups.
(3) Select the user group that requires customising.
(4) A list of printer settings and UI screens will now be displayed. Change the value of each
drop down box to define which settings members of the user group are allowed or not
allowed access to.
(5) Select Save.
End of procedure

EPT026795 Issue 17 June 2020 8-37

PERFORMANCE PACKS

GREEN PACK
Note: Available for Ax350i/Ax550i printers only.
Hardware requirements: Revision 5 main PCB or higher and an available USB Type A port on the
printer cabinet or TouchScreen.
Software requirements: Version 01.00.20 or higher.
The green pack reduces make-up usage by up to 20% with the addition of a Peltier condenser.
Power consumption is also lowered with the addition of configurable energy save modes.
The green pack adds the following features to the printer:
• Peltier device to capture fluid evaporation in the printer cabinet.
• Print head and ink system stand-down mode (configurable).
• Graphics to display make-up and ink usage on the user interface.

Installation
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

WARNING: Pressurised ink system. Risk of ink spray.

When replacing the ITM, ensure the retaining clips are fully engaged.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

8-38 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

Required tools: 7mm spanner.

To install the green pack:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access door on the front of the printer cabinet.
(4) Remove the ink cartridge, make-up cartridge, MUM and ITM from the printer cabinet.
(5) Remove the vanity cover inside the printer cabinet.
(6) Unscrew the two nuts that secure the blank panel, or the blank Peltier condenser.
Note: Depending on when the printer was manufactured, the printer will be equipped with a
blank Peltier condenser, or a blank plate and T piece pipe connector.

EPT026795 Issue 17 June 2020 8-39

PERFORMANCE PACKS

(7) Disconnect the pipes from the blank Peltier condenser, or the T piece pipe connector.

To Cabinet Vent
To Make-up Module

To Distribution Block

To Cabinet Vent

To Distribution Block

To Make-up Module

8-40 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

(8) Install the new Peltier condenser in the printer cabinet and tighten the two nuts.

(9) Connect the pipes to the Peltier condenser.

To Cabinet Vent

To Distribution Block

To Make-up Module

EPT026795 Issue 17 June 2020 8-41

PERFORMANCE PACKS

(10) Connect the Peltier condenser electrical connector onto socket J3301 in the top left of the
cabinet.

(11) Refit the vanity cover, ITM, MUM, ink and make-up cartridges.
(12) Reconnect the power lead to the rear of the printer.
(13) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(14) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(15) Select Start and follow the on screen instructions to complete ink priming.
(16) Insert the green pack USB into a USB port on the printer cabinet or TouchScreen.
(17) Select, Home > Setup > Packs management.
(18) Select the appropriate Install button.
(19) Follow the on screen instructions.
(20) Remove the green pack USB.
(21) Select, Home > Setup > Adjustment > Installation.
(22) Ensure that the Peltier mode setting is set to Auto.
(23) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

8-42 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

Make-up Loss Graph

The make-up loss graph displays how many millilitres per hour of make-up has been consumed
by the printer.
To view the make-up loss graph, select Home > Setup > Printer status > Consumables.

Make-up Loss Graph

EPT026795 Issue 17 June 2020 8-43

PERFORMANCE PACKS

Energy Save Options

The printer has several energy saving features which can be enabled, disabled and customised on
the Power options screen.
To enable or disable the printers energy saving features:
(1) Select Home > Setup > Production line setup > Power options.
(2) Tick the Energy save enabled tick box.
(3) The energy save features described below can now be customised.
Auto Jet Off
If enabled, the ink jet will sequence off when a specified amount of time has passed after the last
print trigger signal is received.
The settings described in table below are used to setup the auto jet off feature.

Setting Name Explanation

Auto jet off enabled Enable or disable auto jet off.

Auto jet off time (mins) Define the amount of time from the last print trigger signal
received to when the ink jet will sequence off.

Auto Sleep
If enabled, the printer will enter sleep mode after a specified amount of time has passed since the
last print trigger signal is received or since the ink jet is sequenced off. This depends on which
Action for auto sleep option is selected.
The settings described in table below are used to setup the auto sleep feature.

Setting Name Explanation

Auto sleep enabled Enable or disable auto sleep.

Action for auto sleep Define the action that triggers auto sleep:

No print - The printer will enter sleep mode after a specified

amount of time has passed since the last print trigger signal is
received.

Jet off - The printer will enter sleep mode after a specified amount
of time has passed since the ink jet was last sequenced off.
Auto sleep time (mins) Define the amount of time from the last print trigger signal
received, or from the time the ink jet was last sequenced off, to
when the printer will enter sleep mode.

8-44 EPT026795 Issue 17 June 2020

PERFORMANCE PACKS

Action for Power Button (Standby Button)

The Action for power button (standby button) setting defines what action will occur when the
standby button on the front of the printer cabinet is pressed.
Standby Button

Standby Button Location

To change the standby button action:

(1) Select Home > Setup > Production line setup > Power options.
(2) Select the Action for power button drop down setting.
(3) Select one of the options described below:

Setting Name Explanation

Sleep The printer will enter sleep mode when the standby button is
pressed.
Shut down The printer will shut down when the standby button is pressed.
Prompt The printer will ask the user if it should enter sleep mode or shut
down when the standby button is pressed.

End of procedure.

EPT026795 Issue 17 June 2020 8-45

PERFORMANCE PACKS

THIS PAGE INTENTIONALLY LEFT BLANK

8-46 EPT026795 Issue 17 June 2020

PART 9 : HARSH ENVIRONMENT PACKS

CONTENTS
Page
HARSH ENVIRONMENT PACK OPTIONS ................................................................................ 9-3
POSITIVE AIR PUMP ................................................................................................................ 9-4
Introduction .......................................................................................................................... 9-4
Specification ......................................................................................................................... 9-4
Installation ............................................................................................................................ 9-5
Air Flow Check ................................................................................................................. 9-7
AIR DRIVEN AIR DRYER ........................................................................................................... 9-8
Introduction .......................................................................................................................... 9-8
Specification ......................................................................................................................... 9-9
Installation ............................................................................................................................ 9-10
Air Flow Check ................................................................................................................. 9-16
Humidity Check ................................................................................................................ 9-17
Air Dryer Fault Finding and Repair ....................................................................................... 9-18
Filter Element Replacement.............................................................................................. 9-19
Pressure Switch Replacement ......................................................................................... 9-20
Air Shut-off Solenoid Replacement .................................................................................. 9-21
Regulator Replacement .................................................................................................... 9-22

EPT026795 Issue 17 June 2020 9-1

HARSH ENVIRONMENT PACKS

THIS PAGE INTENTIONALLY LEFT BLANK

9-2 EPT026795 Issue 17 June 2020

HARSH ENVIRONMENT PACKS

HARSH ENVIRONMENT PACK OPTIONS

Harsh environment packs are designed to improve printer performance when operating in specific
harsh environments.
There are two harsh environment packs available as described in the table below:

Table 1: Harsh Environment Pack Options

Printer
Pack Name Description
Availability

Positive Air Pump - Ax150i The positive air pump adds an air pump which pumps
EPT013760SP Ax350i air from the cabinet into the print head.
Ax550i This create positive air pressure within the print head
to improve resistance to dust, reduce print head
cleaning, keeps ink cleaner for longer and reduces
printer down time in dirty environments.
Air Driven Air Dryer - Ax350i The air drier pack enables factory air to be fed into the
EPT025031SP Ax550i printer cabinet and print head. The pack also driers
and filters the air to improve printer performance in
humid environments. This pack also creates positive
air pressure within the print head to improve
resistance to dust, reduce print head cleaning, keeps
ink cleaner for longer and reduces printer down time in
dirty/humid environments.

EPT026795 Issue 17 June 2020 9-3

HARSH ENVIRONMENT PACKS

POSITIVE AIR PUMP

Introduction
The positive air pump is for use in high dust environments or for use with specific ink types. Refer
to “SYSTEM CONFIGURATION” on page 3-1.
The positive air pump, pumps air from inside the printer cabinet to the print head. This pressurises
the print head to keep the nozzle, gutter and ink jet free from dust.

Specification
Note: The air pump is configured to operate with a fixed maximum speed by joining the Red
and White wires and not connecting Green.

Table 2: Air Pump Pin Out

Pin Name Wire Colour

1 0V Black
2 - -
3 24V Red
3 24V White
4 - -

Air Pump

9-4 EPT026795 Issue 17 June 2020

HARSH ENVIRONMENT PACKS

Installation
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

Required equipment: T10 torx driver and engineer’s USB key.

To install the positive air pump:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove four screws on the rear ink system access panel and
remove the panel.
(4) Fit the positive air pump clamp to the printer cabinet.
(5) Push the silicone tube onto outlet ‘P’ of the positive air pump.
(6) Push the air pipe from the printer conduit into the silicone pipe on the positive air pump.
(7) Connect the cable from the positive air pump to the correct four pin connector on the cable
that passes through the cabinet bulkhead.
(8) Replace the rear ink system access panel.
(9) Reconnect the power lead.
(10) Press and hold the standby button and wait for 2 seconds for the printer to start up.
(11) Insert an engineer’s USB key into a USB slot on the TouchScreen or printer cabinet.
(12) On the TouchScreen, select Home > Setup > Adjustment > Installation.
(13) Select the Airdryer / Positive air pump drop down setting and select Installed.
(14) Select the Airdryer mode drop down setting and select one of the modes described in the
table below.
Table 3: Airdryer Mode Settings

Mode Name Description

Standard Mode The positive air pump will start running as soon as the ink jet starts
running. The air pump will stop when the printer is sequenced off.
Extended Mode The positive air pump will start running during the software loading
process when the printer is switched on. The air pump will only stop
when the printer is shut down.

EPT026795 Issue 17 June 2020 9-5

HARSH ENVIRONMENT PACKS

(15) Remove the engineer’s USB key from the printer.

(16) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
(17) At the print head, remove the holster by pressing in the two holster retaining clips on the
side of the print head.
(18) Check the air flow in the print head, see page 9-7.
End of procedure.

9-6 EPT026795 Issue 17 June 2020

HARSH ENVIRONMENT PACKS

Air Flow Check

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

To check the air flow:

(1) At the print head, remove the holster by pressing in the two holster retaining clips on the
sides of the print head.
(2) Confirm that there is an air flow from the print head positive air pipe.

Print Head Positive Air Pipe

(3) Replace the print head holster.

End of procedure.

EPT026795 Issue 17 June 2020 9-7

HARSH ENVIRONMENT PACKS

AIR DRIVEN AIR DRYER

Introduction
CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Remove the factory air supply to the printer when the printer is switched off to
prevent premature filter changes.

Note: The air dryer is available for the Ax350i/Ax550i only.

The air dryer is for use in high humidity environments or for use with specific ink types. Refer to
“SYSTEM CONFIGURATION” on page 3-1.
The air dryer cleans, dries and regulates factory supplied air to pressurise the print head. This
creates a clean and dry environment around the ink jet and gutter that ensures the ink does not
absorb airborne contaminants.
A pressure switch is connected into the system. If a fault occurs, e.g. a drop in pressure, the
printer will raise an alert.
The air dryer is located in the rear ink compartment, behind the cover on the left side (when
viewed from the rear of the printer).
The factory supplied air is first passed through a filter then a regulator assembly, this conditions
the air, removes any airborne condensate and regulates the air pressure to 2 bar (30psi). An in-line
flow control valve reduces the output airflow to the rate required by the print head. An air shut off
solenoid is fitted to stop the factory air to the print head when power is removed from the printer if
the factory air remains on.

Input Regulator Air Shut-Off Flow Control

Filter Solenoid Valve
Air

Drain Pressure
Vent Switch

Dry
Output
Air
Air Dryer Schematic

9-8 EPT026795 Issue 17 June 2020

HARSH ENVIRONMENT PACKS

Specification
Table 4: Air Dryer Specification

Environment: Temp Range: 5°C - 45°C Operating.

Humidity: 10 - 90% RH non-condensing.
Requirements: Electrical: 24Vdc (Supplied by printer).
Input Air: Air Purity Classes ISO 8573-1:2010
[X(15):4:4] or above 5-8bar (70-116psi)
Performance: Air Flow: 2.1 - 2.3 litres/min.
Output Humidity: <20% RH.
Internal Operating 2bar.
Pressure:
Acoustic Noise Not more than 70dBA.
Level:

Air Driven Air Dryer

EPT026795 Issue 17 June 2020 9-9

HARSH ENVIRONMENT PACKS

Installation
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

Required equipment: 7mm nut driver, 20mm spanner, T10 torx driver and engineer’s USB key.
To install the air dryer:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove four screws on the rear ink system access panel and
remove the panel.
(4) Mount the air dryer inside the printer cabinet and secure it with the two M4 nuts.

9-10 EPT026795 Issue 17 June 2020

HARSH ENVIRONMENT PACKS

(5) Connect the cable from the air dryer to the cable from the printer bulkhead.

Cable Connection

(12) Connect the factory air supply to the bulkhead connector.

(13) Reconnect the power lead at the rear of the printer.
(14) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(15) Insert an engineer’s USB key into a USB slot of the TouchScreen or printer cabinet.
(16) On the TouchScreen, select Home > Setup > Adjustment > Installation.
(17) Select the Airdryer / Positive air pump drop down setting and select Installed.
(18) Select the Airdryer mode drop down setting and select one of the modes described in the
table below.
Table 5: Airdryer Mode Settings

Mode Name Description

Standard Mode The air dryer will start running as soon as the ink jet starts running. The
air dryer will stop when the printer is sequenced off.
Extended Mode The air dryer will start running during the software loading process when
the printer is switched on. The air dryer will only stop when the printer is
shut down.
(19) Remove the engineer’s USB key from the printer.

9-14 EPT026795 Issue 17 June 2020

HARSH ENVIRONMENT PACKS

(20) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
(21) Turn on the air supply and check that there are no leaks.
(22) Check the air flow, page 9-16.
(23) Check the air humidity, page 9-17.
(24) Replace the rear ink system access panel.
End of procedure.

EPT026795 Issue 17 June 2020 9-15

HARSH ENVIRONMENT PACKS

Air Flow Check

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Required equipment: Air dryer test kit (P/N 30455).

To check the air flow:
(1) At the print head, remove the holster by pressing in the two holster retaining clips on the
sides of the print head.
(2) Connect the meter pipe to the end of the print head positive air pipe.
(3) Check that the air flow indicated by the meter is between 2.1 and 2.3 litres/minute. If
required, adjust the flow control valve to set the air flow to within these limits.
(4) Disconnect the meter from the positive air pipe.
(5) Replace the print head holster.
End of procedure.

9-16 EPT026795 Issue 17 June 2020

HARSH ENVIRONMENT PACKS

Humidity Check
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Required equipment: Air dryer test kit (P/N 30455).

To check the humidity:
(1) At the print head, remove the holster by pressing in the two holster retaining clips on the
sides of the print head.
(2) Connect the humidity sample bottle to the positive air pipe in the print head.
(3) Turn on the printer.
(4) Insert the humidity meter into the neck of the sample bottle and switch the meter on.
(5) Wait five minutes to allow the meter to acclimatise.
(6) Note the humidity shown in the meter window. The humidity should be less than 22%
Relative Humidity (RH).
(7) Remove the sample bottle and meter.
(8) Replace the print head holster.
End of procedure.

EPT026795 Issue 17 June 2020 9-17

HARSH ENVIRONMENT PACKS

Air Dryer Fault Finding and Repair

Air Shut-off Solenoid Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised Air System. Risk of injury.

Shut down the printer, remove the power cable and factory air supply before
starting this procedure.

CAUTION: Fragile air shut-off solenoid. Risk of damage to printer.

Do not over tighten the air shut-off solenoid screws on reassembly. Use a torque
driver to tighten the screws to 0.1Nm.

To replace the air shut-off solenoid:

(1) Release the securing bolt and remove the block assembly.
(2) Remove the wiring connector to the solenoid.
(3) Remove the two screws securing the solenoid to the block and remove the solenoid.
(4) Reassembly with a new solenoid body is in the reverse order of removal.
End of procedure.

EPT026795 Issue 17 June 2020 9-21

HARSH ENVIRONMENT PACKS

Regulator Replacement
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised Air System. Risk of injury.

Shut down the printer, remove the power cable and factory air supply before
starting this procedure.

CAUTION: Fragile air shut-off solenoid. Risk of damage to printer.

Do not over tighten the air shut-off solenoid screws on reassembly. Use a torque
driver to tighten the screws to 0.1Nm.

To replace the regulator:

(1) Release the securing bolt and remove the block assembly.
(2) Remove the two screws securing the solenoid to the block and remove the solenoid and
regulator.
(3) Re-assembly with a new regulator, is in the reverse order of removal.
End of procedure.

9-22 EPT026795 Issue 17 June 2020

PART 10 : ACCESSORIES

CONTENTS
Page
ACCESSORIES ...................................................................................................................... 10-3
ALARM BEACON ................................................................................................................... 10-3
Introduction ....................................................................................................................... 10-3
Installation ......................................................................................................................... 10-4
SHAFT ENCODERS ............................................................................................................... 10-5
PRODUCT DETECTORS ........................................................................................................ 10-6
Product Detector (Reflective) ............................................................................................ 10-7
Product Detector (Proximity) ............................................................................................. 10-8
Product Detector (Inductive) ............................................................................................. 10-9
Fibre Optic Sensors .......................................................................................................... 10-10
Proximity Fibre Optic Sensor ........................................................................................ 10-10
Through Beam Fibre Optic Sensor ............................................................................... 10-10
SPECIAL APPLICATION PRODUCT DETECTORS ................................................................ 10-11
Registration Mark Sensor .................................................................................................. 10-11
UV Sleeve Packing Sensor ................................................................................................ 10-12
Transparent Product Sensor ............................................................................................. 10-13
Fork (Label Detection) Product Sensor ............................................................................. 10-14
IP65 PRINT HEAD COVER ..................................................................................................... 10-15
Installation ......................................................................................................................... 10-16
BRACKETS AND STANDS ..................................................................................................... 10-17
Safety Considerations ....................................................................................................... 10-17
Floor Mounting Kit ............................................................................................................. 10-17
Print Head Pole Kit ............................................................................................................ 10-18
Printer Stands .................................................................................................................... 10-19
Stacking Kit ....................................................................................................................... 10-20
Ax350i UI Mounting Bracket ............................................................................................. 10-21
Ax550i UI Mounting Bracket ............................................................................................. 10-22
STROBOSCOPE .................................................................................................................... 10-23
Specification ...................................................................................................................... 10-23
Installation ......................................................................................................................... 10-24
Turn Stroboscope On/Off .................................................................................................. 10-25
Stroboscope External Control ........................................................................................... 10-26
DCI PORT KIT SPARE ........................................................................................................... 10-27
DCI Port Kit Installation (Ax150i) ....................................................................................... 10-28
DCI Port Kit Installation (Ax350i/Ax550i) ........................................................................... 10-32
DCI Port Pin Description ................................................................................................... 10-36
DCI Port PCBA Layout ...................................................................................................... 10-36

EPT026795 Issue 17 June 2020 10-1

ACCESSORIES

THIS PAGE INTENTIONALLY LEFT BLANK

10-2 EPT026795 Issue 17 June 2020

ACCESSORIES

ACCESSORIES
For the full list of available accessories refer to the Ax-Series accessories catalogue available via
the MyDomino manuals portal.

ALARM BEACON
Introduction
WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the beacon from the printer, or remove mains power
supply from the printer before disassembling the beacon to reposition the LED
colours.

Beacon Assembly

The beacon assembly consists of a short tubular aluminium pole carrying four lamps in a “totem
pole” style, with a mounting bracket and 3 metre cable. The beacon lamps illuminate in a solid
state as described below:

Table 1: Alarm Beacon Colour Description

Lamp
Description
Colour

Green Printer is printing or ready to print.

Red There is a fault, the printer has stopped.
Amber Printer requires attention.
Blue Printer powered to standby.

The beacon lamps can be moved into a different positions by removing the centre screw at the
top of the beacon. The lamps are fitted into three individual keyed sections. Once the screw is
removed, the sections can be reassembled into any user specific order.

EPT026795 Issue 17 June 2020 10-3

ACCESSORIES

Installation
WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the beacon from the printer, or remove mains power
supply from the printer before disassembling the beacon to reposition the LED
colours.

CAUTION: Vulnerable cable. Risk of damage to cable or equipment.

Securely route the cable away from moving equipment and other hazards

Note: To connect the alarm beacon to the printer, the printer must have a status pack
installed, see page 7-22.
The beacon can be mounted to the mounting holes on the printer cabinet, cabinet stand or
anywhere within its 3m cable length.
Required Tools: 4mm Hex Key
To install beacon:
(1) Mount the beacon to the two screw holes on the side of the printer cabinet, printer stand or
another suitable location.

Hole Dia 5.5mm

12.5mm
45mm

12.5mm

Mounting Dimensions

(2) Plug the beacon cable into the beacon connector on the printer cabinet, see page 4-17.
End of procedure.

10-4 EPT026795 Issue 17 June 2020

ACCESSORIES

SHAFT ENCODERS
CAUTION: Vulnerable cable. Risk of damage to cable or equipment.

Securely route the cable away from moving equipment and other hazards

CAUTION: Risk of shaft encoder damage.

Shaft encoders are fitted to the production line, the rotation of the shaft encoder follows the
production line movement. Exact details of both the shaft encoder and its installation depend
upon the production line.
Domino provides a number of shaft encoder options with selectable or programmable prints per
revolution depending on the user requirement. The full range of shaft encoders can be viewed in
the Ax-Series accessories catalogue available via the MyDomino manuals portal.
Connection to the printer is via one of the two product detect / shaft encoder connections on the
printer cabinet, see page 4-17.
The product detect / shaft encoder connector pin assignments are shown below.

Table 2: PD/SE Pin Out

Pin Description

1 24V Power Supply

2 Ground 2
5 4
3 Product Detect (+)
3 1
4 Product Detect (-) 8
7 6
5 Encoder Channel A (+)

6 Encoder Channel A (-)

7 Encoder Channel B (+) 8-Way PD / SE Connections

8 Encoder Channel B (-) (External View)

Shell EMC_GND via panel mounting

The printer provides a 24V DC supply for use by the shaft encoder and a selectable 24V NPN or
PNP input for signals from the encoder.
The NPN or PNP can be selected by changing the micro-switches on the PD/SE PCBA as
described on page 15-19.
The printer also has an internal digital gearbox which can be used to multiply or divide the
encoder output.
For instructions on how to calibrate and set the shaft encoder, see page 4-39.

EPT026795 Issue 17 June 2020 10-5

ACCESSORIES

PRODUCT DETECTORS
CAUTION: Vulnerable cable. Risk of damage to cable or equipment.

Securely route the cable away from moving equipment and other hazards

CAUTION: Risk of product detect sensor damage.

Product detectors can be fitted to the production line to detect products and send print trigger
signals to the printer.
The full range of product detectors can be viewed in the Ax-Series accessories catalogue
available via the MyDomino manuals portal.
For instructions on how to calibrate and set the product detectors, see page 4-54.
Exact details of both the product detector and its installation depend upon the production line.
Connection to the printer is via one of the two product detect / shaft encoder connections on the
printer cabinet, see page 4-17.
The product detect / shaft encoder connector pin assignments are shown below.

Table 3: PD/SE Pin Out

Pin Description

1 24V Power Supply

2 Ground 2
4 5
3 Product Detect (+)
1 3
4 Product Detect (-) 8
6 7
5 Encoder Channel A (+)

6 Encoder Channel A (-)

7 Encoder Channel B (+) 8-Way PS / SE Connections

8 Encoder Channel B (-) (External Cabinet View)

Shell EMC_GND via panel mounting

Product Detector (Inductive) Assembly

EPT026795 Issue 17 June 2020 10-9

ACCESSORIES

Fibre Optic Sensors

CAUTION: Vulnerable cable. Risk of damage to cable or equipment.

Securely route the cable away from moving equipment and other hazards

Fibre optic sensors are typically fitted to the production line where space is limited or where more
accuracy is required. A typical application would consist of the amplifier box plugged into one of
the Product Detect connectors on the printer. Sensors can then be configured as a proximity fibre
optic sensor or as a through beam fibre optic sensor as detailed below.

Amplifier
Box

Pin 2 = GND
Pin 4 = Product
Detect (-)

Pin 3 = Product
Detect (+)

Pin 1 = 24V

Through Beam
Sensor
Product Detect Connector
(External Cabinet View)

Typical Proximity Fibre Optic Sensor Set-up

using Through Beam Sensor

Proximity Fibre Optic Sensor

Note: An 8 pin connector (P/N EPP002908SP) us required to connect the proximity fibre
optic sensor to the printer.
A Through Beam Fibre Optic Sensor is attached to the amplifier box with the sensor positioned so
that a light beam from the sensor is reflected back by the product itself. The sensor detects the
reflected beam and printing starts when reflection either begins or ends. The reflection may be
from the body of the product or from a light coloured marking on a darker background on the
product. The sensitivity can be adjusted on the amplifier.
Through Beam Fibre Optic Sensor
Note: An 8 pin connector (P/N EPP002908SP) us required to connect the through beam
fibre optic sensor to the printer.
Installation would be similar to the Proximity Fibre Optic Sensor installation with an additional
Diffused Beam Sensor fitted to allow the detection of the beam passing through the space
between the products on the line.

10-10 EPT026795 Issue 17 June 2020

ACCESSORIES

SPECIAL APPLICATION PRODUCT DETECTORS

Registration Mark Sensor
CAUTION: Vulnerable cable. Risk of damage to cable or equipment.

Securely route the cable away from moving equipment and other hazards

Note: An 8 pin connector (P/N EPP002908SP) us required to connect the registration mark
sensor to the printer.
The registration mark sensor is used to detect registration marks on continuous substrates.
Features:
• 5 metre cable.
• White LED emission.
• “Teach-in”, “Remote Setting” and “Auto-Set”.
• White LED emission.
• Interchangeable lenses and fibre optic versions.
• Metal housing with adjustable orientation of optics and connector.

Pin 2 = GND
Pin 4 = Product
Detect (-)

Pin 3 = Product
Detect (+)

Pin 1 = 24V

Product Detect Connector

(External Cabinet View)

Registration Mark Sensor Assembly

EPT026795 Issue 17 June 2020 10-11

ACCESSORIES

UV Sleeve Packing Sensor

CAUTION: Vulnerable cable. Risk of damage to cable or equipment.

Securely route the cable away from moving equipment and other hazards

Note: An 8 pin connector (P/N EPP002908SP) us required to connect the registration mark
sensor to the printer.
The UV sleeve packing sensor is used to detect sleeve or watch strap style packaging.
Features:
• Detects sleeve/watch strap style packaging.
• Ideal solution for luminescent mark detection.
• High power UV emission for improved sensitivity.
• Fast switching frequency and response time.
• Easy setting and clear bar-graph indicator.
Pin 2 = GND
Pin 4 = Product
Detect (-)

Pin 3 = Product
Detect (+)

Pin 1 = 24V

Product Detect Connector

(External Cabinet View)

Registration Mark Sensor Assembly

10-12 EPT026795 Issue 17 June 2020

ACCESSORIES

Transparent Product Sensor

CAUTION: Vulnerable cable. Risk of damage to cable or equipment.

Securely route the cable away from moving equipment and other hazards

Note: An 8 pin connector (P/N EPP002908SP) us required to connect the transparent

product sensor to the printer.
The transparent product sensor is used to detect transparent materials such as film, PET, etc.
Features:
• Detect transparent materials such as film, PET, etc.
• High excess-gain and operating distances.
• IP69K mechanical protection.
• AISL-316L stainless steel versions.
• Standard 3 wire configuration output.

Pin 2 = GND
Pin 4 = Product
Detect (-)

Pin 3 = Product
Detect (+)

Pin 1 = 24V

Product Detect Connector

(External Cabinet View)

Registration Mark Sensor Assembly

EPT026795 Issue 17 June 2020 10-13

ACCESSORIES

Fork (Label Detection) Product Sensor

CAUTION: Vulnerable cable. Risk of damage to cable or equipment.

Securely route the cable away from moving equipment and other hazards

Note: An 8 pin connector (P/N EPP002908SP) us required to connect the fork sensor to the
printer.
The fork sensor detects labels as they move through the fork sensor.
Features:
• High 25 kHz switching frequency.
• IR light model.
• Detection of semi-transparent labels.
• Detection of register mark.
• 5m cable.
Pin 2 = GND
Pin 4 = Product
Detect (-)

Pin 3 = Product
Detect (+)

Pin 1 = 24V

Product Detect Connector

(External Cabinet View)

Fork Label Detection Sensor Assembly

10-14 EPT026795 Issue 17 June 2020

ACCESSORIES

IP65 PRINT HEAD COVER

Ax-Series printers equipped with a single jet i-pulse print head have the option of an IP65 print
head cover to protect the print head from excessive moisture.
The print head cover is made from stainless steels and complies to IP65 when the print aperture is
in the closed position.

IP65 Print Head Cover

EPT026795 Issue 17 June 2020 10-15

ACCESSORIES

Installation
WARNING: Heavy object. Risk of physical injury or damage to equipment.
Print heads fitted with the IP65 print head cover weigh considerably more than
standard print heads. When mounting a print head fitted with the IP65 print head
cover to a bracket, ensure that the bracket is stable and of sufficient strength to
support the print head.

To install the IP65 print head cover:

(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the standard holster from the print head by pressing in the two holster retaining
clips and withdrawing the holster.
(4) Familiarise the fitting of the print head into the harsh environment cover. In particular note
the orientation of the print head to the sides of the harsh environment cover.
(5) Place the sealing gasket over the print head and along the conduit where it will not cause an
obstruction.
(6) Place the two parts of the sealing gland over the conduit nut. Note that the sealing gland
has contours to fit over the nut flats.
(7) Attach the two top halves by positioning them on either side of the sealing gland. Ensure the
orientation of the top is such that it will be aligned with the top of the holster when the two
are assembled. In particular ensure the recesses for the clips are correctly positioned in
relation to the clips on the sides of the harsh environment cover.
(8) Screw the two top halves together such that the sealing gland is compressed over the
conduit and there is no gap between the two top halves.
(9) Insert the print head part way into the harsh environment cover.
(10) Retrieve the sealing gasket carefully stretch it over the top halves.
(11) Fit the sealing gasket into the recess under the top halves.
(12) Fit the print head fully into the harsh environment cover and use the securing catches to
compress the gasket and secure the assembly together.
End of procedure.

10-16 EPT026795 Issue 17 June 2020

ACCESSORIES

BRACKETS AND STANDS

Safety Considerations
When using a bracket it is important to consider the effect on the stability of any equipment that is
attached to the bracket. When any bracket is attached to the printer it is particularly important
that the printer is securely fixed to a stable surface.
To see the full range of brackets and stands, refer to the Ax-Series Accessories catalogue
available via the MyDomino manuals portal.

Floor Mounting Kit

The floor mounting kit is used to securely mount the print head whilst allowing full adjustment.
Required tools: 6mm Hex Key and 4mm Hex Key.

500
mm
1450mm

Print Head Floor Mounting Kit

EPT026795 Issue 17 June 2020 10-17

ACCESSORIES

Print Head Pole Kit

The print head pole kit is used to securely mount the print head whilst allowing full adjustment.
Required tools: 6mm Hex Key and 2.5mm Hex Key.

500
mm
1500mm

Print Head Pole Kit

10-18 EPT026795 Issue 17 June 2020

ACCESSORIES

Printer Stands
WARNING: Heavy object. Risk of physical injury.

Carry out a risk assessment before lifting the printer cabinet onto a stand. The dry
weight of the printer is between 16kg (35.3lb) and 23kg (50.7lb).

The stand provides secure support for the printer and places it at a convenient height for the
operator.
The stand has four height adjustable feet that provide levelling on uneven floors.
Wheels are provided to enable the printer to be transported. To move the printer on a stand,
ensure the printer is not printing, retract the feet and ensure all doors and external equipment
(cables, print head conduit) are secure and cannot cause a trip hazard.
Two different stands are available for use in different operating environments. Both stands are
physically similar in appearance.
• Type 1 printer stand: Made from 304 grade stainless steel.
• Type 2 printer stand: Made from 316 grade stainless steel for use in harsh operating
environments.

Ax150i Mounted to Type 1 Ax350i/Ax550i Mounted to Type 2

Printer Stand Printer Stand

EPT026795 Issue 17 June 2020 10-19

ACCESSORIES

Stacking Kit
WARNING: Topple hazard. Risk of physical injury.

When using the stacking kit, securely mount the bottom bracket to the floor to
prevent the printers from toppling over.

WARNING: Topple hazard. Risk of physical injury.

Do not stack more than 3 printer cabinets.

Note: Only Ax350i/Ax550i printers can be stacked as described below.

It is possible to mount an Ax350i/Ax550i printer to the floor and stack a maximum of three printer
cabinets using the stacking kit. The stacking kit can also be used to secure a printer stand to the
floor.

Ax350i/Ax550i Printers x 3

Mounting Plate

3 x Fixing Screws

Mounting Plate

Bracket Stand Mounting

Specification

Manual control: Rotating knob

120 to 25000 min¯¹ bzw. 2 to 416,6 sec¯¹
Fast finder function, bisection or doubling of the flash frequency
External control: By square wave impulse 10 to 24 V
Smooth, real-time image shifting 0 to 360°
Slow motion function
Flash duration control: Automatic, related to print frequency or manually by rotating knob.
Range: 1 to 250 μs
Display: 5 digit, 7 segment display
Digit size: 7.6 mm
Power supply: 3 x 1.2 V NiMH rechargeable battery (AA)
Fast charging power supply unit, 5 Vdc
Size (L x W x H): 200 mm x 85 mm x 40 mm
Weight: Approximately 0.5 kg
Illumination intensity: 3600 lx at 200 mm distance
Measured at 50 Hz at 50 μs flash duration
Colour temperature: 6500 K
Illumination Ø: 112 mm at 300 mm distance

EPT026795 Issue 17 June 2020 10-23

ACCESSORIES

Installation
WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver.

To install the stroboscope:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear electronics panel.
(4) Lower the rear electronics panel.
(5) Change the jumpers on LK4 of the GPIO PCBA to NPN.

(6) Replace the printer’s rear electronics panel.

10-24 EPT026795 Issue 17 June 2020

ACCESSORIES

(7) Connect the stroboscope to the printers GPIO socket.

Ax150i Ax350i/Ax550i

(8) Connect the power lead to the rear of the printer.

(9) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(10) Select Home > Setup > I/O port > Assignment.
(11) Change the settings for output pin B-PinJ / Ext25-Pin6 to the values described in the table
below.

Pin Active level Function Pulse time (ms)

B-PinJ / High Good print 10.0

Ext25-Pin6

End of procedure.

Turn Stroboscope On/Off

Press the On/Off button on the stroboscope, to turn the stroboscope On/Off.

Stroboscope On/Off Button

EPT026795 Issue 17 June 2020 10-25

ACCESSORIES

Stroboscope External Control

Press the External button on the stroboscope, to allow the stroboscope freqency to be controlled
by the printer.

Stroboscope External/Internal Button

10-26 EPT026795 Issue 17 June 2020

ACCESSORIES

DCI PORT KIT SPARE

All printer’s that are purchased with a SafeGuard package will come equipped with a DCI port.
The DCI port provides communication between the printer and DCI, it also provides the DCI’s
power supply.
If the printer is not equipped with a DCI port, the DCI port kit spare can be installed by an
engineer certified by Domino.
Notes: (1) The HMI Port used in the Extended Comms Pack (page 7-9) takes the same position
as the DCI port on Ax350i/Ax550i printers. Therefore it is not possible to fit both of
these options on an Ax350i/Ax550i. If a DCI and Extended Comms Pack are required,
it is recommended to connect the DCI to the printer’s Ethernet port and use an
external power supply for the DCI.
(2) The DCI port can only be installed on Ax150i printers from serial number
AX0000008755 onwards. This is because the Ax150i rear panel was updated with a
hole for the DCI port from printer number AX0000008755. The updated rear panel is
not available as a spare part.
The items listed in the table below are contained in the DCI port kit spare:

Table 4: DCI Port Kit Spare Contents

Quantity Item Description

1 DCI PCBA
1 Sealing Cap
1 M3X5 SS T10 Torx Screw with Captive Washer
1 Ethernet Cable, 370mm
1 22W Ribbon Cable, 440mm

DCI Port Kit Spare Contents

EPT026795 Issue 17 June 2020 10-27

ACCESSORIES

DCI Port Kit Installation (Ax150i)

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver.

To install the DCI port kit on an Ax150i:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear panel.

Ax150i Rear Panel

(4) Lower the rear panel.

10-28 EPT026795 Issue 17 June 2020

ACCESSORIES

(5) Mount the DCI PCBA onto the inside of the rear panel and secure it using the M3x5 screw.

(6) Connect the Ethernet cable to connector J3 on the DCI PCBA.

EPT026795 Issue 17 June 2020 10-29

ACCESSORIES

(7) Connect the other end of the Ethernet cable to connector J1001 or J1002 on the printer’s
main PCB.
Note: For clarity the main PCB is illustrated outside of printer with no other connections.

(8) Connect the ribbon cable to J1 on the DCI PCBA.

10-30 EPT026795 Issue 17 June 2020

ACCESSORIES

(9) Connect the other end of the ribbon cable to connector J173 on the printer’s main PCB.
Note: For clarity the main PCB is illustrated outside of printer with no other connections.

(10) Replace the printer’s rear panel.

(11) Connect the power lead to the rear of the printer.
(12) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

EPT026795 Issue 17 June 2020 10-31

ACCESSORIES

DCI Port Kit Installation (Ax350i/Ax550i)

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver.

To install the DCI port kit on an Ax350i/Ax50i:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Use a T10 torx driver to remove the screws securing the rear electronics panel.

Ax350i/Ax550i Rear Electronics Compartment Access

(4) Lower the rear panel.

10-32 EPT026795 Issue 17 June 2020

ACCESSORIES

(5) Mount the DCI PCBA onto the inside of the rear panel and secure it using the M3x5 screw.

(6) Connect the Ethernet cable to connector J3 on the DCI PCBA.

EPT026795 Issue 17 June 2020 10-33

ACCESSORIES

(7) Connect the other end of the Ethernet cable to connector J1001 or J1002 on the printer’s
main PCB.
Note: For clarity the main PCB is illustrated outside of printer with no other connections.

(8) Connect the ribbon cable to J1 on the DCI PCBA.

10-34 EPT026795 Issue 17 June 2020

ACCESSORIES

(9) Connect the other end of the ribbon cable to connector J173 on the printer’s main PCB.
Note: For clarity the main PCB is illustrated outside of printer with no other connections.

(10) Replace the printer’s rear electronics panel.

(11) Connect the power lead to the rear of the printer.
(12) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

EPT026795 Issue 17 June 2020 10-35

ACCESSORIES

DCI Port Pin Description

Table 5: DCI Connector Pin Description

Pin Signal Description

1 +24V 24V supply at 550mA 1 6

nominal
2 0V Power GND 2 7 5

3 TX1+ Transmit +
3 4
4 TX1- Transmit -
5 RX1+ Receive +
DCI Connector
6 RX1- Receive - (external view)

7 NC Not Connected
Shell EMC_GND Ground via panel
mounting

DCI Port PCBA Layout

DCI PCBA Top View DCI PCBA Bottom View

10-36 EPT026795 Issue 17 June 2020

PART 11 : STATUSES, ALERTS AND
FAULT FINDING

CONTENTS
Page
STATUSES ............................................................................................................................. 11-3
ALERTS .................................................................................................................................. 11-4
Alert ID Codes ................................................................................................................... 11-5
FAULT FINDING ..................................................................................................................... 11-13
PRINT QUALITY FAULTS ...................................................................................................... 11-15
ALERT CONFIGURATION ...................................................................................................... 11-17
Configure Alerts ................................................................................................................. 11-17
Ranged Alerts .................................................................................................................... 11-18
ITM Alerts .......................................................................................................................... 11-19
RESTORE DEFAULT ALERT LEVELS .................................................................................... 11-20
Restore Default Fluid Level Alerts ..................................................................................... 11-20
Restore Default Inspection Interval Alerts ......................................................................... 11-20

EPT026795 Issue 17 June 2020 11-1

STATUSES, ALERTS AND FAULT FINDING

THIS PAGE INTENTIONALLY LEFT BLANK

11-2 EPT026795 Issue 17 June 2020

STATUSES, ALERTS AND FAULT FINDING

STATUSES
Shown below are some printer statuses and their explanations. Printer statuses are displayed on
the Status tab at the top of the QuickStep interface.

Status Name Explanation

Idle The ink jet is off and the printer will not print, but the user interface
can still be used.
Sequencing On The printer is getting ready to print. Once completed, the printer
will be in a Ready state.
Printhead warming up The printer is heating the print head to the optimum temperature
for the ink.
Ready The printer is ready to print. If a label is on-line, it will print on
receiving a product detect signal.
Sequencing Off The printer is changing from the Ready state to the Idle state.
Gutter clearing in progress The printer is clearing the gutter and recalibrating, no user action
is required.
This status may be due to ink in the gutter caused by:
• Incorrect shut down process (fast shut down instead of
sequence off).
• The user was cleaning the print head/gutter during shut
down/start up.
• Bad ink jet alignment into gutter.

EPT026795 Issue 17 June 2020 11-3

STATUSES, ALERTS AND FAULT FINDING

ALERTS
Alerts are displayed on the Status tab at the top of the QuickStep interface. When multiple alerts
occur only the highest alert will be displayed. If multiple alerts occur, the full list of alerts can be
viewed by selecting the status tab.
Common alert ID codes, their causes and remedies are listed on page 11-5.
To clear an alert, or view information about how to solve the alert:
(1) Select the Status tab.
(2) The icons illustrated below will become available to select.

Icon Explanation

Select the Details icon to display the following information:

• Date and time the alert occurred.
• Alert ID number.
• Alert level.
• Detailed information about the alert.
• A solve icon which can be pressed to display
recommendations for fixing the problem.
• A QR code which can be scanned by a mobile phone or
tablet device to show a video or further details about how to
solve the alert.
• A clear button to acknowledge and clear the alert.
Select this icon to acknowledge and clear the alert. If this icon is
greyed out then an action must be performed before the alert can
be cleared.
Clear all alerts that can be cleared.

Select to snooze the beacon alarm buzzer for 5 minutes.

End of procedure.

11-4 EPT026795 Issue 17 June 2020

STATUSES, ALERTS AND FAULT FINDING

Alert ID Codes
The table below describes some alerts which the printer might encounter. The table also lists
possible causes and remedies.
If an alert occurs that is not listed in the table:
• Select the Solve icon to view options for solving the alert.
• Scan the QR code with a mobile phone or tablet device to show a video or further details
about how to solve the alert.
• Contact the local support office for further help.

Alert ID Description Possible Cause and Remedy

10 Print Stretch Detected Incorrect print configuration for the production line
speed causing the print to stretch. There are four
solutions are available:
• Reduce the production line speed.
• Increase the Stroke pitch (mm/stroke) value,
see page 5-26.
• Reduce the print quality to allow the label to be
printed faster, see page 5-26.
• Adjust the amount of print stretch allowed
before the alert is triggered. Select Home >
Setup > Production line setup and adjust the
Print stretch threshold (mm) setting.

EPT026795 Issue 17 June 2020 11-5

STATUSES, ALERTS AND FAULT FINDING

Alert ID Description Possible Cause and Remedy

15 Deflection EHT has Spark across the EHT plates.

tripped.
Run the print height calibration wizard and slightly
reduce the EHT (%) value, see page 4-61.
Note: The EHT (%) value must only be
adjusted in small steps.
Ink build up on charge electrode.

Clean the print head, see page 12-4.

Partially blocked nozzle.

Run the nozzle unblocking wizard, see page 12-16.

Ink jet clipping the gutter.

Check the ink jet alignment, see page 12-17.

Also, check the print height calibration, page 4-61.
Excessive print height.

Run the print height calibration wizard, see

page 4-61.
Ink leak at nozzle.

Check for ink drops around the nozzle and call an

engineer certified by Domino to repair or replace
the nozzle.
20 Ink Level Below Minimum The ink level is running low.

Fit a new ink cartridge, see page 6-3.

24 Gutter Dry at Start-up The printer was not shut down correctly.

Clean the print head, see page 12-4 and restart the
printer.
Blocked nozzle.

Run the nozzle unblocking wizard, see page 12-16.

Dried ink in the gutter.

Clean the print head, see page 12-4 and restart the
printer.
Ink jet incorrectly aligned.

Check the ink jet alignment, see page 12-17.

11-6 EPT026795 Issue 17 June 2020

STATUSES, ALERTS AND FAULT FINDING

Alert ID Description Possible Cause and Remedy

25 Add make-up cartridge A new make-up cartridge is required.

Fit a new make-up cartridge, see page 6-3.

41 Ink level too high The ink viscosity has increased and extra make-up
has been added to the ink causing the level to
increase.

Fit a new ITM, see page 6-7.

Or;

Remove the ITM, empty some of the ink into a

suitable container and replace the ITM, see
page 6-7. Follow local waste disposal regulations
to correctly dispose of waste ink.
Frequent flushing has occurred, either due to
repeated start/stop, repeated flushing or cleaning
of the print head.

Avoid frequent start/stop and shut down the printer

before cleaning the print head.
The printer has been moved to a different location
with the ink and make-up cartridges fitted.

Shut down the printer and remove the ink and

make-up cartridges before moving the printer.
53 Make-up Level Below The make-up level is running low.
Minimum
Fit a new make-up cartridge, see page 6-3.
134 Unexpected shutdown The printer was not powered off using the correct
method.

Follow the correct shut down procedure, see

page 5-23.

EPT026795 Issue 17 June 2020 11-7

STATUSES, ALERTS AND FAULT FINDING

Alert ID Description Possible Cause and Remedy

139 Print trigger occurred The printer received a trigger signal before the label
while printing finished printing.

Reduce the speed of the production line.

The printer received a false trigger signal before the
label finished printing.

Increase the persistence level for the print trigger,

see page 4-55.
Label too long for the product.

Check the printed label and reduce the label length.

The product sensor is faulty.

Replace the product sensor.

213 Inspection Required An inspection is required by an engineer certified
by Domino.

Contact the local support office to organise an

inspection.
234 Gutter Stall The operator has cleaned the print head whilst the
printer is running. This has caused excess solvent
to enter the gutter causing it to stall.

The printer will self recover from this fault. Follow

the correct print head cleaning procedure in future,
see page 12-4.
The gutter has stalled.

Restart the printer following the correct procedure,

see page 5-21. If the fault reoccurs, switch off the
printer and contact the local support office.
235 Gutter Pump not Rotating The gutter pump has stopped.

Restart the printer following the correct procedure,

see page 5-21. If the fault reoccurs, switch off the
printer and contact the local support office.
236 Gutter Blocked The printer is attempting to clear an obstruction in
Attempting to Clear the gutter.

11-8 EPT026795 Issue 17 June 2020

STATUSES, ALERTS AND FAULT FINDING

Alert ID Description Possible Cause and Remedy

237 Gutter Blocked Dried ink in the gutter.

Clean the gutter see page 12-6.

Incorrect shut down procedure followed.

Clean the print head, see page 12-4 and restart the
printer.
Blocked nozzle.

Run the nozzle unblocking wizard, see page 12-16.

Ink jet incorrectly aligned.

Check the ink jet alignment, see page 12-17.

238 Insufficient gutter vacuum The printer is attempting to increase the vacuum
- Retrying within the gutter. Follow any instructions given on
the TouchScreen.
517 ITM life expired (currently The ITM has reached the end of its life. The printer
in grace period) will continue to operate for a 120 hour grace period.
After this time the printer will stop. The grace period
can be extended by a Domino Engineer, see
page 19-6. If the ink jet is sequenced off during the
grace period a password is required to continue
operation.
The password should only be used in emergency
circumstances, because the ITM will operate longer
than the recommended life. Over time, this can
negatively affect the printer’s reliability, pump life
and ink system component life, etc.
• Replace the ITM, see page 6-7.
• Enter the password: itmgrace
520 Change ITM - ITM Ink The ITM which has been fitted is the wrong type.
Type Incorrect
Shut down the printer, remove the ITM and replace
it with the correct type, see page 6-7.
521 Change ITM - ITM Tag The ITM has reached the end of its life and can no
Dead longer be used.

Replace the ITM, see page 6-7.

523 Change ITM - Expired The ITM has reached the end of its life and can no
longer be used.

Replace the ITM, see page 6-7.

EPT026795 Issue 17 June 2020 11-9

STATUSES, ALERTS AND FAULT FINDING

Alert ID Description Possible Cause and Remedy

524 Insert ITM - No Valid ITM No ITM fitted.

present
Fit an ITM, see page 6-7.
ITM not fitted correctly

Check that the ITM is correctly fitted in the printer

cabinet, see page 6-7.
The RFID tag on the ITM is not working correctly.

Replace the ITM, see page 6-7.

528 Add ink cartridge A new ink cartridge is required.

Fit a new ink cartridge, see page 6-3.

530 Change Ink Cartridge - Ink The printer has detected that the ink cartridge fitted
Type Incorrect (or offered up to the QMM) is not the correct type.

If the cartridge has been fitted, immediately switch

off the printer and contact the local support office.
531 Change Ink Cartridge - Ink The ink cartridge has expired and a new cartridge is
Cartridge Expired required.

Fit a new ink cartridge, see page 6-3.

532 Change Ink Cartridge - The ink cartridge is empty.
Empty
Fit a new ink cartridge, see page 6-3.
534 Insert Ink Cartridge - No No ink cartridge fitted.
Valid Ink Cartridge Present
Fit an ink cartridge, see page 6-3.
Ink cartridge not fitted correctly

Check that the ink cartridge is correctly fitted in the

printer cabinet, see page 6-3.
The RFID tag on the ink cartridge is not working
correctly.

Replace the ink cartridge, see page 6-3.

539 Insert Make-up Cartridge A new make-up cartridge is required.

Fit a new make-up cartridge, see page 6-3.

540 Make-up low The make-up level in the make-up module (MUM) is
low.

Fit a new make-up cartridge, see page 6-3.

11-10 EPT026795 Issue 17 June 2020

STATUSES, ALERTS AND FAULT FINDING

Alert ID Description Possible Cause and Remedy

542 Change Make-up A new make-up cartridge is required.

Cartridge - Cartridge
Empty Fit a new make-up cartridge, see page 6-3.
543 Change Make-up The make-up cartridge has reached the end of its
Cartridge - Cartridge life and can no longer be used.
Dead
Fit a new make-up cartridge, see page 6-3.
544 Insert Make-up Cartridge - No make-up cartridge fitted.
No valid Cartridge present
Fit a make-up cartridge, see page 6-3.
Make-up cartridge not fitted correctly

Check that the make-up cartridge is correctly fitted

in the printer cabinet, see page 6-3.
The RFID tag on the make-up cartridge is not
working correctly.

Replace the make-up cartridge, see page 6-3.

556 Print head warming up The print head is warming up.

If this status persists, contact the local support

office.
557 Misaligned jet at start-up The gutter is blocked.

Clean the print head, page 12-4.

The nozzle is blocked.

Run the nozzle unblocking wizard, see page 12-16.

The ink jet is misaligned.

Check the ink jet alignment, see page 12-17.

561 The label print height is The Height (%) setting in the label has been set too
out of range high. The printer will not print at the value that has
been set, but will print at the highest possible value.

Reduce the Height (%) to clear the alert, see

page 5-26.
572 The printed label is too Labels are being printed too close together
long, speed too high or meaning there is not enough phasing time. There
the shaft encoder has are two solutions are available:
stopped mid-label. • Increase the gap between printed labels.
• Lower the production line speed.

EPT026795 Issue 17 June 2020 11-11

STATUSES, ALERTS AND FAULT FINDING

Alert ID Description Possible Cause and Remedy

1017 Print delay too short The product detect persistence is set too long.

Reduce the product detect persistence, see

page 4-55.
The product sensor and print head are too close
together.

Physically increase the distance between the

product sensor and print head, then reset the print
trigger settings see, page 4-55.
The print delay is set too short.

Increase the print delay setting, see page 4-55.

1312 Charge Detection Error The printer cannot detect ink drops within the
charge electrode due to a build of ink of the charge
electrode.

Clean the print head, page 12-4.

The ink jet is not modulating correctly.

Check the ink jet modulation and break-up within

the charge electrode. If this is not visible contact
the local support office.
The ink jet is misaligned.

Check the ink jet alignment, see page 12-17.

1313 Recovered Successfully The printer has recovered from a previous fault or
alert, no user action should be required.

If this alert repeats and the print quality is reduced,

contact the local support office.
1370 Print head cover removed The print head cover has been removed.

The i-Pulse RS print head contains a sensor to

detect when the print head cover is removed. When
the print head cover is removed power to the EHT
plates will stop and printing will stop.

Replace the print head cover to clear the alert and

resume printing.

11-12 EPT026795 Issue 17 June 2020

STATUSES, ALERTS AND FAULT FINDING

FAULT FINDING

Issue Possible Cause Remedy

Not Printing, error Gutter Dry is Blocked Nozzle. Home > Setup > Wizards > Nozzle
displayed unblocking.
Ink on deflector plates and/or charge Blocked Nozzle With the printer switched off and
electrode, possible faults could be: or dirty print unplugged, clean the print head.
• Ink detected on Charge head. Refer to page 12-4.
Electrode.
• Charge detection has failed.
• Fall back jet modulation in use.
• Deflection EHT has tripped.
No print occurs but message has Faulty product Check the sensor and its position.
been sent. sensor.
Faulty encoder. Check the encoder is outputting
signals (can be seen via the Ext I/
F screen).
Incorrect setting Check that the active level is set
of product correctly.
sensor.
Print delay and/or Check the delay and offset for
offset set this label is suitable, adjust as
incorrectly. required.
Enable/Disable This button will toggle printing
(Send to Print) within the Home screen, so only
button has been necessary action is to press
pressed when in button again.
the Home screen
External encoder Change to internal encoder. Refer
selected when no to page 4-39.
encoder is fitted.
Print position incorrect. Print offset Set the print offset. Refer to
incorrect. page 5-65.
Product sensor Re-align the product sensor.
misaligned, page 4-55.
Spaces entered Remove spaces from label data.
at the start or end
of the label data.

EPT026795 Issue 17 June 2020 11-13

STATUSES, ALERTS AND FAULT FINDING

Issue Possible Cause Remedy

Print size too small Print height Run print height calibration
calibration wizard. Refer to page 4-61.
incorrect.
Print head too Check and adjust print head
close to product height above product or adjust
or incorrect ink the ink jet throw distance value.
jet throw Refer to page 4-58.
distance.
Solvent on Dry the print head deflector
deflector plates plates.
(after cleaning).
Ink jet alignment Check the ink jet alignment, refer
with deflector to page 12-17.
plates incorrect. Check the deflector plate
alignment, refer to page 12-28.
Ink jet velocity Lower the ink jet velocity, refer to
too high. page 4-60.
Ink overflowing in gutter. Gutter tube Clean the gutter tube, refer to
blocked. page 12-6.
Gutter filter Change ITM, refer to page 6-7.
blocked.
Blocked or Check gutter pipe for blocks or
kinked gutter kinks.
pipe.
Air leak Check gutter pipe for leaks.
preventing
vacuum at gutter.
Gutter pump Check the gutter pump, refer to
faulty. page 16-60.
Replace the gutter pump if
necessary, refer to page 16-61.
High ink viscosity (thick ink) and Dirty 0.3mm Clean the restrictor, refer to
printer not adding make-up. restrictor. page 16-21.
Swollen make-up On printers earlier than serial
solenoid valve number AX0000002780 the valve
seat. seals on Burkert solenoid valves
may swell up. This issue has been
solved on later printers. Check
the make-up solenoid valve and
replace if necessary, refer to
page 16-17.

11-14 EPT026795 Issue 17 June 2020

STATUSES, ALERTS AND FAULT FINDING

PRINT QUALITY FAULTS

Illustrated below are examples and possible causes of print quality faults. If print quality is poor,
first ensure that the print head is clean, properly aligned and there are no alerts on the printer.

• The print head is not mounted at 90° to the direction of print surface movement.
• The print surface is moving and is not square to the print head.

• The print head is too far from the print surface, refer to page 4-58.
• The print height is incorrectly set, refer to page 4-61.
• The ink jet velocity is set too low, refer to page 4-60.

• The print head is dirty, refer to page 12-4.

• The ink jet is not properly aligned, refer to page 12-17.
• The charge electrode is out of alignment, refer to page 12-37.
• The print height is incorrectly set, refer to page 4-61.
• The ink jet velocity is set too low, refer to page 4-60.
• The ink viscosity is out of operating range.

• The print head is too close to the print surface, refer to page 4-58.
• The print height is incorrectly set, refer to page 4-61.
• The ink jet velocity is set too high, refer to page 4-60.

EPT026795 Issue 17 June 2020 11-15

STATUSES, ALERTS AND FAULT FINDING

• The print head is dirty, refer to page 12-4.

• The print head is too close to the print surface, refer to page 4-58.
• The print height is incorrectly set, refer to page 4-61.
• The charge electrode is out of alignment, refer to page 12-37.
• The ink jet velocity is set too high/low, refer to page 4-60.
• The ink viscosity is out of operating range.

• The print head is dirty, refer to page 12-4.

• The ink jet is not properly aligned, refer to page 12-17.
• The ink jet velocity is set too low/high, refer to page 4-60.
• The print height is incorrectly set, refer to page 4-61.

• The print head is dirty, refer to page 12-4.

• The ink jet is not properly aligned, refer to page 12-17.
• The charge electrode is out of alignment, refer to page 12-37.
• The print height is incorrectly set, refer to page 4-61.
• The nozzle is blocked, refer to page 12-16.
• The ink jet velocity is set too low/high, refer to page 4-60.
• The ink viscosity is out of operating range.

11-16 EPT026795 Issue 17 June 2020

STATUSES, ALERTS AND FAULT FINDING

ALERT CONFIGURATION
Configure Alerts
Alerts can be set to display on the status tab in different orders of importance depending on the
user requirement.
To adjust the order that alerts are displayed:
(1) On the TouchScreen, select Home > Setup > Alert configuration > Configure alerts.
(2) Select the Arrange alerts by drop down box and select one of the options described below:

Setting Name Description

Importance Display alerts with a higher importance first.

Time of occurrence Display the most recent alert first.

(3) Select the Order drop down box and select one of the options described below:

Setting Name Description

Warnings first Display red alerts first.

Faults first Display amber alerts first.

End of procedure.

EPT026795 Issue 17 June 2020 11-17

STATUSES, ALERTS AND FAULT FINDING

Ranged Alerts
The ranged alerts screen is used to adjust the fluid levels that trigger make-up and ink alerts.
The level of print stretch allowed before a print stretch detected alert is displayed can also be set
on this screen.
It is not recommended to change these settings from the factory default as this could interfere
with the operation of the printer. To restore the alerts to their factory default settings see,
page 11-20.
If it is necessary to view or adjust the ranged alerts:
(1) On the TouchScreen, select Home > Setup > Alert configuration > Ranged alerts.
(2) If required, select the value to adjust it. The default values are described in the tables below.

Table 1: Ranged Ink Alert Default Values

Alert Default Value

Ink high 100

Ink low 50
Ink empty 0

Table 2: Ranged Make-up Alert Default Values

Alert Default Value

Makeup high 100

Makeup low 42
Makeup empty 0

End of procedure.

11-18 EPT026795 Issue 17 June 2020

STATUSES, ALERTS AND FAULT FINDING

ITM Alerts
The remaining hours that trigger the ITM life remaining alerts can be adjusted by an engineer with
an engineer’s USB key.
The ITM’s grace period can also be adjusted.
To adjust the ITM life remaining alert triggers and the grace period length:
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Alert configuration > ITM alerts.
(3) The settings described in the table below are available for adjustment:

Table 3: ITM Alerts

Setting Name Default Value Description

First ITM alert 350 Adjust the number of ITM hours remaining that will
(hours) trigger the first ITM replacement alert.

This alert is intended to inform the customer to check

they have a replacement ITM available. if not, the
customer should order a new ITM immediately.
Final ITM alert 8 Adjust the number of ITM hours remaining that will
(hours) trigger the second ITM replacement alert.

This alert is intended to inform the customer/operator

that they should prepare to change the ITM.
Grace period 120 Adjust the length of the grace period.

When the ITM reaches the end of its life, the printer
will enter grace period. The printer will continue to
operate for 120 hours. After this time the printer will
stop. If the ink jet is sequenced off during the grace
period a password is required to continue operation.

End of procedure.

EPT026795 Issue 17 June 2020 11-19

STATUSES, ALERTS AND FAULT FINDING

RESTORE DEFAULT ALERT LEVELS

Restore Default Fluid Level Alerts
To restore the fluid level alerts to their default values:
(1) On the TouchScreen, select Home > Setup > Backup & restore > Defaults > Fluid Label
Alerts.
(2) Select Continue.
End of procedure.

Restore Default Inspection Interval Alerts

To restore the inspection interval alerts to their default values:
(1) Insert an engineer’s USB key into a USB slot of the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Backup & restore > Defaults > Inspection
Interval Settings.
(3) Select OK.
(4) Remove the engineer’s USB key from the printer.
End of procedure.

11-20 EPT026795 Issue 17 June 2020

PART 12 : I-PULSE PRINT HEAD REPAIR

CONTENTS
Page
INTRODUCTION .................................................................................................................... 12-3
PRINT HEAD CLEANING PROCEDURES .............................................................................. 12-4
Print Head Cleaning .......................................................................................................... 12-4
Gutter Cleaning ................................................................................................................. 12-6
Nozzle Removal and Cleaning .......................................................................................... 12-8
Remove Nozzle Assembly ............................................................................................ 12-8
Clean the Nozzle............................................................................................................ 12-11
Replace Nozzle Assembly ............................................................................................. 12-14
PRINT HEAD REPAIR PROCEDURES ................................................................................... 12-16
Nozzle Unblocking ............................................................................................................ 12-16
Ink Jet Alignment Check ................................................................................................... 12-17
Ink Jet Alignment Procedure ............................................................................................. 12-18
Gutter Airflow Adjustment ................................................................................................. 12-22
Drop Generator Assembly Replacement .......................................................................... 12-23
Deflector Plate Replacement ............................................................................................ 12-26
Deflector Plate Alignment .................................................................................................. 12-28
All Nozzle Sizes (Without Setting Tool) ......................................................................... 12-28
60 μm and 75 μm Nozzles (With Setting Tool) .............................................................. 12-31
Strobe LED and Charge Electrode Replacement .............................................................. 12-35
Charge Electrode Alignment ............................................................................................. 12-37
Holster Retaining Clip Replacement ................................................................................. 12-39
Print Head and Conduit Replacement .............................................................................. 12-40
Print Head Solenoid Screw Adjustment ............................................................................ 12-43
Flush Line Pipe Loop ......................................................................................................... 12-46
Installation Procedure ................................................................................................... 12-46
EHT DEFLECTOR PLATE/HV TEST ....................................................................................... 12-52
INK JET PROFILE CHECK AND TUNE .................................................................................. 12-55
Ink Jet Profile Check ......................................................................................................... 12-55
Ink Jet Profile Examples .................................................................................................... 12-56
Good/Acceptable Ink Jet Profiles ................................................................................. 12-56
Flat/High Peak Ink Jet Profiles ...................................................................................... 12-57
Low Peak Ink Jet Profiles .............................................................................................. 12-58
Unusual Ink Jet Profiles 1 .............................................................................................. 12-59
Unusual Ink Jet Profiles 2 .............................................................................................. 12-61
Nozzle Tuning Procedure .................................................................................................. 12-62

EPT026795 Issue 17 June 2020 12-1

i-PULSE PRINT HEAD REPAIR

THIS PAGE INTENTIONALLY LEFT BLANK

12-2 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

INTRODUCTION
This chapter describes cleaning and repair procedures for the single jet i-Pulse Print Head.

Single Jet i-Pulse Print Head

EPT026795 Issue 17 June 2020 12-3

i-PULSE PRINT HEAD REPAIR

PRINT HEAD CLEANING PROCEDURES

Print Head Cleaning
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

If the printer is running whilst this procedure is carried out, wash will enter the
gutter and may cause the viscosity of the ink to thin. Shut down the printer before
starting this procedure.

Required tools: T6 torx driver, wash and lint free tissue.

Clean the print head as follows:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) At the print head, press in the two retaining clips on the sides of the print head and remove
the holster.
(4) Remove the moulded cover over the internal pipework and wiring by gently squeezing the
sides of the cover inwards and withdrawing away from the print head.
(5) Follow the annotated instructions in the illustration below. If required, place an earthed
beaker underneath the print head to catch any waste fluid.

Loosen screw and remove the

Charge Electrode. Clean in the
slot with relevant wash, dry using
lint free tissue.

Clean any ink residue from

deflector plates

Clean any ink residue from gutter

area

i-Pulse Print Head Cleaning

12-4 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

Nozzle Removal and Cleaning

Remove Nozzle Assembly
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of damage to nozzle assembly.

Touching the nozzle with bare fingers may contaminate the nozzle. Do not touch
the nozzle with bare fingers.

To clean the nozzle:

(1) Carefully remove the O-ring from the nozzle assembly.

CAUTION: Risk of damage to piezo crystals.

Remove the O-ring before removing the piezo crystals. Failure remove the O-ring
first will damage the piezo crystals.

O-ring

(2) Gently remove the two piezo crystals and the tag from the nozzle assembly.

Crystals
Crystal

Tag

(3) Remove the insulator sleeve.

Insulator
Sleeve

EPT026795 Issue 17 June 2020 12-11

i-PULSE PRINT HEAD REPAIR

(4) Put the nozzle into a clean beaker filled with the correct wash solution that is compatible
with the printer’s ink type.

Wash
Solution

(5) Stand the beaker in an ultrasonic bath filled with water.

Water Water

Ultrasonic Bath
10 Minutes

(6) Switch on the ultrasonic bath and clean the nozzle for 10 minutes.
(7) Remove the nozzle from the ultrasonic bath.
(8) Replace the insulator sleeve.

Insulator
Sleeve

12-12 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

(9) Replace the first piezo crystal.

Note: The piezo crystals have a copper coloured side and a silver coloured side. The copper
coloured side of the first piezo crystal must face up.

Copper
Side
Silver Side
Piezo
Crystal
Copper Side

(10) Replace the tag.

Tag

(11) Replace the second piezo crystal.

Note: The copper coloured side of the second piezo crystal must face down.

Copper Sides
Together

(12) Replace the O-ring.

O-ring

End of procedure.

EPT026795 Issue 17 June 2020 12-13

i-PULSE PRINT HEAD REPAIR

Replace Nozzle Assembly

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Risk of ink spray if Wake-up mode is enabled.

CAUTION: Risk of damage to nozzle assembly.

Touching the nozzle with bare fingers may contaminate the nozzle. Do not touch
the nozzle with bare fingers.

Required tools: T6 torx driver and 8mm spanner.

To replace the nozzle assembly:
(1) Carefully refit the nozzle assembly into the drop generator and use an 8mm spanner to
lightly tighten it.

Refitting Nozzle Assembly

(2) Refit the drop generator onto its mounting, ensuring that it is correctly fitted onto the
locating pins.

12-14 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

(3) At the rear of the print head, use a T6 Torx driver to tighten the two drop generator securing
screws.

Drop Generator Securing Screws

(4) Reconnect the power lead to the rear of the printer.

(5) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(6) If the new nozzle is a different size, update the settings on the Hardware screen, see
page 19-11.
(7) On the TouchScreen, select Home > Setup > Diagnostics > Tests.
(8) Run the Bleed head test.
(9) Check the ink jet alignment by following the procedure on page 12-17.
(10) Check the ink jet profile and tune the nozzle, see page 12-55.
End of procedure.

EPT026795 Issue 17 June 2020 12-15

i-PULSE PRINT HEAD REPAIR

PRINT HEAD REPAIR PROCEDURES

Nozzle Unblocking
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

Each time the unblocking wizard is run, the printer adds make-up to the ink. If the
unblocking wizard is run more than two times, the ink viscosity will thin and go out
of the printer’s operating range. Do not run the unblocking wizard more than two
times. If the nozzle is not clear after 2 attempts, the nozzle can be removed from
the print head, cleaned, replaced and retuned by following the procedures starting
on page 12-8.

To clear a blocked nozzle:

(1) On the TouchScreen, select Home > Setup > Wizards > Nozzle unblocking.
(2) Select Start nozzle unblocking.
(3) Follow the on screen instructions.
End of procedure.

12-16 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

Ink Jet Alignment Check

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Flammable material. Risk of fire.

Required tools: Magnifying eye glass.

Check the ink jet alignment as follows:
(1) Remove the holster from the print head by pressing in the two holster retaining clips and
withdrawing the holster.
(2) Fit the print head into a wash station, or place a beaker made of a conducting material and
connected to earth (ground) underneath the print head.
(3) With the ink jet running, check the position that the ink jet enters the gutter as shown in the
following diagrams.

Ink jet ⅓ from left side of the Ink jet in centre of

gutter wall. gutter.

Front View Side View

(4) If the alignment is incorrect, carry out the ink jet alignment procedure described on
page 12-18.
End of procedure.

EPT026795 Issue 17 June 2020 12-17

i-PULSE PRINT HEAD REPAIR

Ink Jet Alignment Procedure

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Flammable material. Risk of fire.

Required tools: T6 torx driver and 1.5mm hex key and magnifying eye glass.
To align the ink jet:
(1) Ensure the printer is switched on and in the Idle state.
(2) Remove the holster from the print head by pressing in the two holster retaining clips and
withdrawing the holster.
(3) Place a beaker made of a conducting material and connected to earth (ground) underneath
the print head to catch stray ink drops.
(4) Use a T6 torx driver to remove the screw that secures the charge electrode and carefully
move the charge electrode out of the print head.

Charge Electrode Securing Screw

(5) On the TouchScreen, select Home > Setup > Diagnostics > Tests.
(6) Select Alignment.
(7) Tick the Valve Open tick box.
(8) Select Start.

12-18 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

(9) Loosen the locking screw.

Locking Screw

(10) Adjust the left/right alignment cam to set the ink jet ⅓ from the left side of the gutter wall when
looking at the front of the print head.
‘

Ink jet ⅓ from left side of the

gutter wall.

Left/Right Alignment Cam Front View

EPT026795 Issue 17 June 2020 12-19

i-PULSE PRINT HEAD REPAIR

(11) Adjust the forward/backward alignment cam to set the ink jet in the centre of the gutter when
looking at the side of the print head.
‘

Ink jet in centre of

gutter.
Forward/Backward Alignment Cam Side View

(12) Tighten the locking screw.

Locking Screw

12-20 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

(13) On the TouchScreen, select Done.

(14) Replace the charge electrode.
(15) Replace the print head holster.
End of procedure.

EPT026795 Issue 17 June 2020 12-21

i-PULSE PRINT HEAD REPAIR

Gutter Airflow Adjustment

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Notes: (1) Available on software version 30 and above.

(2) Increasing the gutter airflow will increase make-up consumption.
Airflow through the gutter is automatically controlled by the printer. The printer’s software adjusts
the gutter pump speed to reach a predicted gutter airflow target.
If the gutter is not clearing ink, gutter stall alerts are occurring or the gutter block is messy it may
be necessary to manually increase the gutter airflow.
Clean the gutter (page 12-6) and check the ink jet alignment (page 12-17) before adjusting the
gutter airflow.
To adjust the gutter airflow:
(1) Select Home > Setup > Advanced > Gutter.
(2) Increase the Airflow adjustment (ml/min) value in small increments until the issue is
resolved.

End of procedure.

12-22 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

Drop Generator Assembly Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

If the printer is started without the nozzle or drop generator, ink will spray out of the
print head and may injure persons standing close-by. Do not start the printer with
the nozzle or drop generator removed.

WARNING: Pressurised ink system. Risk of ink spray.

Required tools: T6 torx driver.

To replace the drop generator assembly:
(1) Put the printer into the Idle state.
(2) Insert the engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(3) Select Home > Setup > Advanced > Ink system manual mode.
(4) Remove pressure from the print head by selecting the Bleed valve closed tick box.
(5) Deselect the Bleed valve open tick box.
(6) Disconnect the engineer’s USB key.

WARNING: Risk of ink spray if Wake-up mode is enabled.

(7) Press and hold the standby button for 2 seconds and wait for the printer to shut down.
(8) Disconnect the power lead from the rear of the printer.
(9) Remove the holster from the print head by pressing in the two holster retaining clips and
withdrawing the holster.
(10) Remove the moulded cover over the internal pipework and wiring by gently squeezing the
sides of the cover inwards and withdrawing away from the print head.
(11) Remove the wire box cover by removing the 4 securing screws accessed from the back of
the print head.

EPT026795 Issue 17 June 2020 12-23

i-PULSE PRINT HEAD REPAIR

(12) Disconnect connector J3 on the print head PCB.

Print Head PCB

(13) Trace the wires back to the cable gland in the bulkhead seal. Carefully push the cable gland
out of the bulkhead seal in the direction of the drop generator assembly.
(14) At the rear of the print head, unscrew the two screws securing the drop generator assembly.

Drop Generator Securing Screws

Note: Before removing the pipes in the following step, ensure that enough pipe will remain
after trimming.
(15) Carefully cut along the length of the barbs on the drop generator to remove the pipes.

12-24 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

(16) Remove the drop generator assembly from the print head.

Remove Drop Generator Assembly

(17) Fit the new drop generator assembly into the print head (but do not secure with the fixing
screws).
(18) Pass the wires up through the bulkhead seal into the upper part of the print head.
(19) Carefully push the cable glands into the bulkhead seal.
(20) Reconnect the connector to J3 on the print head board.
Note: In the following step, ensure that the pipes cover both of the barbs.
(21) Using pipe cutters to ensure a clean square cut, trim the pipes removed in step (15) and
push over the barbs.
(22) Fit the drop generator assembly into position and secure the two fixing screws.
(23) Re-pack the wiring into the wire box.
(24) Ensure the wire box seal is located correctly and refit the wire box cover using the four
screws.
(25) Replace the moulded cover over the internal pipework and wiring and replace the holster.
(26) Reconnect the power lead at the rear of the printer.
(27) Press and hold the standby button for 2 seconds and wait for the printer to turn on.
(28) On the TouchScreen, select Home > Setup > Diagnostics > Tests.
(29) Run the Bleed head test.
(30) Check the ink jet alignment by following the procedure on page 12-17.
End of procedure.

EPT026795 Issue 17 June 2020 12-25

(9) On the TouchScreen, deselect the Valve open tick box.

EPT026795 Issue 17 June 2020 12-29

i-PULSE PRINT HEAD REPAIR

(10) Check that the top area of the left hand deflector plate is 4mm away from and parallel to the
right hand deflector plate.

(11) If the left hand deflector plate is not set correctly, loosen the 2 securing screws on the rear
of the print head, adjust the deflector plate position and re-tighten the screws.
Note: A 4mm hex key can be used as a setting guide between the deflector plates.

(12) On the TouchScreen, select Done.

End of procedure.

12-30 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

60 μm and 75 μm Nozzles (With Setting Tool)

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Note: The ink jet must be correctly aligned in the gutter before the deflector plate alignment
can be accurately checked and set. See “Ink Jet Alignment Check” on page 12-17.
This procedure describes how to set the deflector plates on an i-Pulse print head equipped with a
60 μm or 75 μm nozzle using the deflector plate setting tool. If you do not have a deflector plate
setting tool, or you’re setting the deflector plates on a print head equipped with a 40 μm or 50 μm
nozzle, see page 12-28.
Required tools: T6 torx driver and deflector plate setting tool (P/N EPT054062).
To set the deflector plate alignment:
(1) Put the printer into the Idle state.
(2) Remove the holster from the print head by pressing in the two holster retaining clips and
withdrawing the holster.
(3) Remove the moulded cover over the internal pipework and wiring by gently squeezing the
sides of the cover inwards and withdrawing away from the print head.
(4) Loosen the charge electrode fixing screw and lift the charge electrode off the mounting
pillar, clear of the print head.

Charge Electrode Removal

EPT026795 Issue 17 June 2020 12-31

i-PULSE PRINT HEAD REPAIR

(5) Loosen the 4 deflector plate securing screws on the rear of the print head.

(6) Insert the deflector plate alignment tool between the deflector plates.

12-32 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

(7) Push the deflector plates against the alignment tool and tighten the screws on the rear of
the print head.

(8) Remove the deflector plate alignment tool.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Flammable material. Risk of fire.

The charge electrode must be adjusted so that the ink jet is in the centre of the charge electrode
slot and runs parallel with the slot. Adjustment should only be necessary when a charge electrode
or the charge electrode mounting is replaced. To correct a slight misalignment of the ink jet in the
charge electrode slot start the procedure from step (12).
Required tools: T6 and T10 torx driver.
To align the charge electrode:
(1) Put the printer into the Idle state.
(2) Remove the holster from the print head by pressing in the two holster retaining clips and
withdrawing the holster.
(3) Place a beaker made of a conducting material and connected to earth (ground) underneath
the print head to catch stray ink drops.
(4) Remove the moulded cover over the internal pipework and wiring by gently squeezing the
sides of the cover inwards and withdrawing away from the print head.
(5) Loosen the charge electrode fixing screw and lift the charge electrode off the mounting
pillar, clear of the jet position.

Charge Electrode Securing Screw

(6) On the TouchScreen, select Home > Setup > Diagnostics > Tests > Alignment > Start.

EPT026795 Issue 17 June 2020 12-37

i-PULSE PRINT HEAD REPAIR

(7) Select the Valve open tick box to toggle the ink jet on.
(8) Carefully slide the charge electrode onto its mounting pillars, and watch the ink jet and its
position in the charge electrode slot. If the ink jet collides with the charge electrode, pull the
charge electrode off of the mounting pillars and adjust the position of the mounting bracket
as described in the next step.
(9) At the rear of the print head, loosen the screws which secure the charge electrode mount.

Charge Electrode Securing Screws

(10) Move the charge electrode to a position where it is possible to slide the charge electrode
onto the mounting pillars without making contact with the ink jet.
(11) Tighten the charge electrode securing screws on the rear of the print head.
(12) Inspect the position of the ink jet in the charge electrode slot.
(13) With the charge electrode mount screws sufficiently loose to allow movement of the charge
electrode, adjust the charge electrode until the ink jet is in the correct position in the charge
electrode slot.
(14) Tighten the charge electrode mount securing screws on the rear of the print head.
(15) The adjustment is now complete, select Done and wait for the jet alignment sequence to
stop.
(16) Follow the procedure described on page 12-4 to clean the print head.
(17) Replace the print head holster.
End of procedure.

12-38 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

Holster Retaining Clip Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Required tools: Small pozi drive screwdriver.

To replace the holster securing clips:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) If not already removed, remove the holster from the print head by pressing in the two holster
retaining clips and withdrawing the holster.
(4) Remove the wire box dovetail moulding by undoing the four inner securing screws that
attach it to the print head chassis.
(5) Lift the broken retaining clip off its securing post and replace it.
(6) Replace the rear moulding and replace the four securing screws.

CAUTION: Risk of print head damage.

Do not over tighten the securing screws.

(7) Replace the print head holster.

End of procedure.

EPT026795 Issue 17 June 2020 12-39

i-PULSE PRINT HEAD REPAIR

Print Head and Conduit Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: High voltage electricity. Risk of death or injury from electric shock.

The printer electronics compartment contains high voltage components. Shut

down the printer and disconnect the power cable before accessing the electronics
compartment.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

EPT026795 Issue 17 June 2020 12-45

i-PULSE PRINT HEAD REPAIR

Flush Line Pipe Loop

Note: Further information can be found in Ax-Series Technical Briefing Note No. 014.
Single jet i-Pulse print heads manufactured on or after October 2nd 2018 have a loop on the flush
line inside the print head. The loop is designed to correct print quality and reliability problems
when printing upwards at an angle greater than 45°.
As illustrated below, print heads that are angled in the green area are unaffected. However, print
heads angled in the amber area may require a loop on the flush line. The loop is available as a
spare that can be fitted to older Ax-Series i-Pulse print heads.

Installation Procedure
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Notes: (1) To install the loop, 12cm of flush line must be pulled through the conduit into the print
head. If this is not possible, a replacement conduit or print head and conduit assembly
will be required.
(2) Update the printer to standard Ax-Series software If beta software has been used as a
temporary solution. Beta software versions include V28 r41 and V29 r90.
Required tools: Pipe Cutters and Sandpaper.
To install the flush line pipe loop:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the holster from the print head by pressing in the two holster retaining clips and
withdraw the holster.

12-46 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

(4) Carefully disconnect the flush tube (green stripe) from the drop generator.
Note: Sandpaper can be used to help grip the flush pipe.

(5) Cut and remove a small piece of the flush tube to ensure a tight fit when the tube is
reconnected.

EPT026795 Issue 17 June 2020 12-47

i-PULSE PRINT HEAD REPAIR

(6) Pull at least 12cm of the flush tube out of the conduit.

m
12c

(7) Pass the flush tube through the pipe loop former as illustrated below.

12-48 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

(8) Pass the flush tube through the pipe loop former as illustrated below.

(9) Pass the flush tube through the pipe loop former as illustrated below.

EPT026795 Issue 17 June 2020 12-49

i-PULSE PRINT HEAD REPAIR

(10) Clip the pipe into the loop former.

(11) Carefully reconnect the flush pipe to the drop generator.

Note: Sandpaper can be used to help grip the flush pipe.

12-50 EPT026795 Issue 17 June 2020

Loosen Nozzle Assembly

12-62 EPT026795 Issue 17 June 2020

i-PULSE PRINT HEAD REPAIR

(3) Continue to support the drop generator and carefully re-tighten the nozzle assembly.

Tighten Nozzle Assembly

(4) Repeat the “Ink Jet Profile Check” procedure to check if the adjustment has corrected the
ink jet profile.
(5) Check the ink jet alignment to ensure that the alignment has not changed.
End of procedure.

EPT026795 Issue 17 June 2020 12-63

i-PULSE PRINT HEAD REPAIR

Required tools: T10 torx driver.

To clean the print head:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Unscrew the thumb screw on the rear of the print head and slide the print head cover off.
(4) Follow the annotated instructions in the following illustration.

Loosen screw and remove the Loosen screw and remove the
Charge Electrode. Clean in the Charge Electrode. Clean in the
slot with relevant wash, dry using slot with relevant wash, dry using
lint free tissue. lint free tissue.

Clean any ink residue from

deflector plates

Clean any ink residue from gutter

area

i-Pulse Duo Print Head Cleaning

(5) Replace the print head cover and tighten the thumb screw.
End of procedure.

13-4 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

Gutter Cleaning
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

To clean the gutter:

(1) Ensure the printer is on and in the Idle state.
(2) Unscrew the thumb screw on the rear of the print head and slide the print head cover off.
(3) On the TouchScreen, select Home > Setup > Advanced > Gutter.
(4) Tick the Gutter pump at maximum speed tick box.
(5) Select the icon on the Information Bar.
(6) Swipe the screen from right to left twice to navigate to the Live status screen.
(7) Observe the Vacuum pressure (mBar) value.

Vacuum Pressure (mBar) Value

EPT026795 Issue 17 June 2020 13-5

i-PULSE DUO PRINT HEAD REPAIR

(8) If the Gutter pump speed (rpm) value is greater than -180rpm it is likely that both gutter
pipes are partially blocked with dried ink. To check each individual gutter pipe, put on a
latex or nitrile glove, use a gloved finger to block each gutter pipe in turn to see if the Gutter
pump speed (rpm) value changes.
(9) If one or both gutter pipes are blocked with dried ink, squirt a small amount of solvent into
the blocked gutter pipe and wait for the Gutter pump speed (rpm) value to stabilise.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

If a large amount of solvent enters the gutter, the ink viscosity will thin and go out
of the printer’s operating range.

Gutter Pipe Location

(10) If the Gutter pump speed (rpm) value is now lower than -180rpm continue to the next step. If
the Gutter pump speed (rpm) value is still greater than -180rpm, squirt a small amount of
solvent into the blocked gutter pipe and wait for the Gutter pump speed (rpm) value to
stabilise.
(11) Select the icon at the bottom of the screen.
(12) Select Home > Setup > Advanced > Gutter.
(13) Untick the Gutter pump at maximum speed tick box.
(14) Replace the print head cover and tighten the thumb screw.
End of procedure.

13-6 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

Nozzle Removal and Cleaning

Remove Nozzle Assembly
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Risk of ink spray if Wake-up mode is enabled.

WARNING: Pressurised ink system. Risk of ink spray.

If the printer is started without the nozzle, ink will spray out of the print head and
may injure persons standing close-by. Do not start the printer with the nozzle
removed.

WARNING: Pressurised ink system. Risk of ink spray.

CAUTION: Risk of damage to piezo crystals.

Remove the O-ring before removing the piezo crystals. Failure remove the O-ring
first will damage the piezo crystals.

O-ring

(2) Gently remove the two piezo crystals and the tag from the nozzle assembly.

Crystals
Crystal

Tag

(3) Remove the insulator sleeve.

Insulator
Sleeve

13-10 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

(4) Put the nozzle into a clean beaker filled with the correct wash solution that is compatible
with the printer’s ink type.

Wash
Solution

(5) Stand the beaker in an ultrasonic bath filled with water.

Water Water

Ultrasonic Bath
10 Minutes

(6) Switch on the ultrasonic bath and clean the nozzle for 10 minutes.
(7) Remove the nozzle from the ultrasonic bath.
(8) Replace the insulator sleeve.

Insulator
Sleeve

EPT026795 Issue 17 June 2020 13-11

i-PULSE DUO PRINT HEAD REPAIR

(9) Replace the first piezo crystal.

Note: The piezo crystals have a copper coloured side and a silver coloured side. The copper
coloured side of the first piezo crystal must face up.

Copper
Side
Silver Side
Piezo
Crystal
Copper Side

(10) Replace the tag.

Tag

(11) Replace the second piezo crystal.

Note: The copper coloured side of the second piezo crystal must face down.

Copper Sides
Together

(12) Replace the O-ring.

O-ring

End of procedure.

13-12 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

Replace Nozzle Assembly

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Risk of ink spray if Wake-up mode is enabled.

CAUTION: Risk of damage to nozzle assembly.

Touching the nozzle with bare fingers may contaminate the nozzle. Do not touch
the nozzle with bare fingers.

Required tools: T6 torx driver and 8mm spanner.

To replace the nozzle assembly:
(1) Carefully refit the nozzle assembly into the drop generator and use an 8mm spanner to
lightly tighten it.
Note: Image shows single jet i-Pulse print head.

Refitting Nozzle Assembly

(2) Refit the drop generator onto its mounting.
Notes: (1) Ensure the temperature sensor film is correctly replaced on the rear of the drop
generator.
(2) Ensure the drop generator is correctly fitted onto the locating pins.

EPT026795 Issue 17 June 2020 13-13

i-PULSE DUO PRINT HEAD REPAIR

(3) At the rear of the print head, use a T6 Torx driver to tighten the drop generator securing
screws.
Note: Ensure the ground wire is correctly re-attached to the drop generator securing screw.

Drop Generator Securing Screws

(4) If the new nozzles are a different size, update the settings on the Hardware screen, see
page 19-11.
(5) On the TouchScreen, select Home > Setup > Diagnostics > Tests.
(6) Run the Bleed head test.
(7) Check the ink jet alignment by following the procedure on page 13-16.
(8) Check the ink jet profile and tune the nozzle, see page 13-37.
End of procedure.

13-14 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

PRINT HEAD REPAIR PROCEDURES

Nozzle Unblocking
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

To clear a blocked nozzle:

(1) On the TouchScreen, select Home > Setup > Wizards > Nozzle unblocking.
(2) Select Start nozzle unblocking.
(3) Follow the on screen instructions.
End of procedure.

EPT026795 Issue 17 June 2020 13-15

i-PULSE DUO PRINT HEAD REPAIR

Ink Jet Alignment Check

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Flammable material. Risk of fire.

Required tools: Magnifying eye glass.

Check the ink jet alignment as follows:
(1) Loosen the thumb screw on the rear of the print head and slide the cover off.
(2) Fit the print head into a wash station, or place a beaker made of a conducting material and
connected to earth (ground) underneath the print head.
(3) With both ink jets running, check the position that each ink jet enters the gutter as shown in
the following diagrams.

Ink jets ¼ from the left side of Ink jets in the centre of the gutter.
the gutter wall.

Front View Side View

(4) If the alignment is incorrect, re-align the ink jet by following the procedure on page 13-17.
End of procedure.

13-16 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

Ink Jet Alignment Procedure

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Flammable material. Risk of fire.

CAUTION: Wire pinch point. Risk of print head damage.

Ensure the wires on the left side of the print head do not become pinched and
damaged when adjusting the left charge electrode.

Required tools: T6 torx driver and 1.5mm hex key and magnifying eye glass.
To align the ink jet:
(1) Ensure the printer is switched on and in the Idle state.
(2) Loosen the thumb screw on the rear of the print head and slide the cover off.
(3) Place a beaker made of a conducting material and connected to earth (ground) underneath
the print head to catch stray ink drops.
(4) Use a T6 torx driver to remove the screws that secure the charge electrodes and carefully
move the charge electrodes out of the print head.

Gutter Pipe Location

EPT026795 Issue 17 June 2020 13-17

i-PULSE DUO PRINT HEAD REPAIR

(5) On the TouchScreen, select Home > Setup > Diagnostics > Tests.
(6) Select Alignment.
(7) Tick the Valve Open tick box.
(8) Select Start.
(9) Loosen the locking screws on the rear of the print head.

Locking Screws

(10) Adjust the forwards/backwards adjustment screws so that the ink jets are aligned with the
centre of the gutter when viewed from the side.

Ink jets in the centre of the gutter.

Forward/backwards Adjustment Side View

Screw Locations

13-18 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

(11) Adjust the left/rights adjustment screws so that both ink jets are aligned 1/3rd from the left
side of the gutter wall when viewed from the front.

Ink jets ¼ from the left side of

the gutter wall.

Front View

Left/Right Adjustment Screw

Locations

EPT026795 Issue 17 June 2020 13-19

i-PULSE DUO PRINT HEAD REPAIR

(12) After the jet has been aligned, tighten the locking screws.

Locking Screws

(13) On the TouchScreen, select Done.

(14) Replace the charge electrodes.
(15) Replace the print head cover and tighten the thumb screw.
End of procedure.

13-20 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

Gutter Airflow Adjustment

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Notes: (1) Available on software version 31 and above.

(2) Increasing the gutter airflow will increase make-up consumption.
Airflow through the gutter is automatically controlled by the printer. The printer’s software adjusts
the gutter pump speed to reach a predicted gutter airflow target.
If the gutter is not clearing ink, gutter stall alerts are occurring or the gutter block is messy it may
be necessary to manually increase the gutter airflow.
Clean the gutter (page 13-5) and check the ink jet alignment (page 13-16) before adjusting the
gutter airflow.
To adjust the gutter airflow:
(1) Select Home > Setup > Advanced > Gutter.
(2) Increase the Airflow adjustment (ml/min) value in small increments until the issue is
resolved.

End of procedure.

EPT026795 Issue 17 June 2020 13-21

i-PULSE DUO PRINT HEAD REPAIR

Print Head Solenoid Screw Adjustment

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Follow this procedure only if you are certain that the solenoid screw requires adjustment. The
solenoid screw is normally set in the factory using a camera rig system. Adjustment in the field will
not be as accurate as the original setup.
Problems obtaining a good print window (with both pressure and modulation) can occur If the
print head solenoid screws are improperly set. Follow the procedure below to re-set the print head
solenoid screws.
Required tools: T6 torx driver and small flat head screw driver.
To adjust the print head solenoid screws:
(1) Ensure the printer is on and in the Idle state.
(2) Unscrew the thumb screw on the rear of the print head and slide the print head cover off.
(3) At the rear of the print head, unscrew the screws that secure the drop generators.

Drop Generator Securing Screws

13-22 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

(4) Gently pull the drop generator away from the chassis to enable access to the solenoid
adjustment screw. Avoid pulling on the wiring.
(5) Place an earthed beaker underneath the nozzle assembly to catch the ink drops from the
nozzle.
(6) Select Home > Setup > Diagnostics > Tests > Alignment > Start.
(7) Select the Valve open tick box to toggle the ink jet on.
(8) Turn the nozzle solenoid adjustment screw clockwise until the ink jet stops. Then, turn the
adjustment screw anticlockwise by 2 full turns.
Note: Do not fully tighten the nozzle solenoid adjustment screw.

Nozzle Solenoid Adjustment Screw

(9) Select Done and wait for the jet alignment sequence to stop.
(10) Refit the drop generator onto its mounting.
Notes: (1) Ensure the temperature sensor film is correctly replaced on the rear of the drop
generator.
(2) Ensure the drop generator is correctly fitted onto the locating pins.

EPT026795 Issue 17 June 2020 13-23

i-PULSE DUO PRINT HEAD REPAIR

(11) At the rear of the print head, use a T6 Torx driver to tighten the drop generator securing
screws.
Note: Ensure the ground wire is correctly re-attached to the drop generator securing screw.

Drop Generator Securing Screws

(12) Replace the print head cover and tighten the thumb screw.
(13) Dispose of waste ink by following local waste disposal regulations.
(14) Check the ink jet alignment by following the procedure on page 13-16.
End of procedure.

13-24 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

Deflector Plate Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Electricity. Risk of injury

Required tools: T6 torx driver, T10 torx driver, wire cutters and heat gun.
To replace the deflector plates:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Unscrew the thumb screw on the rear of the print head and slide the print head cover off.
(4) Remove the wire box cover by removing the 6 securing screws.

Wire Box Cover Removal

EPT026795 Issue 17 June 2020 13-25

i-PULSE DUO PRINT HEAD REPAIR

(5) Disconnect the cables from the PCB, remove the PCB mounting screws and remove the
PCB.

PCB Removal

(6) Trace the wires from the deflector plates to their connections in the upper part of the head.
(7) Cut the heatshrink sleeving around the connections and disconnect the deflector plate
wires.
(8) Trace the wires to their cable gland in the bulkhead seal. Carefully push the cable gland out
of the bulkhead seal in the direction of the deflector plates.
(9) Remove the screws securing the deflector plates to the chassis and remove the plates from
the print head.

Deflector Plate Securing Screws

13-26 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

(14) Use a heat gun to tighten the heatshrink sleeving around the connectors.
(15) Replace the PCB in the print head.

PCB Replacement

(16) Reconnect the wiring to the PCB.

Wiring Connection

EPT026795 Issue 17 June 2020 13-27

i-PULSE DUO PRINT HEAD REPAIR

(17) Ensure seal is located correctly and refit the cover over the upper part of the head.

Wire Box Cover Removal

(18) Check the deflector plate alignment and adjust if necessary. See “Deflector Plate
Alignment” on page 13-29.
End of procedure.

13-28 EPT026795 Issue 17 June 2020

EPT026795 Issue 17 June 2020 13-31

i-PULSE DUO PRINT HEAD REPAIR

Print Head PCBA Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

To remove and replace print head PCBA:

(1) Press and hold the standby button for 2 seconds and wait for the printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the screws on the print head electronics cover and remove the cover.

(4) Disconnect all the electrical connectors from the print head PCBA, remove the two
highlighted screws and remove the print head PCBA.

13-32 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

(5) Insert the new print head PCBA in the print head, install the two screws and re-connect all
the electrical connectors.

(6) Replace the print head electronics cover.

(7) Reconnect the power lead at the rear of the printer.

(8) Turn the printer on by pressing and holding the standby button for 2 seconds.
End of procedure.

EPT026795 Issue 17 June 2020 13-33

i-PULSE DUO PRINT HEAD REPAIR

EHT DEFLECTOR PLATE/HV TEST

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Several different factors can cause EHT faults. Before doing this test:
• Check that the print head is clean and dry, refer to page 13-4.
• Check that the ink jet is correctly aligned in the gutter, refer to page 13-16.
• Lastly, check that the EHT plates are correctly aligned, refer to page 13-29.
If the fault still cannot be identified after doing these checks and doing the test described below,
there could be a problem with the ink, ink viscosity or jet profile.
Required tools: Digital Volt Meter (DVM), EHT high voltage probe.
To do an EHT deflector plate/HV test on an i-Pulse duo print head:
(1) Make sure the printer is in the Idle state.
(2) Unscrew the thumb screw on the rear of the print head and slide the print head cover off.
(3) Connect the ground lead from the DVM to a suitable ground point such as a metal part of
the print head chassis (not an EHT plate).
(4) Connect the EHT high voltage probe from the DVM to one of the print head’s EHT plates.
Notes: (1) Make sure the probe is connected to the EHT plate before enabling the HV test. If the
probe is connected after the HV test is enabled, an EHT trip will occur.
(2) The image below illustrates which plate is negative and which is positive.

Positive
Positive
Negative

13-34 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

(5) Set the DVM to measure Voltage DC.

(6) On the TouchScreen, select Home > Setup > Diagnostics > Tests.
(7) Run the HV test.
(8) Tick the HV enabled tick box.
(9) Do the tests listed in the table below to check if there is a fault:

Test Possible Fault

EPT026795 Issue 17 June 2020 13-35

i-PULSE DUO PRINT HEAD REPAIR

Test Possible Fault

Watch the voltage value on the DVM and move/ If the voltage changes, one of the
manipulate the print head, conduit and wiring. faults listed below may be
responsible:
• Loose wiring connection in the
print head/conduit
• Faulty EHT plate
• Faulty print head PCB.
Leave the test enabled for a period of time such as 10 If an EHT trip occurs, one of the
minutes and check if an EHT trip occurs. faults listed below may be
responsible:
• Wiring fault or loose connection
in the print head/conduit
• Faulty EHT plate.
Short the EHT plate to earth and check if the DVM value If the voltage does not drop to 0 V,
goes to 0 V. there maybe a fault in the EHT trip
circuit.
Short the EHT plates together and check if the DVM If the voltage does not drop to 0 V,
value goes to 0 V. there maybe a fault in the EHT trip
circuit.

(4) Repeat these tests on the second EHT plate.

i-PULSE DUO PRINT HEAD REPAIR

13-42 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

Unusual Ink Jet Profiles 2

EPT026795 Issue 17 June 2020 13-43

i-PULSE DUO PRINT HEAD REPAIR

Nozzle Tuning Procedure

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Loosen Nozzle Assembly

13-44 EPT026795 Issue 17 June 2020

i-PULSE DUO PRINT HEAD REPAIR

(3) Continue to support the drop generator and carefully re-tighten the nozzle assembly.
Note: The image below illustrates a single jet i-Pulse print head.

Tighten Nozzle Assembly

EPT026795 Issue 17 June 2020 13-45

i-PULSE DUO PRINT HEAD REPAIR

Note: The i-Pulse RS print head contains a sensor that detects when the print head cover is
removed. When the cover is removed power to the EHT plates will stop and printing
will not be possible. Ensure the print head cover is present to enable printing.
The i-Pulse RS print head requires regular cleaning when using heavily pigmented ink. Check the
print head before every shift and clean as necessary.
To clean the i-Pulse RS print head:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Twist and remove the print head cover.

Remove Print Head Cover Removal

14-4 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

(3) Follow the annotated instructions on the following page. If required, place an earthed
beaker underneath the print head to catch any waste fluid.

Clean in the slots with relevant

wash, dry using lint free tissue.
When cleaned, use a
magnifying glass to ensure
both slots are lint free.

Clean any ink residue

from deflector plates

Clean any ink residue from

gutter area

i-Pulse RS Print Head Cleaning

(4) Dispose of waste solvent by following local waste disposal regulations.

(5) If the gutter pipe is blocked, follow the gutter cleaning procedure described on page 14-6.
End of procedure.

EPT026795 Issue 17 June 2020 14-5

i-PULSE RS PRINT HEAD REPAIR

Gutter Cleaning
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Remove Print Head Cover

(3) On the TouchScreen, select Home > Setup > Advanced > Gutter.
(4) Tick the Gutter pump at maximum speed tick box.
(5) Select the icon on the Information Bar.
(6) Swipe the screen from right to left twice to navigate to the Live status screen.

14-6 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

(7) Observe the Vacuum pressure (mBar) value.

Vacuum Pressure (mBar) Value

(8) If the Gutter pump speed (rpm) value is greater than -180rpm it is likely that the gutter pipe
is partially blocked with dried ink. Squirt a small amount of solvent into the gutter pipe and
wait for the Gutter pump speed (rpm) value to stabilise.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

If a large amount of solvent enters the gutter, the ink viscosity will thin and go out
of the printer’s operating range.

Gutter Pipe Location

EPT026795 Issue 17 June 2020 14-7

i-PULSE RS PRINT HEAD REPAIR

(9) If the Gutter pump speed (rpm) value is now lower than -180rpm continue to the next step. If
the Gutter pump speed (rpm) value is still greater than -180rpm repeat step (8).
(10) Select the icon at the bottom of the screen.
(11) Select Home > Setup > Advanced > Gutter.
(12) Untick the Gutter pump at maximum speed tick box.
(13) Replace the print head cover.
End of procedure.

14-8 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

Nozzle Removal and Cleaning

Remove Nozzle Assembly
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Risk of ink spray if Wake-up mode is enabled.

WARNING: Pressurised ink system. Risk of ink spray.

If the printer is started without the nozzle, ink will spray out of the print head and
may injure persons standing close-by. Do not start the printer with the nozzle
removed.

WARNING: Pressurised ink system. Risk of ink spray.

CAUTION: Risk of damage to nozzle assembly and ink system.

Removing the nozzle assembly could cause contamination to enter the ink system.
Remove the nozzle assembly only as a last resort. Follow the print head cleaning
procedure on page 14-4 and the nozzle unblocking procedure on page 14-20
before attempting this procedure.

CAUTION: Risk of damage to nozzle assembly.

Touching the nozzle with bare fingers may contaminate the nozzle. Do not touch
the nozzle with bare fingers.

Notes: (1) The i-Pulse RS print head contains a sensor that detects when the print head cover is
removed. When the cover is removed power to the EHT plates will stop and printing
will not be possible. Ensure the print head cover is present to enable printing.
(2) It is not possible to swap an i-Pulse RS nozzle to a different nozzle size. The chassis
design and geometry of the print head is different between nozzle sizes.
Required tools: T6 torx driver, 8mm spanner, 1.5mm hex key and engineer’s USB key.
To remove the nozzle:
(1) Put the printer into the Idle state.

EPT026795 Issue 17 June 2020 14-9

i-PULSE RS PRINT HEAD REPAIR

(2) Insert the Engineer’ USB key into a USB port on the TouchScreen or printer cabinet.
(3) Select Home > Setup > Advanced > Ink system manual mode.
(4) Remove pressure from the print head by selecting the Bleed valve closed tick box.
(5) Deselect the Bleed valve open tick box.
(6) Disconnect the engineer’s USB key.

CAUTION: Risk of damage to nozzle assembly and ink system.

Risk of ink spray. If the printer’s Wake-up mode is enabled the printer’s pump will
run for 2-3 minutes every 20 minutes. This will cause ink to spray out of the print
head if the nozzle has been removed. Shut down and disconnect the printer from
the power supply before removing the nozzle.

(7) Press and hold the standby button for 2 seconds and wait for the printer to shut down.
(8) Disconnect the power lead from the rear of the printer.
(9) Twist and remove the print head cover.

Remove Print Head Cover

(10) Use a 1.5mm hex key to remove the drop generator cover.

Remove Drop Generator Cover

14-10 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

(11) Use a 1.5mm hex key to remove the drop generator locking screw.

Remove Drop Generator Locking Screw

(12) Use a 1.5mm hex key to remove the drop generator mounting screws.

Remove Drop Generator Mounting Screws

EPT026795 Issue 17 June 2020 14-11

Clean the Nozzle

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of damage to nozzle assembly.

Touching the nozzle with bare fingers may contaminate the nozzle. Do not touch
the nozzle with bare fingers.

Clean the nozzle assembly as follows:

(1) Place the nozzle upside down into a small beaker filled with solvent.

Solvent

(2) Stand the beaker in an ultrasonic bath filled with water.

Water Water

Ultrasonic Bath

(3) Switch the ultrasonic bath on for 10 minutes.

(4) Dry the nozzle with a filtered air supply or lint free tissue.
(5) Replace the nozzle assembly as described on page 14-16.
End of procedure.

EPT026795 Issue 17 June 2020 14-15

i-PULSE RS PRINT HEAD REPAIR

Replace Nozzle Assembly

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Risk of ink spray if Wake-up mode is enabled.

CAUTION: Risk of damage to nozzle assembly.

Touching the nozzle with bare fingers may contaminate the nozzle. Do not touch
the nozzle with bare fingers.

Note: The i-Pulse RS print head contains a sensor that detects when the print head cover is
removed. When the cover is removed power to the EHT plates will stop and printing
will not be possible. Ensure the print head cover is present to enable printing.
Required tools: 8mm spanner, T6 torx driver, 1.5mm hex key, 2.5mm hex key and small screw
driver.
To replace the nozzle assembly:
(1) Replace the insulator sleeve.

Insulator
Sleeve

(2) Replace the first piezo crystal.

Note: The piezo crystals have a copper coloured side and a silver coloured side. The copper
coloured side of the first piezo crystal must face up.

Copper
Side
Silver Side
Piezo
Crystal
Copper Side

14-16 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

(3) Replace the tag.

Tag

(4) Replace the second piezo crystal.

Note: The copper coloured side of the second piezo crystal must face down.

Copper Sides
Together

(5) Replace the O-ring.

O-ring

(6) Carefully refit the nozzle assembly into the drop generator and use an 8mm spanner to
lightly tighten it.

Refit Nozzle

EPT026795 Issue 17 June 2020 14-17

i-PULSE RS PRINT HEAD REPAIR

(7) Replace the drop generator onto the print head base plate and tighten the drop generator
mounting screws.

Replace Drop Generator Mounting Screws

(8) Replace the drop generator lock screw.

Replace Drop Generator Locking Screw

14-18 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

(9) Replace the drop generator cover and tighten the screws.

Remove Drop Generator Cover

(10) Replace the print head cover.

Replace Print Head Cover

(11) On the TouchScreen, select Home > Setup > Diagnostics > Tests Bleed head.
(12) When the bleed head sequence is complete, select OK.
(13) Check the ink jet alignment by following the procedure on page 14-21.
(14) Check the ink jet profile and tune the nozzle, see page 14-52.
End of procedure.

EPT026795 Issue 17 June 2020 14-19

i-PULSE RS PRINT HEAD REPAIR

PRINT HEAD REPAIR PROCEDURES

Nozzle Unblocking
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

(5) Loosen the locking screw with a 1.5mm hex driver by turning it ¼ turn anti-clockwise.

Loosen Drop Generator Locking Screw

EPT026795 Issue 17 June 2020 14-23

i-PULSE RS PRINT HEAD REPAIR

(6) Loosen the drop generator mounting screws with a 1.5mm hex driver by turning them ¼
turn anti-clockwise.

Loosen Drop Generator Mounting Screws

(7) On the TouchScreen select, Home > Setup > Diagnostics > Tests > Alignment > Start.
(8) Select the Valve Open tick box to toggle the ink jet on.

14-24 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

(9) Adjust the forward/backward alignment screw to set the ink jet in the centre of the gutter
when looking at the side of the print head.

Ink jet in centre of

gutter.
Forward/Backward Alignment Screw Side View

EPT026795 Issue 17 June 2020 14-25

i-PULSE RS PRINT HEAD REPAIR

(10) Adjust the left/right alignment screw to set the ink jet close to the left wall of the gutter when
looking at the front of the print head.

Ink jet nearly touching left side

of the gutter wall.
Left/Right Alignment Screw Front View

clamping screw

“Straight” shim

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Required tools: T6 and T10 torx driver.

To install a shim in the i-Pulse RS ink jet:
(1) Press and hold the standby button for 2 seconds and wait for the printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Twist and remove the print head cover.

Remove Print Head Cover

EPT026795 Issue 17 June 2020 14-29

i-PULSE RS PRINT HEAD REPAIR

(4) Remove the drop generator cover.

Remove Drop Generator Cover

(5) Loosen the screws illustrated below.

Loosen Screws

14-30 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

(6) Decide which side to insert the shim and fully push the shim in between the metal plate and
plastic part.
Insert shim here...

...to move ink jet left.

...to move ink jet right.

Insert shim here...

Shim Fully Inserted in Gap

EPT026795 Issue 17 June 2020 14-31

i-PULSE RS PRINT HEAD REPAIR

(7) Tighten the screws illustrated below.

Tighten Screws

(8) Replace the drop generator cover.

Remove Drop Generator Cover

(9) Connect the power lead to the rear of the printer.

(10) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(11) Check the ink jet alignment again by following the procedure on page 14-21.
End of procedure.

14-32 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

Gutter Pump Airflow Adjustment

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Notes: (1) Available on software version 31 and above.

(2) Increasing the gutter airflow will increase make-up consumption.
Airflow through the gutter is automatically controlled by the printer. The printer’s software adjusts
the gutter pump speed to reach a predicted gutter airflow target.
If the gutter is not clearing ink, gutter stall alerts are occurring or the gutter block is messy it may
be necessary to manually increase the gutter [Link] the gutter (page 14-6) and check the
ink jet alignment (page 14-21) before adjusting the gutter pump airflow.
To adjust the gutter airflow:
(1) Select Home > Setup > Advanced > Gutter.
(2) Increase the Airflow adjustment (ml/min) value in small increments until the issue is
resolved.

End of procedure.

EPT026795 Issue 17 June 2020 14-33

i-PULSE RS PRINT HEAD REPAIR

Drop Generator Assembly Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Note: It is not possible to swap an i-Pulse RS drop generator to a different nozzle size. The
chassis design and geometry of the print head is different between nozzle sizes.
Required tools: T6 torx driver, 1.5mm hex key, 2.5mm hex key and small screw driver.
To remove and replace drop generator:
(1) Put the printer into the Idle state.
(2) Insert the engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(3) Select Home > Setup > Advanced > Ink system manual mode.
(4) Remove pressure from the print head by selecting the Bleed valve closed tick box.
(5) Deselect the Bleed valve open tick box.
(6) Disconnect the engineer’s USB key.

WARNING: Risk of ink spray if Wake-up mode is enabled.

(7) Press and hold the standby button for 2 seconds and wait for the printer to shut down.
(8) Disconnect the power lead from the rear of the printer.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Required tools: T6 torx driver, wire cutters and a cable tie.

(12) Turn the printer on by pressing and holding the standby button for 2 seconds.
End of procedure.

EPT026795 Issue 17 June 2020 14-43

i-PULSE RS PRINT HEAD REPAIR

Print Head Chassis Assembly Replacement (HV, CE & Gutter)

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Required tools: T6 torx driver, 2.5mm hex key, wire cutters and a cable tie.
To remove and replace the print head chassis with HV plates, charge electrode & gutter assembly:
(1) Press and hold the standby button for 2 seconds and wait for the printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Twist and remove the print head cover.

(4) Use a T6 torx driver to remove the screws on the print head electronics cover.

14-44 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

(5) Pull the print head electronics cover up and over the conduit.

(6) Cut the cable tie in the print head electronics area.

(7) Remove the 2 screws illustrated below.

EPT026795 Issue 17 June 2020 14-45

i-PULSE RS PRINT HEAD REPAIR

(8) Lift the chassis assembly up off the locating pins, then carefully pull the chassis assembly
away from the print head.

(9) Trace the wires and gutter pipe from the chassis assembly to their terminals in the main print
head and disconnect them.

(10) Feed the gutter pipe and wires from the new print head chassis back into the main print
head.

14-46 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

(11) Replace the print head chassis on the locating pins and replace the 2 screws illustrated
below.

(12) Reconnect the wires and gutter pipe.

Note: The image below highlights which connector each cable connects to on the print head
PCBA.
CHARGE
(BLUE COAX)
PHASE
(WHITE COAX)
CHARGE
(8 Pin)
AGND
(22 Pin)

TOF
(RED COAX)

STROBE
(6 Pin)

(13) Pack the wires into the print head electronics area and secure them with a new cable tie.

EPT026795 Issue 17 June 2020 14-47

i-PULSE RS PRINT HEAD REPAIR

(14) Replace the print head electronics cover.

(15) Replace the screws securing the print head electronics cover.

(16) Reconnect the power lead at the rear of the printer.

(17) Turn the printer on by pressing and holding the standby button for 2 seconds.
(18) Check the ink jet alignment and adjust if necessary. See “Ink Jet Alignment Check” on
page 14-21.
End of procedure.

14-48 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

EHT DEFLECTOR PLATE/HV TEST

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Several different factors can cause EHT faults. Before doing this test:
• Check that the print head is clean and dry, refer to page 14-4.
• Check that the ink jet is correctly aligned in the gutter, refer to page 14-21.
If the fault still cannot be identified after doing these checks and doing the test described below,
there could be a problem with the ink, ink viscosity or jet profile.
Required tools: Digital Volt Meter (DVM), EHT high voltage probe and a small magnet.
To do an EHT deflector plate/HV test on an i-Pulse RS print head:
(1) Make sure the printer is in the Idle state.
(2) Remove the print head cover/holster.
(3) Put a magnet on the back of the print head, to prevent the alert “1370 - Print head cover
removed”.
Note: Electrical tape or an improvised clip can be used to secure the magnet.

i-PULSE RS PRINT HEAD REPAIR

EPT026795 Issue 17 June 2020 14-57

i-PULSE RS PRINT HEAD REPAIR

Unusual Ink Jet Profiles 2

14-58 EPT026795 Issue 17 June 2020

i-PULSE RS PRINT HEAD REPAIR

Nozzle Tuning Procedure

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Loosen Nozzle Assembly

EPT026795 Issue 17 June 2020 14-59

i-PULSE RS PRINT HEAD REPAIR

(3) Continue to support the drop generator and carefully re-tighten the nozzle assembly.
Note: The image below illustrates a single jet i-Pulse print head.

Tighten Nozzle Assembly

14-60 EPT026795 Issue 17 June 2020

PART 15 : ELECTRONICS SYSTEM REPAIR

CONTENTS
Page
ELECTRONICS SYSTEM ACCESS ........................................................................................ 15-3
Ax150i Rear Ink and Electronics Compartment ................................................................ 15-3
Ax350i/Ax550i Rear Electronics Compartment ................................................................. 15-4
VANITY SHIELD REMOVAL ................................................................................................... 15-5
ELECTRONICS SYSTEM REPAIR ......................................................................................... 15-6
High Voltage Power Supply Replacement ........................................................................ 15-6
Low Voltage Power Supply Replacement ......................................................................... 15-9
Main Fan Replacement (Ax150i) ....................................................................................... 15-12
Main Fan Replacement (Ax350i/Ax550i) ........................................................................... 15-13
Electronics Compartment Fan Replacement .................................................................... 15-14
Product Detect / Shaft Encoder PCB Replacement ......................................................... 15-16
Product Detect / Shaft Encoder PNP, NPN and DIFF Selection ................................... 15-19
User Interface PCB Replacement ..................................................................................... 15-21
Main PCB Replacement .................................................................................................... 15-23
Main PCB Battery Replacement ....................................................................................... 15-29
Main PCB Jumper Link Connectors (Ax350i/Ax550i) ........................................................ 15-32
Jumper Link Connector Overview ................................................................................. 15-33
Jumper Link Connector for 40μ Nozzle, 3 Meter Conduit (EPT021966SP)................... 15-34
Jumper Link Connector for 40μ Nozzle, 4 Meter Conduit (EPT021967SP)................... 15-35
Jumper Link Connector for 50μ Nozzle, 3 Meter Conduit (EPT036400SP)................... 15-36
Jumper Link Connector for 50μ Nozzle, 4 Meter Conduit (EPT036401SP)................... 15-37
Jumper Link Connector for 60μ Nozzle, 3 Meter Conduit (EPT021964SP)................... 15-38
Jumper Link Connector for 60μ Nozzle, 6 Meter Conduit (EPT021965SP)................... 15-39
Jumper Link Connector for 75μ Nozzle, 3 Meter Conduit (EPT021970SP)................... 15-40
Jumper Link Connector for 75μ Nozzle, 6 Meter Conduit (EPT021971SP)................... 15-41
Smart Card (SIM Card) Replacement ................................................................................ 15-42
Micro SD Card Replacement ............................................................................................ 15-43
Micro SD Card Formatting ................................................................................................ 15-46
Test Procedure ............................................................................................................. 15-46
Formatting Procedure.................................................................................................... 15-47
Solenoid Valve Harness Replacement .............................................................................. 15-51
QMM (Quality Management Module) Replacement .......................................................... 15-54
LSM (Level Sense Module) Replacement ......................................................................... 15-55
Calibrate the Ink and Make-up Level Sensor .................................................................... 15-59

EPT026795 Issue 17 June 2020 15-1

ELECTRONICS SYSTEM REPAIR

THIS PAGE INTENTIONALLY LEFT BLANK

High Voltage Power Supply Replacement
WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver and 7mm nut spinner.

To replace the high voltage power supply:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access panel to the rear electronics compartment.
(4) Disconnect the J2801 and J2802 connectors from the main PCB.

PSU to Main PCB Connectors

15-6 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before following the step
below.

(5) Disconnect the red and black wires from the high voltage power supply.

Disconnect Red and Black Wires

(6) Loosen the two nuts securing the high voltage power supply to the printer chassis with a
7mm nut spinner.

Loosen PSU Securing Nuts

EPT026795 Issue 17 June 2020 15-7

ELECTRONICS SYSTEM REPAIR

(7) Lift the high voltage power supply upwards and remove it from the printer cabinet.
(8) Refit the high voltage power supply in the reverse order of removal.
(9) Replace the access panel for the rear electronics compartment.
(10) Reconnect the power lead to the rear of the printer.
(11) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(12) Select Home > Setup > Adjustment > Inspection > Add...
(13) Select the Replaced part drop down menu and select PSU.
(14) Select Operator name and enter your name.
(15) Select Notes and enter a note to explain that the high voltage PSU was replaced.
(16) Select Save.
End of procedure.

15-8 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

Low Voltage Power Supply Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver and 7mm nut spinner.

To replace the low voltage power supply:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access panel to the rear electronics compartment.
(4) Disconnect the J2701 connector from the main PCB.

PSU to Main PCB Connectors

EPT026795 Issue 17 June 2020 15-9

ELECTRONICS SYSTEM REPAIR

(5) Loosen the two nuts securing the low voltage power supply to the printer chassis with a
7mm nut spinner.

Loosen PSU Securing Nuts

(6) Lift the low voltage power supply upwards and remove it from the printer cabinet.

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before following the step
below.

(7) Disconnect the cables from the rear of the mains connector.

Disconnect Cables from Mains Connector

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver, cross head screw driver and 7mm nut spinner.
To replace the fan:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access panel to the rear ink compartment.
(4) Use the 7mm nut spinner to unscrew the nuts which secure the fan ducting to the printer
cabinet and remove the ducting.
(5) Disconnect the fan connector.
(6) Unscrew the two fixing screws securing the fan to the printer cabinet and remove the fan
from the printer cabinet.
(7) Fit a new fan in the reverse order of removal.
(8) Connect the power lead to the rear of the printer.
(9) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

EPT026795 Issue 17 June 2020 15-13

ELECTRONICS SYSTEM REPAIR

Electronics Compartment Fan Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver and cross head screw driver.
Replace the fan as follows:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access panel to the rear electronics compartment.
(4) Locate the fan in the printer cabinet.

Ax150i Ax350i/Ax550i

(5) Disconnect the fan connector.

(6) Unscrew the two fixing screws securing the fan to the printer cabinet and remove the fan
from the printer cabinet.
(7) Fit a new fan in the reverse order of removal.

15-14 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

(8) Connect the power lead to the rear of the printer.

(9) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

EPT026795 Issue 17 June 2020 15-15

ELECTRONICS SYSTEM REPAIR

Product Detect / Shaft Encoder PCB Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

CAUTION: Risk of damage to product detect sensor or shaft encoder.

The product detect sensor or shaft encoder can be damaged if the pins on the
product detect sensor or shaft encoder plug make contact with the wrong pins on
the PD/SE socket. Shut down the printer and disconnect the power lead from the
rear of the printer before connecting a product detect sensor or shaft encoder to
the PD/SE socket.

Required tools: T10 torx driver and Lumberg key tool.

To replace the product detect/shaft encoder PCB:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access panel to the rear electronics compartment.

15-16 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

(4) Disconnect the cable from socket J1503 on the main PCB.

Product Detect / Shaft Encoder PCB to Main PCB Connector

(5) Use a Lumberg Key Tool to remove the locking rings on the product detect and shaft
encoder connectors.

Ax150i Ax350i / Ax550i

(6) Remove the two torx screws that secure the PCB to the printer cabinet.
(7) Remove the PCB from inside the printer cabinet.

EPT026795 Issue 17 June 2020 15-17

ELECTRONICS SYSTEM REPAIR

(8) Fit a new PCB in the reverse order of removal.

(9) Replace the access panel for the rear electronics compartment.
(10) Reconnect the power lead to the rear of the printer.
End of procedure.

15-18 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

Product Detect / Shaft Encoder PNP, NPN and DIFF Selection

The pictures below illustrate the PNP/NPN/DIFF selection switches on the Product Detect / Shaft
Encoder PCB. The configuration of these switches will set the product sensor and shaft encoder
inputs to PNP, NPN or DIFF. There are LEDs on the PCB to indicate that the signal is correct.
When a single channel (non-quadrature) shaft encoder is used, only the channel SE_A can be
utilised.
When a quadrature shaft encoder is used, both the Channels SE_A and SE_B can be utilised.
For information on the settings:

PD = Product Detect Sinking = NPN Configuration

SE_A = Shaft Encoder 1 > Shaft Encoder Phase A Sourcing = PNP Configuration
SE_B = Shaft Encoder 1 > Shaft Encoder Phase B

Switches set to PNP

Switches set to NPN

EPT026795 Issue 17 June 2020 15-19

ELECTRONICS SYSTEM REPAIR

Switches set to DIFF

15-20 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

User Interface PCB Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver and 5mm hex driver.

Replace the user interface PCB as follows:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Disconnect the TouchScreen cable from the connector on the rear of the printer.
(4) Open the access panel to the rear electronics compartment.
(5) Disconnect the cable from socket J32 on the main PCB.

User Interface PCB to Main PCB Connector

(6) Remove the two nuts and the torx screw which secure the PCB to the printer cabinet.

EPT026795 Issue 17 June 2020 15-21

ELECTRONICS SYSTEM REPAIR

(7) Remove the PCB from inside the printer cabinet.

(8) Replace the access panel for the rear electronics compartment.
(9) Reconnect the power lead to the rear of the printer.
End of procedure.

15-22 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

Main PCB Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver and small metal tweazers.

To replace the main PCB:
(1) If the main PCB is being replaced under warranty, manually save an Uber Log (page 18-13)
and create a service backup (page 18-7).
(2) Zip the log files and save it using the name convention illustrated below:
PrinterSerialNumber_PCBSerialNumber_Date.zip
(3) Email the .zip file to: groupquality@[Link]
Note: If it is not possible to take an uber log and create a service backup, return the PCB’s
SD card with the PCB for RMA.
(4) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(5) Disconnect the power lead from the rear of the printer.
(6) Remove the vanity cover inside the printer cabinet as described on page 15-5.

EPT026795 Issue 17 June 2020 15-23

ELECTRONICS SYSTEM REPAIR

(7) Disconnect the electrical connectors on the rear of the main PCB, located in the top left of
the printer cabinet as illustrated below.
Note: Note where each cable is connected so they can easily be reconnected later in this
procedure.

Electrical Connectors on Rear of Main PCB

(8) Remove the high voltage power supply as described on page 15-6.
(9) Remove the low voltage power supply as described on page 15-9.
Note: Removal of the power supplies provides room to remove the main PCB without
causing damage.
(10) Use a T10 Torx driver to remove the 6 screws which secure the main PCB to the cabinet
chassis.

Main PCB Securing Screws

15-24 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

(11) Tilt the PCB and carefully remove it from the printer cabinet.

PCB Removal

(12) Transfer the smart card (SIM card) from the old main PCB to the new main PCB.

Smart
Card

Smart Card Location

EPT026795 Issue 17 June 2020 15-25

ELECTRONICS SYSTEM REPAIR

(13) Use tweezers to push the micro SD card into the holder to release it.

(14) Use tweezers to remove the micro SD card from the old PCB.

15-26 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

(15) Push the micro SD card into the holder on the new PCB.

(16) Transfer the jumpers that set the print head conduit length and nozzle size from the old main
PCB to the new main PCB.
Notes: (1) To check the jumper positions, see page 15-32.
(2) The jumper links on Ax150i printers manufactured after February 2019 are hard wired
and cannot be changed

Main PCB Jumper Positions

EPT026795 Issue 17 June 2020 15-27

ELECTRONICS SYSTEM REPAIR

(17) Refit the main PCB in the reverse order of removal.

(18) Refit the high voltage and low voltage power supplies.
(19) Refit the vanity cover, ITM, MUM and ink and make-up cartridges.
(20) Replace the access panel for the rear electronics compartment.
(21) Reconnect the power lead to the rear of the printer.
(22) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(23) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(24) Select Start and follow the on screen instructions to prime the ink system.
(25) Select Home > Setup > Adjustment > Inspection > Add...
(26) Select the Replaced part drop down menu and select Electronics board set.
(27) Select Operator name and enter your name.
(28) If necessary, select Notes and enter any notes which may be useful.
(29) Select Save.
(30) If returning the PCB for RMA, carefully pack the old PCB in the new PCB’s packaging.
End of procedure.

15-28 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

Main PCB Battery Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

WARNING: Lithium Battery. Risk of fire or explosion.

Use a tool made of a non-conducting material to remove the button battery. If a

tool made of a conducting material is used, there is a risk of short circuiting or
piercing the battery causing it to catch fire or explode.

WARNING: Lithium Battery. Risk of death or serious injury if swallowed.

Do not swallow the button battery, ingestion of lithium button batteries can cause
serious injury or death. If the battery is accidentally swallowed, seek medical
attention immediately.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

EPT026795 Issue 17 June 2020 15-29

ELECTRONICS SYSTEM REPAIR

Required tools: T10 torx driver, plastic non conducting tweezers and a replacement CR2450N
button battery.
To replace the main PCB battery:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access panel to the rear electronics compartment.
(4) Locate the button battery on the main PCB.

Button Battery Location

WARNING: Lithium Battery. Risk of fire or explosion.

Use a tool made of a non-conducting material to remove the button battery. If a

tool made of a conducting material is used, there is a risk of short circuiting or
piercing the battery causing it to catch fire or explode.

WARNING: Lithium Battery. Risk of death or serious injury if swallowed.

Do not swallow the button battery, ingestion of lithium button batteries can cause
serious injury or death. If the battery is accidentally swallowed, seek medical
attention immediately.

CAUTION: Ensure correct orientation of battery terminals. Risk of damage to printer.

Ensure the new battery is oriented correctly. The negative terminal faces down, the
positive terminal faces up. The battery holder or main PCB could be damaged if
the battery is incorrectly orientated.

(5) Carefully remove the battery from the main PCB and replace it with a new one.
(6) Dispose of the old battery by following local waste disposal and recycling regulations.
(7) Replace the access panel for the rear electronics compartment.

15-30 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

(8) Reconnect the power lead to the rear of the printer.

(9) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(10) Select Setup > Wizards > Installation.
(11) Use the drop down settings to select the required Language, Keyboard layout and Primary
currency.
(12) Select the Next Screen icon.

(13) Select the System date and enter the current date.
(14) Select Save.
(15) Select the System time and enter the current time.
(16) Select Save.
(17) Select Complete.
End of procedure.

EPT026795 Issue 17 June 2020 15-31

ELECTRONICS SYSTEM REPAIR

Main PCB Jumper Link Connectors (Ax350i/Ax550i)

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

CAUTION: Avoid contact with the button battery. Risk or printer damage.

Contact with the battery could short circuit to the PCB.

Different Jumper link connectors configure printers for different nozzle sizes and conduit lengths.
The next few pages in this document describe the different jumper link connectors.
Notes: (1) The links in the jumper link connectors are fixed and cannot be moved.
(2) The jumper links on Ax150i printers manufactured after February 2019 are hard wired
and cannot be changed. Ax150i supports a single jet i-Pulse print head with 60 micron
nozzle and 3 meter conduit only.

Jumper Link Connector

Main PCB Jumper Link Connector Location

15-32 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

Jumper Link Connector Overview

The table below describes what jumper link connector is required for each printer configuration.

Table 1: Jumper Link Connector Overview

Jumper Link Connector

Printer Nozzle Size and Conduit Configuration
Part Number

EPT021966SP 40μ Nozzle with 3 Meter Conduit, see page 15-34.

EPT021967SP 40μ Nozzle with 4 Meter Conduit, see page 15-35.
EPT036400SP 50μ Nozzle with 3 Meter Conduit, see page 15-36.
EPT036401SP 50μ Nozzle with 4 Meter Conduit, see page 15-37.
EPT021964SP 60μ Nozzle with 3 Meter Conduit, see page 15-38.
EPT021965SP 60μ Nozzle with 6 Meter Conduit, see page 15-39.
EPT021970SP 75μ Nozzle with 3 Meter Conduit, see page 15-40.
EPT021971SP 75μ Nozzle with 6 Meter Conduit, see page 15-41.

EPT026795 Issue 17 June 2020 15-33

ELECTRONICS SYSTEM REPAIR

Jumper Link Connector for 40μ Nozzle, 3 Meter Conduit (EPT021966SP)

Jumper link connector EPT021966SP is required for printers equipped with a 40μ nozzle and 3
meter conduit.
The jumper links on the jumper link connector are illustrated below.
Note: The jumper links on the connector are not movable.

02 01
02 01
04 03 Y
06 05
08 07
10 09 Y
12 11 Y
14 13 Y
16 15 Y
18 17
20 19
22 21
24 23
26 25
28 27
30 29
32 31
34 33 Y
36 35
38 37
40 39 40 39

EPT021971SP Top View

EPT026795 Issue 17 June 2020 15-41

ELECTRONICS SYSTEM REPAIR

Smart Card (SIM Card) Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Note: Software for any performance packs installed on the printer are stored on the smart
card. Migrate any performance packs installed on the printer back to the performance
pack USB before changing the smart card.
The main board contains a socket which holds a SIM card known as the smart [Link] smart
card is fitted to all printers and must not be removed unless it is being fitted to a new replacement
main PCB.
The illustration below shows the location of the smart card on the main PCB.

Smart
Card

15-42 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

Micro SD Card Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

CAUTION: Risk of damage to printer.

Do not move micro SD cards from printer to printer when troubleshooting. This
activity can/will corrupt the printer hardware and software. A replacement main
PCB might be required to repair the printer.

The micro SD card contains software required for the printer to operate.
The micro SD card is an industrial 8GB Class 10.
Notes: (1) Early Ax-Series printers were fitted with a 4GB Class 4 micro SD card. If the 4GB card
is faulty, it is recommended to replace it with a new 8GB Class 10 micro SD card for
higher read and write speeds. Refer to the Ax-Series Spares Catalogue for part
numbers.
(2) A video showing how to correctly remove and replace the micro SD card is also
available on the TIP (click here).
Required tools: T10 torx driver, small metal tweezers.
To replace the micro SD card:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access panel to the rear electronics compartment.

EPT026795 Issue 17 June 2020 15-43

ELECTRONICS SYSTEM REPAIR

(4) Put a sheet of paper in the bottom of the electronics compartment to catch the micro SD
card if it falls.

(5) Locate the micro SD card holder on the main PCB.

15-44 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

(6) Use tweezers to push the micro SD card into the holder to release it.

(7) Use tweezers to remove the micro SD card from the holder.

(8) Refit the micro SD card in the reverse order of removal.

End of procedure.

EPT026795 Issue 17 June 2020 15-45

ELECTRONICS SYSTEM REPAIR

(7) Select the Micro SD card size.

(8) Select Yes.

EPT026795 Issue 17 June 2020 15-49

ELECTRONICS SYSTEM REPAIR

(9) Select Close when the formatting and image copying process is complete.

(10) Check the micro SD card to ensure the formatting and image process was successful.

(11) Refit the micro SD card into the printer, see page 15-43.
(12) Follow the instructions contained in the software release notes to configure the printer.
End of procedure.

15-50 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

Solenoid Valve Harness Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver and 5mm hex driver.

To replace the solenoid valve harness:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the vanity cover inside the printer cabinet as described on page 15-5.

EPT026795 Issue 17 June 2020 15-51

ELECTRONICS SYSTEM REPAIR

(4) Disconnect the cable from socket J3601 in the top left of the cabinet.

(5) Disconnect the wiring harness from each solenoid.

(6) Remove the solenoid valve harness from the printer.

(7) Refit the solenoid valve harness in the reverse order of removal.

15-52 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

(8) Refit the vanity cover, ITM, MUM and ink and make-up cartridges.
(9) Close the door to the front ink compartment.
(10) Reconnect the power lead to the rear of the printer.
(11) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(12) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(13) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 15-53

ELECTRONICS SYSTEM REPAIR

QMM (Quality Management Module) Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Note: For detailed information about the QMM’s operation, and for QMM fault finding, refer
to “EPT026795 - QMM Detail Reference Guide” on the Domino Technical Information
Portal (TIP).
Required tools: T10 torx driver.
To replace the QMM:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Open the access door to the main ink compartment on the front of the printer.
(3) Squeeze the retaining clip underneath the QMM and withdraw the QMM by pulling it toward
you.

(4) Replace the QMM in the reverse order of removal.

(5) Close the door to the front ink compartment.
(6) Reconnect the power lead to the rear of the printer.
(7) Press and hold the standby button for 2 seconds to re-start the printer.
End of procedure.

15-54 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

LSM (Level Sense Module) Replacement

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver and 7mm spanner.

To replace the LSM:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the vanity cover inside the printer cabinet as described on page 15-5.

EPT026795 Issue 17 June 2020 15-55

ELECTRONICS SYSTEM REPAIR

(4) Remove the QMM from the printer cabinet by squeezing the latch that secures the QMM
and pulling the QMM towards you.

QMM Removal

(5) Disconnect the cable from socket J27 in the top left of the cabinet.

15-56 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

(6) Remove the 2 screws which secure the QMM Latch.

(7) Remove the 2 nuts which secure the LSM and remove the LSM from the printer cabinet.

LSM Removal

(8) Refit the LSM in the reverse order of removal.

(9) Refit the vanity cover.
Note: Do not fit the ITM, MUM or ink and make-up cartridges at this stage. The LSM must be
calibrated before the consumable items are refitted.
(10) Reconnect the power lead to the rear of the printer.
(11) Press and hold the standby button for 2 seconds and wait for the printer to start up.

EPT026795 Issue 17 June 2020 15-57

ELECTRONICS SYSTEM REPAIR

(12) On the TouchScreen, select Home > Setup > Diagnostics > Tests.
(13) Run the Calibrate ink sensor test.
(14) After the ink sensor calibration has completed, run Calibrate solvent sensor test.
(15) Replace the ITM, MUM and make-up and ink cartridges.
(16) Close the access door on the front of the printer cabinet.
(17) Select Home > Setup > Wizards > Ink priming.
(18) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

15-58 EPT026795 Issue 17 June 2020

ELECTRONICS SYSTEM REPAIR

Calibrate the Ink and Make-up Level Sensor

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10 torx driver.

To calibrate the ink and make-up sensor:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access door on the front of the printer cabinet.

CAUTION: Risk of risk setting incorrect fluid level.

Follow the steps described below. Ensure the make-up cartridge, ink cartridge,
ITM and MUM are removed from the printer. If they are not removed, the printer’s
zero fluid level will be reset to the wrong value.

(4) Remove both the make-up and ink cartridges and place them in a safe area.
(5) Remove the ITM by lifting up the two yellow retaining clips and sliding the ITM out of the
printer cabinet. Keep the ITM upright to avoid spilling fluid and place the ITM in a safe area.
(6) Remove the make-up module by unscrewing the retaining screw sliding the make-up
module out of the printer cabinet. When just clear of the Low Drip Valves, remove the vent
pipe from the rear of the make-up module. Once clear keep module upright and place it in
safe area.
(7) Reconnect the power lead to the rear of the printer.
(8) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(9) On the TouchScreen, select Home > Setup > Diagnostics > Tests.
(10) Run the Calibrate ink sensor test.
(11) Wait for the printer to calibrate the sensor.
(12) Run the Calibrate solvent sensor test.
(13) Wait for the printer to calibrate the sensor.
(14) Replace the ITM, MUM and make-up and ink cartridges.
(15) Close the access door on the front of the printer cabinet.
(16) Select Home > Setup > Wizards > Ink priming.
(17) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 15-59

ELECTRONICS SYSTEM REPAIR

THIS PAGE INTENTIONALLY LEFT BLANK

15-60 EPT026795 Issue 17 June 2020

PART 16 : INK SYSTEM REPAIR

CONTENTS
Page
INK SYSTEM ACCESS .......................................................................................................... 16-3
Ax150i Main Ink Compartment .......................................................................................... 16-3
Ax150i Rear Ink and Electronics Compartment ................................................................ 16-4
Ax350i/Ax550i Main Ink Compartment ............................................................................. 16-6
Ax350i/Ax550i Rear Ink Compartment .............................................................................. 16-7
Vanity Shield Removal ....................................................................................................... 16-9
INK SYSTEM REPAIR ............................................................................................................ 16-11
Flip Flop MUM Restrictor Kit Installation .......................................................................... 16-11
Solenoid Assembly Replacement ..................................................................................... 16-17
0.3mm Restrictor Cleaning ................................................................................................ 16-21
Distribution Block Replacement ........................................................................................ 16-25
Viscometer Replacement .................................................................................................. 16-28
Feed Filter Replacement ................................................................................................... 16-30
Temperature Sensor Replacement ................................................................................... 16-32
Pressure Sensor Replacement .......................................................................................... 16-34
Gutter Vacuum Sensor Replacement ................................................................................ 16-36
Flush NRV (Non Return Valve) Replacement .................................................................... 16-38
1PSI PRV (Pressure Release Valve) Replacement ............................................................ 16-40
Jet Pump Cartridge Replacement ..................................................................................... 16-42
Jet Pump Cleaning ............................................................................................................ 16-46
With an Ultrasonic Bath ................................................................................................ 16-46
Without an Ultrasonic Bath............................................................................................ 16-47
Low Drip Valve Replacement ............................................................................................ 16-48
Ink Pump Speed Check .................................................................................................... 16-50
Ink Pump Replacement ..................................................................................................... 16-51
Ink Pump Identification and Software Configuration .................................................... 16-51
Replace the Ink Pump ................................................................................................... 16-52
Peltier Condenser Replacement ....................................................................................... 16-56
Damper Replacement ....................................................................................................... 16-58
Gutter Pump Check .......................................................................................................... 16-60
Gutter Pump Replacement ................................................................................................ 16-61
Flush Ink System ............................................................................................................... 16-64
Ink of the Same Base ................................................................................................... 16-64
Ink of Different Colour and Base ................................................................................... 16-68
Ink of Different Colour and Base (Sensitive Inks) .......................................................... 16-73

EPT026795 Issue 17 June 2020 16-1

INK SYSTEM REPAIR

THIS PAGE INTENTIONALLY LEFT BLANK

16-2 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

INK SYSTEM ACCESS

Ax150i Main Ink Compartment
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

WARNING: Risk of ink spray.

If the printer’s Wake-up mode is enabled the printer’s ink pump will run for 2-3
minutes every 20 minutes. This will cause ink to spray out of the ink system if ink
system components have been removed. Shut down and disconnect the printer
from the power supply before removing any ink system components.

Ax150i Main Ink Compartment Access

When looking at the front of the Ax150i printer cabinet, the main ink compartment is accessed by
twisting the door latch on the side of the printer anti-clockwise and opening the door. Further
access to the ink system can be gained by removing the vanity shield as described on page 16-9.

EPT026795 Issue 17 June 2020 16-3

INK SYSTEM REPAIR

Ax150i Rear Ink and Electronics Compartment

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

WARNING: Risk of ink spray.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver

16-4 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

Ax150i Rear Ink and Electronics Compartment

The Ax150i rear ink and electronics compartment is accessed by removing the nine securing
screws on the rear panel. The panel can then be lowered on its hinges.

EPT026795 Issue 17 June 2020 16-5

INK SYSTEM REPAIR

Ax350i/Ax550i Main Ink Compartment

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

WARNING: Risk of ink spray.

Ax350i/Ax550i Main Ink Compartment Access

When looking at the front of the Ax350i/Ax550i printer cabinet, the main ink compartment is
accessed by twisting the door latch anti-clockwise and opening the door. Further access to the
ink system can be gained by removing the vanity shield as described on page 16-9.

16-6 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

Ax350i/Ax550i Rear Ink Compartment

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

WARNING: Risk of ink spray.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required tools: T10 torx driver.

Ax350i/Ax550i Rear Ink Compartment Access

When replacing the vanity shield and consumables, prime the ink system as described below:
(1) Replace the vanity shield, ITM, MUM, ink and make-up cartridge in the reverse order of
removal.
(2) Connect the power lead to the rear of the printer.
(3) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(4) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(5) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

16-10 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

Flip Flop MUM Restrictor Kit Installation
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Some Ax-Series printers assembled before the 18th May 2020 can suffer with viscosity control
issues that affect printing performance, when using the ink 2BK156. To correct this problem, the
flip flop MUM restrictor kit (EPT052827SP) can be installed.
All printers manufactured from the 18th May 2020 onwards have this part fitted as standard.
Refer to technical advisory note “TAN-011”.
Required tools/parts: Small flat head screw driver, T10 torx driver and the flip flop MUM restrictor
kit (EPT052827SP).

Table 1: MUM Restrictor Kit (EPT052827SP) BOM

Item Quantity

MUM Restrictor Block 1

(12) Connect the two red wires to the make-up solenoid.

EPT026795 Issue 17 June 2020 16-15

INK SYSTEM REPAIR

(13) Replace the vanity cover, ITM, MUM, ink cartridge and make-up cartridge.
(14) Connect the power lead to the rear of the printer.
(15) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(16) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(17) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

16-16 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

Solenoid Assembly Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

On printers earlier than serial number AX0000002780 the valve seats on Burkert solenoid valves
may swell up. This issue has been solved on later printers. Refer to technical bulletin “pibnax003”
and “pibnax004”.
Required tools: T10 torx driver.
To replace a solenoid assembly:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the vanity cover inside the printer cabinet as described on page 16-9.
(4) Remove the QMM from the printer cabinet by squeezing the latch that secures the QMM
and pulling the QMM towards you.

QMM Removal

EPT026795 Issue 17 June 2020 16-17

INK SYSTEM REPAIR

(5) Identify the solenoid that requires replacement.

Make-up Feed Wash Bleed Viscometer

Solenoid Identification

(6) Disconnect the two wires from the solenoid.

16-18 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(7) Use a T10 torx drive to remove the two screws that secure the solenoid.

(8) Pull the solenoid away from the distribution block.

EPT026795 Issue 17 June 2020 16-19

INK SYSTEM REPAIR

(9) Fit a new solenoid in the reverse order of removal.

(10) Replace the vanity cover, ITM, MUM, ink cartridge and make-up cartridge.
(11) Connect the power lead to the rear of the printer.
(12) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(13) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(14) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

16-20 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

0.3mm Restrictor Cleaning

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

The 0.3mm restrictor in the make-up line prevents the loss of vacuum in the gutter line when the
make-up valve opens. The restrictor is located in the distribution block behind the make-up
solenoid.
Symptoms of a dirty or blocked restrictor include thick ink and the printer not adding make-up to
the ink. These symptoms are more likely when using heavy duty opaque ink types.
Required tools: T10 torx driver, 2mm hex driver, needle nose pliers, wash and an M2 screw.
To clean the 0.3mm restrictor:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the vanity cover inside the printer cabinet as described on page 16-9.
(4) Identify the make-up solenoid.

EPT026795 Issue 17 June 2020 16-21

INK SYSTEM REPAIR

(5) Use a T10 torx drive to remove the two screws that secure the solenoid.

(6) Pull the solenoid away from the distribution block.

QMM Latch Removal

(6) Disconnect all of the cables from the rear of the main PCB in the top left of the cabinet.

Cable Disconnection

16-26 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(7) Remove the two nuts that secure the LSM and remove the LSM from the printer cabinet.

LSM Removal

(8) Disconnect all of the pipes that are connected to the distribution block. Take care not to spill
or drip any ink from the pipes. Note the location of each pipe on the distribution block.
(9) Remove the three T25 torx screws which secure the distribution block to the printer cabinet.

Distribution Block Removal

(10) Gently remove the distribution block from the printer cabinet. Take care not to damage any
cables or pipes.
(11) Replace the distribution block in the reverse order of removal.
(12) Replace the vanity cover, ITM, MUM, ink cartridge and make-up cartridge.
(13) Connect the power lead to the rear of the printer.
(14) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(15) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(16) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 16-27

INK SYSTEM REPAIR

Viscometer Replacement
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: 7mm spanner.

To replace the viscometer:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the vanity cover inside the printer cabinet as described on page 16-9.
(4) Identify the viscometer in the top right corner of the printer cabinet.

Viscometer Location

16-28 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(5) Disconnect the viscometer connector from J3801 on the rear of the main PCB.

(6) Hold lint free tissue around the pipe connectors on the viscometer to absorb ink and
disconnect the pipes.
(7) Remove the nuts that secure the viscometer to the printer cabinet chassis and remove the
viscometer from the printer cabinet.
(8) Refit a new viscometer in the reverse order of removal.
(9) Refit the vanity cover, ITM, MUM, ink and make-up cartridges.
(10) Reconnect the power lead to the rear of the printer.
(11) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(12) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(13) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 16-29

INK SYSTEM REPAIR

Feed Filter Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10 and T25 torx driver.

To replace the feed filter:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the distribution block as described on page 16-25.
(4) Locate the feed filter on top of the distribution block.

Feed Filter Location

16-30 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(5) Remove the two T10 torx screws that secure the feed filter and remove the filter from the
distribution block.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10 and T25 torx driver.

To replace the flush NRV:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the ink cartridge, make-up cartridge, ITM, MUM and vanity cover as described on
page 16-9.
(4) Locate the flush NRV on top of the distribution block.

NRV Location

(5) Disconnect the pipe from the NRV.

16-38 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(6) Remove the two T10 torx screws that secure the top of the valve assembly and remove it
from the distribution block.

NRV Removal

(7) Remove the top cap from the valve assembly.

Top Cap Removal

(8) Remove the valve and spring from inside the chamber.

Spring and Valve Removal

(9) Clean and refit the flush NRV, or refit a new flush NRV in the reverse order of removal.
(10) Refit the ITM, MUM, ink cartridge, make-up cartridge and vanity shield.
(11) Connect the power lead to the rear of the printer.
(12) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(13) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(14) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 16-39

INK SYSTEM REPAIR

1PSI PRV (Pressure Release Valve) Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10 and T25 torx driver.

To replace the flush 1PSI PRV:
(1) Remove the distribution block as described on page 16-25.
(2) Locate the PRV on the distribution block.

1PSI PRV Location

16-40 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(3) Remove the two T10 torx screws that secure the top cap and remove the top cap from the
distribution block.

1PSI PRV Top Cap Removal

(4) Remove the 1PSI spring and ball bearing by tilting the distribution block until they fall out.
Take care as ink inside the distribution block may leak out.

1PSI Spring and Ball Bearing Removal

(5) Refit the new spring and ball bearing into the distribution block.
(6) Refit the top cap and ensure that the spring and ball bearing are properly seated inside the
distribution block before tightening the screws.
(7) Refit the distribution block inside the printer cabinet.
(8) Refit the ITM, MUM, ink cartridge and make-up cartridge.
(9) Connect the power lead to the rear of the printer.
(10) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(11) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(12) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 16-41

INK SYSTEM REPAIR

Jet Pump Cartridge Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10 and T25 torx driver.

To replace the jet pump:
(1) Remove the vanity cover inside the printer cabinet as described on page 16-9.
(2) Remove the QMM from the printer cabinet by squeezing the latch that secures the QMM
and pulling the QMM towards you.

QMM Removal

16-42 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(3) Remove the 2 screws which secure the QMM Latch and move the QMM latch away from
the distribution block.

QMM Latch Removal

(4) Locate the jet pump cover on the front of the distribution block and place tissue underneath
the cover to absorb any leaking ink.

Jet Pump Cover Location

EPT026795 Issue 17 June 2020 16-43

INK SYSTEM REPAIR

(5) Remove the six T10 torx screws that secure the jet pump cover.

Jet Pump Cover Removal

(6) Carefully remove the jet pump cover. Take care not to loose any O-Rings that may fall off.
Note: In the picture below the jet pump has two O-Rings.

Jet Pump Cover Removal

(7) Insert a small flat blade screwdriver underneath the lip of the jet pump cartridge and lever
the cartridge out of the distribution block.

Jet Pump Cartridge Removal

16-44 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(8) Either clean the jet pump as described on page 16-46, or fit a new jet pump in the reverse
order of removal.
(9) Refit the QMM and vanity shield.
(10) Refit the ITM, MUM, ink cartridge and make-up cartridge.
(11) Connect the power lead to the rear of the printer.
(12) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(13) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(14) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(15) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 16-45

INK SYSTEM REPAIR

Jet Pump Cleaning

The jet pump can be cleaned with an ultrasonic or without an ultrasonic bath. Both cleaning
methods are described below.
With an Ultrasonic Bath
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Required tools: Ultrasonic bath, small beaker and wash.

To clean the jet pump with an ultrasonic bath:
(1) Remove the jet pump from the printer as described on page 16-42.
(2) Dismantle the jet pump as illustrated below.

Jet Pump

(3) Place the jet pump into a small beaker filled with the correct type of wash.
(4) Place the beaker into the ultrasonic bath filled with water.
(5) Run the ultrasonic bath for approximately five minutes.
(6) Refit the jet pump into the printer’s distribution block.
(7) Refit the printer’s QMM and vanity shield.
(8) Refit the ITM, MUM, ink cartridge and make-up cartridge.
(9) Connect the power lead to the rear of the printer.
(10) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(11) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(12) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(13) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

16-46 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

Without an Ultrasonic Bath

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Required tools: Small beaker, wash bottle and wash.

To clean the jet pump without an ultrasonic bath:
(1) Remove the jet pump from the printer as described on page 16-42.
(2) Dismantle the jet pump as illustrated below.

Jet Pump

(3) Hold the jet pump over a beaker.

(4) Hold the nozzle of a wash bottle filled with the correct wash over the jet pump and use the
wash to flush out the blockage in the jet pump.
(5) Refit the jet pump into the printer’s distribution block.
(6) Refit the printer’s QMM and vanity shield.
(7) Refit the ITM, MUM, ink cartridge and make-up cartridge.
(8) Connect the power lead to the rear of the printer.
(9) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(10) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(11) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(12) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 16-47

INK SYSTEM REPAIR

Low Drip Valve Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10 torx driver and lint free tissue.

To replace the low drip valves:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access door on the front of the printer cabinet.
(4) Remove both the make-up and ink cartridges and place them in a safe area.
(5) Remove the ITM by lifting up the two yellow retaining clips and sliding the ITM out of the
printer cabinet. Keep the ITM upright to avoid spilling fluid and place the ITM in a safe area.
(6) Remove the make-up module by unscrewing the retaining screw sliding the make-up
module out of the printer cabinet. When just clear of the Low Drip Valves, remove the vent
pipe from the rear of the make-up module. Once clear keep module upright and place it in
safe area.
(7) Place lint free tissue underneath the low drip valves to soak up any ink which may leak out.
(8) Remove the seven T10 torx screws that secure the front plate of the low drip valves.

Low Drip Valve Screw Removal

(9) Remove the plate from the distribution block.

16-48 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(10) Push a torx driver forward into the valve to open it and gently lever the rubber valve seal out
of the distribution block. After the seal has been removed, the valve and spring assembly
will pop out of the distribution block.

Low Drip Valve Removal

(11) Discard the old low drip valve.

(12) Clean the valve port in the distribution block with the correct wash type.
(13) Dry the valve port with a lint free tissue.
(14) Insert the new spring, valve and O-Ring into the valve port.
Note: Fit the outer O-Ring with the groove facing inwards.
(15) Refit the low drip valve cover and tighten the T10 torx screws.
(16) Refit the ITM, MUM, Ink and Make-up cartridges in the printer.
(17) Reconnect the power lead to the rear of the printer.
(18) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(19) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(20) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 16-49

INK SYSTEM REPAIR

Ink Pump Speed Check

To check the speed of the main ink pump:
(1) Ensure the ink jet is running and the printer is in the Ready state.
(2) Select the icon on the Information Bar.
(3) Swipe the screen from right to left twice to navigate to the Live status screen.
(4) Observe the Pump speed (rpm) value.

Vacuum Pressure (mBar) Value

(5) The Pump speed (rpm) value should somewhere between 1100 and 1400. The pump speed
could also be slightly outside of this range. The printer’s configuration, nozzle size, ink
viscosity and temperature can all affect the pump speed. If the pump speed is far outside of
the specified range, for example 3500rpm or above, it is advisable to replace the pump, see
page 16-51.
End of procedure.

16-50 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

Ink Pump Replacement

Ink Pump Identification and Software Configuration
Depending on supplier availability, new pumps supplied in spare kits may be different to the
original pump fitted in the printer. If the new pump is different to the original, update the pump
type setting in the printer’s software or the printer will not work correctly. Refer to the table below
to identify the ink pump.

Table 2: Ink Pump Identification

EPT015770 - Heavy Duty

EPT011933 - Dye Pump EPT011936 - Dye Pump
Pump

Viewed from Front of Printer Viewed from Front of Printer Viewed from Front of Printer

Viewed from Rear of Printer Viewed from Rear of Printer Viewed from Rear of Printer

To configure the printer software to use a different pump:

(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen select Home > Setup > Advanced > Hardware.
(3) Scroll down the Pump type and select the correct ink pump part number.
(4) Remove the engineer’s USB key from the USB slot.
End of procedure.

EPT026795 Issue 17 June 2020 16-51

INK SYSTEM REPAIR

Replace the Ink Pump

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10 torx driver, 7mm nut spinner and lint free paper towel.
To replace the ink pump:
(1) Connect the 8mm and 6mm pipes from the kit to the new ink pump.
(2) If the printer is on, press and hold the standby button for 2 seconds and wait for the
printer to shut down.
(3) Disconnect the power lead from the rear of the printer.
(4) Remove the vanity cover inside the printer cabinet as described on page 16-9.
(5) Remove the 2 nuts that secure the LSM and move the LSM to one side.

LSM Removal

(6) Place lint free paper towel underneath the ink block to absorb ink that may leak.

16-52 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(7) Disconnect the two pipes from the bottom of the ink block.

Pipe Disconnection

(8) Use a T10 torx driver to open the access panel to the rear ink compartment.

Ax150i Ax350i/Ax550i

EPT026795 Issue 17 June 2020 16-53

INK SYSTEM REPAIR

(9) Disconnect the ink pump cable.

Ink Pump Cable Disconnection

(10) Use a 7mm nut spinner to remove the nuts that secure the ink pump to the printer cabinet
chassis.
Note: Place lint free paper towel in the bottom left corner of the cabinet to catch dropped
nuts.

Ink Pump Nut Removal

16-54 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(11) Remove the ink pump from the printer cabinet.

Ink Pump Removal

(12) Refit the new ink pump in the reverse order of removal.
(13) Refit the vanity cover, ITM, MUM, ink and make-up cartridges.
(14) Reconnect the power lead to the rear of the printer.
(15) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(16) If the new pump is a different type to the printer’s original pump, update the Pump type
setting in the printer’s software. Refer to page 16-51.
(17) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(18) Select Start and follow the on screen instructions to prime the ink system.
(19) Wait for the ink priming process to complete and select OK.
(20) Select Home > Setup > Adjustment > Inspection > Add...
(21) Select the Replaced part drop down menu and select Pump.
(22) Select Operator name and enter your name.
(23) If necessary, select Notes and enter any notes which may be useful.
(24) Select Save.
End of procedure.

EPT026795 Issue 17 June 2020 16-55

INK SYSTEM REPAIR

Peltier Condenser Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: 7mm spanner and lint free tissue.

To replace the Peltier condenser:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the access door on the front of the printer cabinet.
(4) Remove the vanity cover inside the printer cabinet as described on page 16-9.
(5) Remove the vanity cover inside the printer cabinet.
(6) Disconnect the Peltier condenser electrical connector J3301 from the rear of the main PCB.

16-56 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(7) Unscrew the two nuts that secure the Peltier condenser to the printer cabinet.

Peltier Nuts

(8) Make a note of the pipe locations and transfer the pipes from the old Peltier condenser to
the new Peltier condenser.
(9) Secure the new Peltier condenser onto the printer cabinet.
(10) Connect the Peltier condenser electrical connector to J3301 on the rear of the main PCB.
(11) Refit the vanity cover, ITM, MUM, ink and make-up cartridges.
(12) Reconnect the power lead to the rear of the printer.
(13) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(14) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(15) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 16-57

INK SYSTEM REPAIR

Damper Replacement
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T20 torx driver and lint free tissue.

Printers equipped with a standard “dye” ink system are fitted with one damper. Printers equipped
with a heavy duty ink system are fitted with two dampers. The same damper type is used for both
ink system types.
To replace the damper:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Remove the vanity cover inside the printer cabinet as described on page 16-9.
(4) Locate the damper in the top left of the printer cabinet.

Damper Location

(5) Place lint free tissue underneath the damper to catch any ink which may leak out of the
damper or connecting pipes.
(6) Disconnect the two pipes from the John Guest fittings on the damper.

16-58 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(7) Remove the two securing screws on from the damper and remove the damper from the
printer cabinet.
(8) Replace the damper in the reverse order of removal.
(9) Refit the vanity cover, ITM, MUM, ink and make-up cartridges.
(10) Reconnect the power lead to the rear of the printer.
(11) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(12) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(13) Select Start and follow the on screen instructions to prime the ink system.
End of procedure.

EPT026795 Issue 17 June 2020 16-59

INK SYSTEM REPAIR

Gutter Pump Check

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

The gutter pump speed depends on the printer configuration and is automatically controlled by
the printer software. Over speed and under speed warnings are given if the speed deviates more
than 250rpm from the expected value.
Should an under speed condition occur then the pump connections should be checked. If no fault
is found then the pump should be replaced. If an over speed condition occurs then it is also
advisable to replace the pump.
Symptoms of a failing gutter pump are a partial or total loss of gutter clearance that cannot be
attributed to:
• Blocked or kinked pipework.
• Partly blocked gutter filter.
• Ink too viscous (out of range).
It is possible to check for correct gutter function at the beginning of the sequence on process. A
small amount of make-up can be squirted into the gutter and an audible suction noise will be
heard.
The vacuum pressure value can also be used to check the gutter pump by performing the
procedure described below:
(1) Put the printer into the Idle state.
(2) On the TouchScreen, select Home > Setup > Advanced > Gutter.
(3) Tick the Gutter pump at maximum speed tick box.
(4) Select Home > Setup > Diagnostics.
(5) A printer fitted with a 60μ nozzle will display Vacuum pressure (mBar) value of approximately
-120. If the Vacuum pressure (mBar) value is greater than -180 than it is likely that the gutter
pipe is partially blocked by dry ink. Follow the gutter pipe clean procedure on page 12-6 to
clear the gutter.
(6) Remove the holster from the print head by pressing in the two holster retaining clips and
withdrawing the holster.
(7) Put on a clean protective glove and block the gutter pipe with 1 finger.
(8) If the gutter pump is working correctly, the Vacuum pressure (mBar) value will change to
approximately -600.
(9) Select Home > Setup > Advanced > Gutter.
(10) Untick the Gutter pump at maximum speed tick box.
End of procedure.

16-60 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

Gutter Pump Replacement

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10 torx driver and lint free tissue.

To replace the gutter pump:
(1) Remove the vanity cover inside the printer cabinet as described on page 16-9.
(2) Squeeze the retaining clip underneath the QMM and withdraw the QMM by pulling it toward
you.

QMM Removal

EPT026795 Issue 17 June 2020 16-61

INK SYSTEM REPAIR

(3) Locate the gutter pump in the printer cabinet.

Gutter Pump Location

(4) Disconnect the gutter pump electrical connector from the rear of the main PCB.

16-62 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(5) Place lint free tissue underneath the gutter pump to catch any ink which may leak out.
(6) Remove the two securing screws on from the gutter pump and remove the gutter pump
from the printer cabinet.
Note: If there is not enough room or if the securing screws are stiff, it may be necessary to
remove the distribution block to gain better access to the gutter pump, see
page 16-25.
(7) Replace the gutter pump in the reverse order of removal.
(8) Refit the QMM, vanity cover, ITM, MUM, ink and make-up cartridges.
(9) Reconnect the power lead to the rear of the printer.
(10) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(11) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(12) Select Start and follow the on screen instructions to prime the ink system.
(13) Check the gutter pump by following the procedure described on page 16-60.
End of procedure.

EPT026795 Issue 17 June 2020 16-63

INK SYSTEM REPAIR

Flush Ink System

Ink of the Same Base
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

CAUTION: Risk of damage to printer’s ink system

Do not allow foreign objects to enter the ITM or ink block. Observe good
cleanliness procedures.

CAUTION: Hazardous chemicals. Risk of environmental damage.

Waste ink and make-up are hazardous to the environment. Follow local waste
disposal regulations to safely dispose of waste ink, make-up and other
contaminated items

(18) Wait for the flush process to complete.
(19) Select the Next Screen icon two times.

(20) Select the Complete icon.

(21) Remove the flushing rig from the distribution block.
(22) Disconnect the pipe connected to the print head gutter.
(23) Rinse the print head gutter with wash solution.
(24) Replace the print head holster.
(25) Place paper towel or similar on top of the level sensor modules to catch excess fluid.
(26) Use wash to clean and lubricate the distribution block valve face.
(27) Insert the engineer’s USB key into one of the USB socket on the TouchScreen or another
USB socket on the printer cabinet.
(28) Select Home > Setup > Advanced > Ink details > Ink details > Current Ink.
(29) Select the new ink type from the drop down list.
(30) Disconnect the engineer’s USB key.
(31) Fit a new ITM and MUM.
(32) Fit the new ink and make-up cartridges.
(33) Dispose of all waste materials by following local waste disposal regulations.
End of procedure.

EPT026795 Issue 17 June 2020 16-67

INK SYSTEM REPAIR

Ink of Different Colour and Base

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

CAUTION: Risk of damage to printer’s ink system

Do not allow foreign objects to enter the ITM or ink block. Observe good
cleanliness procedures.

CAUTION: Hazardous chemicals. Risk of environmental damage.

Waste ink and make-up are hazardous to the environment. Follow local waste
disposal regulations to safely dispose of waste ink, make-up and other
contaminated items

Follow this procedure when changing the ink to an ink type with a different colour and base. Once
started, the flush process will take approximately 40 minutes.
Required tools: Engineer’s USB key, flush manifold assembly (P/N EPT025259), empty make-up
cartridge, empty ink cartridge, lint free tissue and wash solution.
Flush the ink system as follows:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the front access door to the main ink compartment.
(4) Remove the ink and make-up cartridges.
(5) Remove the ITM and MUM.

16-68 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(6) Place paper towel or similar on top of the level sensor modules to catch excess fluid. Use
wash to remove any dried residual ink from the distribution block valve face.

Cleaning the Distribution Block

(7) Fit the flushing rig assembly onto the distribution block and insert the drain pipe into an
empty wash bottle.

Flushing Rig and Empty Wash Bottle Connected to Distribution Block

(8) Remove the holster from the print head by pressing in the two holster retaining clips and
withdrawing the holster.
(9) Rinse the print head gutter with wash solution.

EPT026795 Issue 17 June 2020 16-69

INK SYSTEM REPAIR

(10) Connect the flushing rig input pipe to the gutter pipe in the print head.

Flushing Rig Input Pipe Connected to Gutter Pipe

(11) Insert the other end of the input pipe into a bottle containing 900ml of wash solution that is
compatible with the current ink type.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

Do not connect the input pipe to a bottle containing more than 900ml of wash
solution. Otherwise too much wash will be drawn into the ink system and the ink
viscosity will become too thin.

Wash Bottle Connected to Print Head Gutter

16-70 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(12) Reconnect the power lead to the rear of the printer.

(13) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(14) On the TouchScreen select Home > Setup > Wizards > Ink flushing.
(15) Select Inks of different colour and different base.
(16) Select the Next Screen icon eight times to move to step nine of the ink flushing wizard.

(17) Select Begin Flush.

(18) Wait for the flush process to complete.
(19) Remove the full wash bottle from the flushing rig assembly, empty it according to local
waste disposal regulations and reconnect it to the flushing rig assembly.
(20) Disconnect the input pipe connected to the gutter pipe in the print head.
(21) Rinse the print head gutter with wash solution.
(22) Reconnect the input pipe to the print head gutter pipe.
(23) Insert the other end of the input pipe into a bottle containing 900ml of wash solution that is
compatible with the new ink type.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

Do not connect the input pipe to a bottle containing more than 900ml of wash
solution. Otherwise too much wash will be drawn into the ink system and the ink
viscosity will become too thin.

(24) Select the Next Screen icon eight times to move to step 17 of the ink flushing wizard.

(25) Select Begin Flush.

(26) Wait for the flush process to complete.
(27) Select the Next Screen icon two times.

(28) Select the Complete icon.

(29) Remove the flushing rig from the distribution block.
(30) Disconnect the input pipe from the print head gutter.
(31) Rinse the print head gutter with wash solution.
(32) Replace the print head holster.
(33) Place paper towel or similar on top of the level sensor modules to catch excess fluid.
(34) Use wash to clean and lubricate the distribution block valve face.
(35) Insert the engineer’s USB key into one of the USB socket on the TouchScreen or another
USB socket on the printer cabinet.
(36) Select Home > Setup > Advanced > Ink details > Ink details > Current Ink.
(37) Select the new ink type from the drop down list.
(38) Disconnect the engineer’s USB key.
(39) Fit a new ITM and MUM.

EPT026795 Issue 17 June 2020 16-71

INK SYSTEM REPAIR

(40) Fit the new ink and make-up cartridges.

(41) Dispose of all waste materials by following local waste disposal regulations.
End of procedure.

16-72 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

Ink of Different Colour and Base (Sensitive Inks)

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

CAUTION: Risk of damage to printer’s ink system

Do not allow foreign objects to enter the ITM or ink block. Observe good
cleanliness procedures.

CAUTION: Hazardous chemicals. Risk of environmental damage.

Waste ink and make-up are hazardous to the environment. Follow local waste
disposal regulations to safely dispose of waste ink, make-up and other
contaminated items

Followed this procedure when changing the printer ink type to a sensitive ink with a different
colour and base. Once started, the flush process will take approximately 60 minutes.
Required tools: Engineer’s USB key, flush manifold assembly (P/N EPT025259), empty make-up
cartridge, empty ink cartridge, lint free tissue and wash solution.
Flush the ink system as follows:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the front access door to the main ink compartment.
(4) Remove the ink and make-up cartridges.
(5) Remove the ITM and MUM.

EPT026795 Issue 17 June 2020 16-73

INK SYSTEM REPAIR

(6) Place paper towel or similar on top of the level sensor modules to catch excess fluid. Use
wash to remove any dried residual ink from the distribution block valve face.

Cleaning the Distribution Block

(7) Fit the flushing rig assembly onto the distribution block and insert the drain pipe into an
empty wash bottle.

Flushing Rig and Empty Wash Bottle Connected to Distribution Block

(8) Remove the holster from the print head by pressing in the two holster retaining clips and
withdrawing the holster.
(9) Rinse the print head gutter with wash solution.

16-74 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(10) Connect the flushing rig input pipe to the gutter pipe in the print head.

Flushing Rig Input Pipe Connected to Gutter Pipe

(11) Insert the other end of the input pipe into a bottle containing 900ml of wash solution that is
compatible with the current ink type.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

Do not connect the input pipe to a bottle containing more than 900ml of wash
solution. Otherwise too much wash will be drawn into the ink system and the ink
viscosity will become too thin.

Wash Bottle Connected to Print Head Gutter

EPT026795 Issue 17 June 2020 16-75

INK SYSTEM REPAIR

(12) Reconnect the power lead to the rear of the printer.

(13) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(14) On the TouchScreen select Home > Setup > Wizards > Ink flushing.
(15) Select Inks of different colour and different base (sensitive inks).
(16) Select the Next Screen icon eight times to move to step nine of the ink flushing wizard.

(17) Select Begin Flush.

(18) Wait for the flush process to complete.
(19) Remove the full wash bottle from the flushing rig assembly, empty it according to local
waste disposal regulations and reconnect it to the flushing rig assembly.
(20) Disconnect the input pipe connected to the gutter pipe in the print head.
(21) Rinse the print head gutter with wash solution.
(22) Reconnect the input pipe to the print head gutter pipe.
(23) Insert the other end of the input pipe into a bottle that contains a mix of 450ml wash solution
compatible with the old ink type, and 450ml wash solution compatible with the new ink
type.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

Do not connect the input pipe to a bottle containing more than 900ml of wash
solution. Otherwise too much wash will be drawn into the ink system and the ink
viscosity will become too thin.

(24) Select the Next Screen icon eight times to move to step 17 of the ink flushing wizard.

(25) Select Begin Flush.

(26) Wait for the flush process to complete.
(27) Remove the full wash bottle from the flushing rig assembly, empty it according to local
waste disposal regulations and reconnect it to the flushing rig assembly.
(28) Disconnect the input pipe connected to the gutter pipe in the print head.
(29) Rinse the print head gutter with wash solution.
(30) Reconnect the input pipe to the print head gutter pipe.
(31) Insert the other end of the input pipe into a bottle containing 900ml of wash solution that is
compatible with the new ink type.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

Do not connect the input pipe to a bottle containing more than 900ml of wash
solution. Otherwise too much wash will be drawn into the ink system and the ink
viscosity will become too thin.

(32) Select the Next Screen icon eight times to move to step 25 of the ink flushing wizard.

(33) Select Begin Flush.

16-76 EPT026795 Issue 17 June 2020

INK SYSTEM REPAIR

(34) Wait for the flush process to complete.

(35) Select the Next Screen icon two times.

(36) Select the Complete icon.

(37) Remove the flushing rig from the distribution block.
(38) Disconnect the input pipe from the print head gutter.
(39) Rinse the print head gutter with wash solution.
(40) Replace the print head holster.
(41) Place paper towel or similar on top of the level sensor modules to catch excess fluid.
(42) Use wash to clean and lubricate the distribution block valve face.
(43) Insert the engineer’s USB key into one of the USB socket on the TouchScreen or another
USB socket on the printer cabinet.
(44) Select Home > Setup > Advanced > Ink details > Ink details > Current Ink.
(45) Select the new ink type from the drop down list.
(46) Disconnect the engineer’s USB key.
(47) Replace the ITM and MUM.
(48) Fit the new ink and make-up cartridges.
(49) Dispose of all waste materials by following local waste disposal regulations.
End of procedure.

EPT026795 Issue 17 June 2020 16-77

INK SYSTEM REPAIR

THIS PAGE INTENTIONALLY LEFT BLANK

16-78 EPT026795 Issue 17 June 2020

PART 17 : TOUCHSCREEN REPAIR

CONTENTS
Page
TOUCHSCREEN FAULT DIAGNOSIS .................................................................................... 17-3
Diagnosis Flow Chart 1 ..................................................................................................... 17-3
Diagnosis Flow Chart 2 ..................................................................................................... 17-3
Diagnosis Flow Chart 3 ..................................................................................................... 17-4
TOUCHSCREEN CALLIBRATION .......................................................................................... 17-5

EPT026795 Issue 17 June 2020 17-1

TOUCHSCREEN REPAIR

THIS PAGE INTENTIONALLY LEFT BLANK

17-2 EPT026795 Issue 17 June 2020

TOUCHSCREEN REPAIR

TOUCHSCREEN FAULT DIAGNOSIS

TouchScreen faults and TouchScreen calibration issues are commonly misdiagnosed as main
PCB failures. The flow charts in this chapter are designed to help diagnose and solve
TouchScreen faults.
If the problem persists after following the flow charts, test the printer with another TouchScreen.

Diagnosis Flow Chart 1

SYMPTOM: Black Screen SYMPTOM: Black Screen SYMPTOM: Different

(Remote TouchScreen 10") (Remote TouchScreen 7") coloured test patter shown on
power up
(Remote TouchScreen 7")

POSSIBLE CAUSE: 24V not

applied to TouchScreen due to
Is printer software less than No cable/connection issue.
SW v26?
SOLUTION: Switch printer off,
check cables and connections.

Yes

POSSIBLE CAUSE: Corrupt or POSSIBLE CAUSE: Some 7"

missing TouchScreen driver file TouchScreens have incorrect
on second partition of SD card. backlight timing parameters set at
manufacturing. Addressed in SW
SOLUTION: Replace SD Card v26 and above.
(page 15-43).
SOLUTION: Replace TouchScreen

Diagnosis Flow Chart 2

SYMPTOM: Screen goes “white”
on power up then fades to black
before splash screen
disappears.

(Remote TouchScreen 7")

POSSIBLE CAUSE: Printer has

an older version of PIC firmware
installed.

SOLUTION: Replace printer’s

main PCB (page 15-23).

EPT026795 Issue 17 June 2020 17-3

Diagnosis Flow Chart 3
17-4

SYMPTOM: No response SYMPTOM: Different areas of POSSIBLE CAUSE:

from TouchScreen. the screen respond. TouchScreen swapped to one
of same size whilst power is
still on.

POSSIBLE CAUSE:
TouchScreen swapped to one
of different size whilst power
is still on.

TOUCHSCREEN REPAIR
Is printer software SW v26 or No
later? POSSIBLE CAUSE: Faulty
TouchScreen.

SOLUTION: Replace
Yes TouchScreen.
EPT026795 Issue 17 June 2020

POSSIBLE CAUSE: POSSIBLE CAUSE: Software POSSIBLE CAUSE: Calibration ACTION: Power cycle printer
TouchScreen never calibrated. was v26 and has been updated. data overwritten on SD Card. and recheck.

ACTION: Replace SD Card (page 15-43).

POSSIBLE RESOLUTION: Recalibrate

TouchScreen (page 17-5).
TOUCHSCREEN REPAIR

TOUCHSCREEN CALLIBRATION
The TouchScreen’s calibration settings are stored within the TouchScreen and also on the
printer’s micro SD card.
TouchScreen type 4s earlier than serial number 8695800190 and type 3s earlier than serial
number 8844400384 did not ship with calibration settings stored on the TouchScreen. Therefore,
these early TouchScreens have been using the calibration values saved on the micro SD only.
When the printer software is updated, it is possible that the micro SD card values could be set to
default or overwritten, This will result in a loss of calibration if the calibration values are stored on
the printer SD card only.
The procedure below describes how to complete a full recalibration of the TouchScreen. This
procedure will write the calibration settings to both the TouchScreen and printer’s micro SD card.
Required tools: USB keyboard.
To recalibrate a TouchScreen:
(1) Connect the USB keyboard to the TouchScreen.
(2) Press the “Windows” button on the keyboard.
(3) Use the keyboard Arrows and Enter button to select Settings > Control Panel.

(4) Select Stylus.

EPT026795 Issue 17 June 2020 17-5

TOUCHSCREEN REPAIR

(5) Select Calibration.

(6) Follow the on screen instructions.

(7) Disconnect the USB keyboard.

(8) On the TouchScreen, select Home > Setup > User interface > UI Setup > Calibrate.
(9) Follow the on screen instructions.
Note: A printer reboot is required to ensure the calibration settings are properly saved.
(10) Press and hold the printers standby button for 2 seconds and wait for the printer to shut
down.
(11) Press and hold the printers standby button for 2 seconds to re-start the printer.
End of procedure.

17-6 EPT026795 Issue 17 June 2020

PART 18 : SOFTWARE UPGRADE, BACKUP/
RESTORE AND LOGS

CONTENTS
Page
SOFTWARE UPGRADE ......................................................................................................... 18-3
Introduction ....................................................................................................................... 18-3
Upgrade Procedure ...................................................................................................... 18-4
Check Printer Settings................................................................................................... 18-5
SOFTWARE ROLLBACK ........................................................................................................ 18-6
BACKUP AND RESTORE ...................................................................................................... 18-7
Service Backup ................................................................................................................. 18-7
Create a Service Backup ................................................................................................... 18-7
Label Backup .................................................................................................................... 18-9
Create a Label Backup ...................................................................................................... 18-9
Restore Labels from a Backup .......................................................................................... 18-9
SAVE CONFIGURATION AS FACTORY DEFAULT ................................................................ 18-10
LOG FILES ............................................................................................................................. 18-11
View Log Files on TouchScreen ........................................................................................ 18-11
Export Log Files to USB .................................................................................................... 18-12
UBER LOG FILES .................................................................................................................. 18-13
Manually Create an Uber Log File ................................................................................ 18-13
Export Uber Log Files to USB ....................................................................................... 18-14
R-DRIVE MICRO SD CARD IMAGE ....................................................................................... 18-15
Create an Image of the Micro SD Card ............................................................................. 18-15
Restore from an Image of the Micro SD Card ................................................................... 18-20
UI SCREENSHOT .................................................................................................................. 18-25
Save to USB Flash Drive ................................................................................................... 18-25
Save Internally ................................................................................................................... 18-26

EPT026795 Issue 17 June 2020 18-1

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

THIS PAGE INTENTIONALLY LEFT BLANK

18-2 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

SOFTWARE UPGRADE
Introduction
CAUTION: Risk of damage to printer.
Disconnect all printer cables, connections, ancillaries, Domino Cloud Interface
(DCI), beacon, alarm port, shaft encoder and sensors etc. This ensures no
communication or electrical signals can be received during the upgrade process.
Failure to remove all connections before the upgrade process starts may corrupt
the printer’s software.

Notes: (1) Non-standard files which have been uploaded manually onto the printer may be lost
during a software upgrade. For example, trial inks or development rasters. If these files
are not available in the printer after the upgrade, contact the Domino Technical
Support Group (TSG) and check if the files are compatible with the new software
revision. Re-install the files manually after the upgrade is complete.
(2) The “Print Delay” setting will not persist during a software upgrade. Manually reset the
“Print Delay” setting after the upgrade is complete.
(3) Do not directly upgrade the printer to a software revision that is more than 2 releases
ahead of the printers current software revision.
Upgrading the printer’s software can take between 11 and 22 minutes. A typical upgrade process
consists of the following timings:

Time Description

00:00 Insert USB flash drive with valid .UPG upgrade file.
00:15 USB detected and upgrade wizard started.
01:00 After “Next”, Etc. The printer software release notes are displayed on
screen.
02:06 Once the “Upgrade Now” button is pressed and USB removed a black
screen will appear.
03:00 The printer has restarted and shows the Domino blue wave bootup
screen.
03:05 The white QuickStep3 software upgrading screen shows 1%.
05:22 The white QuickStep3 software upgrading screen shows 34%.
08:42 2nd black screen as the printer reboots/restarts a 2nd time.
09:15 The printer is now restarting and shows the Domino blue wave bootup
screen.
09:20 A white no pending updates screen appears for a short period of time.
10:51 The printer is booting up/starting up normally as it loads applications
and plugins.
10:55 QuickStep3 is fully loaded and the software upgrade is complete.

EPT026795 Issue 17 June 2020 18-3

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

Upgrade Procedure
To upgrade the printer’s software:
(1) Copy the upgrade file to the root folder of a USB flash drive.
(2) Disconnect all printer cables, connections, ancillaries, Domino Cloud Interface (DCI),
beacon, alarm port, shaft encoder and sensors etc. This ensures no communication or
electrical signals can be received during the upgrade process. Failure to remove all
connections before the upgrade process starts may corrupt the printer’s software.
(3) Power on the printer and wait for it to fully boot-up/start-up into the Idle state.

CAUTION: Risk of damage to printer.

Do not sequence the ink jet on and do not insert any USB device during the
boot-up/start-up sequence.

(4) Insert the USB flash drive into a USB port on the printer cabinet or TouchScreen.
(5) Wait for the Available upgrades pop up screen to appear, and select Yes.
(6) Select the upgrade file.
(7) The TouchScreen will now display a summary of the release notes for the upgrade file.
Select the Arrow icon to continue the upgrade.
(8) Select when the upgrade should take place, either:
• Now (will restart printer automatically).
• The next time the printer is restarted.
(9) Select the Arrow icon.
(10) Select Backup to perform a full backup of the printer files to the USB flash drive. Or, select
the Arrow icon to continue the upgrade without backing up.
Notes: (1) If you do not require a full USB backup, remove the USB flash drive after the upgrade
wizard has started. You will see/read the on-screen release notes, at this point the
.UPG file is inside the printer and the USB flash drive can be removed. Removing the
USB flash drive at this point reduces the risk of other USB activity during the upgrade
process. This ensures the upgrade process is faster and more reliable.
(2) A backup to USB can take over 2 hours to complete and is not necessary in most
cases. If you do require a backup, remove the USB flash drive after the backup has
completed. Removing the USB flash drive after the backup has completed reduces
the risk of other USB activity during the upgrade process. This ensures the upgrade
process is faster and more reliable.
(11) Select Upgrade now.
(12) The printer will now begin the upgrade process which will take between 11 and 22 minutes
to complete.
(13) If the upgrade fails the software can be rolled back to a previous version, see page 18-6.
You can then try the upgrade process again. If the upgrade continues to fail, replace the
printer’s Micro SD card, see page 15-43.
End of procedure.

18-4 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

Check Printer Settings

The procedure below is recommended to check the printer settings after the software has been
upgraded from a very old version. From v01.00.0026Rev26 onwards most of these printer settings
are remembered by the printer. An Engineer’s USB key is required to change some of the settings.
It is recommended to create a new label in the new software version if time allows. This will ensure
there are no incompatibility issues between old labels created in old software and the new
software.
It is also recommended to complete encoder calibration in the new software version. This will
ensure the encoder calibration is correct. Print a label and check that the label length shown in the
label editor preview screen is the same as the printed label.
Check the following printer settings:
(1) Select Home > Setup > Regional > Date & time. Check and update the “System date” and
“System time”.
(2) Select Home > Setup > System information > Overview. Check and update the “Printer
model”, “Printer name” and “Serial number”.
(3) Select Home > Setup > Advanced > Hardware. Check and update the “Print head”, “Pump
Type” and “Ink System”.
Notes: (1) Most standard dye based printers = ITM02 or ITM04 / EPT011933 pump / Standard
ink system
(2) Most heavy duty printers = ITM03 / EPT015770 pump / Opaque ink system.
(5) Select Home > Setup > Advanced > Ink details. Check and update the “Current ink” to your
appropriate ink type if different.
(6) Select Home > Setup > Adjustment > Installation. Check and update the “Pelter mode” and
“Airdryer/Positive air pump” settings.
Note: Peltier selection is only available on Ax350i/Ax550i printers equipped with a Green
Pack.
(7) For a direct Domino Cloud Interface (DCI) connection, the Ethernet settings need to be
checked and set. [Link] / Subnet [Link] / Default [Link] / DNS [Link]
/ INTERCOMM 4 / 700.
(8) Calibrate the ink and make-up level sensor, see page 15-59.
End of procedure.

EPT026795 Issue 17 June 2020 18-5

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

SOFTWARE ROLLBACK
Note: This feature was added in software version 01.30.0073.
The procedure below describes how to rollback the printer’s software to the previous version.
To rollback the software to the previous version:
(1) On the TouchScreen, select Home > Setup > Production line setup > Power options >
Restart and wait for the printer to restart.
(2) Select Rollback during the bootup sequence.
(3) Enter the pin number: 3123
Notes: (1) Rollback will start as soon as the pin is entered.
(2) Restart the procedure from step one if the wrong pin is entered.

Rollback Pin Number Entry

End of procedure.

18-6 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

BACKUP AND RESTORE

Service Backup
The Domino Technical Support Group (TSG) will always request the printer’s service backup files
when you report an issue. To save time, create a service backup before contacting TSG.
The printer’s service backup files provide information for service engineers. Information includes
log files, labels, screen shots, diagnostic data, jet profile and uber logs.
Service backup files cannot be copied back to the printer, the files are for information only.
A service backup can be completed when the ink jet is on and the printer is running.
Service backup times can take up-to thirty minutes depending on the printer state, number of
alerts and the data quantity.

Create a Service Backup

To create a service backup:
(1) Insert a USB flash drive into the USB port on the TouchScreen.
(2) Wait for the USB icon on the information bar to turn green.
(3) Select, Home > Setup > Backup & Restore > Backup.
(4) Select the Select backup type drop down setting and select Service.

(5) Select Backup.

(6) A prompt will display when the backup is complete, select OK to clear the prompt.
(7) Remove the USB flash drive from the printer and insert it into a computer.
(8) Open the computer’s file explorer and navigate to the USB flash drive’s root folder.

EPT026795 Issue 17 June 2020 18-7

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

(9) Open the DominoBackup folder. The backup file will be available as a “.zip” file.

End of procedure.

18-8 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

Label Backup
A label backup will copy all the labels in the current label store. The label backup files can also be
copied (restored) to other printers or retained to restore the original printer’s label files.

Create a Label Backup

To create a backup of the printer’ labels:
(1) Insert a USB flash drive into the USB port on the TouchScreen.
(2) Wait until the USB icon on the information bar turns green.

(3) Select, Home > Setup > Backup & Restore > Backup.
Notes: (1) The “Select folder for backup” setting can be used to select a specific folder on the
USB flash drive to save the backup file to.
(2) The “Optional reference string” setting can be used to enter information that will help
identify the backup file after it is saved on the USB flash drive.
(4) Select the Select backup type drop down setting and select Label.
(5) Select Backup.
(6) A prompt will display when the backup is complete, select OK to clear the prompt.
(7) Remove the USB flash drive from the TouchScreen.
End of procedure.

Restore Labels from a Backup

Only Label backup files can be restored to the printer. The backup file will override the current
labels that are saved on the printer.
Note: It is necessary to restart the printer as part of the restore procedure.
To restore the printer’s labels from a label backup file:
(1) Insert the USB flash drive containing the backup file into the USB port on the TouchScreen.
(2) Wait until the USB icon on the information bar turns green.

(3) Select, Home > Setup > Backup & Restore > Restore.
(4) Select the Select backup file setting.
(5) Select the label backup file.
(6) Select Restore.
(7) A prompt will display when the restore is complete, select OK to clear the prompt.
(8) Remove the USB flash drive from the TouchScreen.
(9) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

EPT026795 Issue 17 June 2020 18-9

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

SAVE CONFIGURATION AS FACTORY DEFAULT

To save the printer’s current configuration as the factory default:
(1) Insert an engineer’s USB key into a USB slot on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select, Home > Setup > Backup & Restore > Defaults.
(3) Select Save configuration as factory defaults.
(4) Select Home > Setup > Production line setup > Power options > Restart.
End of procedure.

18-10 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

LOG FILES
The printer’s service log files may be requested by the Domino Technical Support Group (TSG) to
diagnose and resolve printer faults.
The printer saves following types of information as log files in it’s internal memory:
• Alert Log
• Status Log
• Data Log
• Config Log
• Audit Log
• IC comms Log
Log files can be viewed on the TouchScreen and exported to a USB flash drive. If a log file is
exported it will be saved with a .csv file extension.

View Log Files on TouchScreen

To view the log files on the TouchScreen:
(1) Select Home > Setup > Diagnostics > Logs.
(2) Select Open next to the required log.

Open Logs

End of procedure.

EPT026795 Issue 17 June 2020 18-11

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

Export Log Files to USB

To export log files to a USB flash drive:
(1) Insert a USB flash drive into a USB port on the TouchScreen.
(2) Wait until the USB icon on the information bar turns green.

(3) Select Home > Setup > Diagnostics > Logs.

(4) Select the Export icon next to the required log.

Open Logs

(5) Select the Path data entry box, open the USB folder and select Select.
(6) Select Export
(7) Select Ok.
(8) Remove the USB flash drive from the TouchScreen.
End of procedure.

18-12 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

UBER LOG FILES

An uber log is a file which contains a detailed record of printer parameters and status information.
Uber log files are automatically created and saved each time a red alert occurs. The log will record
four hours of data leading up to the alert and four hours of data after the alert. Only the last five
red alert uber log files will be saved in the printer’s memory.
An Uber log file will be automatically saved when a service backup of the printer is created, see
page 18-7. When a service backup is created the uberlog file will record the eight hours of data
immediately before the service backup is created.
Additionally, uber log files can be manually created by an on-site engineer. A manual uberlog will
record the eight hours of data immediately before the manual uberlog is created.
Manually Create an Uber Log File
To manually create an uber log file:
(1) Select Home > Setup > Diagnostics > Tests.
(2) Scroll down to Uberlog manual save and select Run test.

Run Test

(3) A prompt will display when the manual save is complete, select OK to clear the prompt.
End of procedure.

EPT026795 Issue 17 June 2020 18-13

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

Export Uber Log Files to USB

Note: A USB flash drive and computer are required for this procedure.
The printer’s uber log files can be exported to a USB flash drive by completing a service backup.
To export the uber log files to a USB:
(1) Insert a USB flash drive into the USB port on the TouchScreen.
(2) Wait until the USB icon on the information bar turns green.

(3) Select, Home > Setup > Backup & Restore > Backup.
Notes: (1) The “Select folder for backup” setting can be used to select a specific folder on the
USB flash drive to save the backup file to.
(2) The “Optional reference string” setting can be used to enter information that will help
identify the backup file after it is saved on the USB flash drive.
(4) Select the Select backup type drop down setting and select Service.
(5) Select Backup.
(6) A prompt will display when the backup is complete, select OK to clear the prompt.
(7) Remove the USB flash drive from the printer and insert it into a computer.
(8) Open the computer’s file explorer and navigate to the USB flash drive’s root folder.
(9) Open the DominoBackup folder and unzip the BACKUP_SERVICE_XXXXX.zip file.

Backup Service File

(10) Open StorageCard2 > Diagnostics > DataCollection. The uber log .csv files can be copied to
the computer or opened in Microsoft Excel.

Uber Log Files

End of procedure.

18-14 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

R-DRIVE MICRO SD CARD IMAGE

The Domino Technical Support Group (TSG) may request an image of a printer’s micro SD card to
diagnose and resolve printer faults.
R-Drive Image software can be used to create and restore an exact image of the printer’s micro
SD card. A 30 day free trial of the R-Drive Image software can be downloaded from
[Link]. After the 30 day trial is over, the user will be required to purchase a
license.

Create an Image of the Micro SD Card

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required equipment: T10 torx driver, micro SD card reader, PC, R-Drive Image software.
To create an image of the printer’s micro SD card:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the rear access panel to the printer’s electronics compartment.

EPT026795 Issue 17 June 2020 18-15

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

(4) Locate the micro SD card on the main PCB. Push in the micro SD card to release it, then
slide it out of the socket.

Micro SD Card

(5) Insert the micro SD card into a micro SD card reader and connect it to a PC.
(6) Start the R-Drive software and select Create an Image.

18-16 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

(7) Select the micro SD card, then select Next.

Note: Click on the box in front so that the whole SD card is selected. If you click on the blue
bar, only one partition will be selected.

(8) Select a folder to store the image, give the image file a name and select Next.

EPT026795 Issue 17 June 2020 18-17

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

(9) Select the smallest image size, enter important information in the Description text box and
select Next.

(10) Select Next.

18-18 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

(11) Select Start.

Note: The imaging process will take between one and two minutes.

(12) When the imaging process in complete, replace the micro SD card in the micro SD card
socket on the printer’s main PCB.
(13) Refit the access panel to the printer’s rear electronics compartment.
(14) Connect the power lead to the rear of the printer.
(15) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

EPT026795 Issue 17 June 2020 18-19

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

Restore from an Image of the Micro SD Card

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: High voltage electricity. Risk of death or injury from electric shock.

To avoid injury, disconnect the mains power supply before accessing the printer’s
electronics compartment.

CAUTION: Electrostatic sensitive components. Risk of damage to printer.

Required equipment: T10 torx driver, micro SD card reader, PC, R-Drive Image software.
To restore a printer’s micro SD card from an image:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the rear access panel to the printer’s electronics compartment.
(4) Locate the micro SD card on the main PCB. Push in the micro SD card to release it and slide
it out of the socket.

Micro SD Card

(5) Insert the micro SD card into a micro SD card reader and connect it to a PC.

18-20 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

(6) Start the R-Drive software and select Restore from an Image.

(7) Select the image file to be restored, then select Next.

EPT026795 Issue 17 June 2020 18-21

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

(8) Select Next.

(9) Select the source partitions to be restored, select the destination micro SD card then select
Next.
Note: Click on the box in front so that the whole image and destination SD card are selected.
If you click on the blue bar, only one partition will be selected.

18-22 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

(10) Select the Raw disk copy option and select Next.

(11) Select Start.

Note: The restore process will take between one and two minutes.

EPT026795 Issue 17 June 2020 18-23

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

(12) When the restore process is complete, replace the micro SD card in the micro SD card
socket on the printer’s main PCB.
(13) Refit the access panel to the printer’s rear electronics compartment.
(14) Connect the power lead to the rear of the printer.
(15) Press and hold the standby button for 2 seconds and wait for the printer to start up.
End of procedure.

18-24 EPT026795 Issue 17 June 2020

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

UI SCREENSHOT
Note: Screenshots cannot be taken if a popup box is open on the UI.
Screenshots can be taken of the user interface and saved to a USB flash drive, or saved internally
then exported to a USB flash drive when a backup is created.

Save to USB Flash Drive

To save a UI screenshot directly to a USB flash drive:
(1) Insert a USB flash drive into the USB port on the TouchScreen.
(2) Wait until the USB icon on the information bar turns green.

(3) Select and hold the light grey bar at the bottom of the UI.
Note: A popup box will confirm the location and name of the screenshot file after it has been
created.

Screenshot Creation

End of procedure.

EPT026795 Issue 17 June 2020 18-25

SOFTWARE UPGRADE, BACKUP/RESTORE AND LOGS

Save Internally
To save a UI screenshot internally to export later when a service backup is created:
(1) Select and hold the light grey bar at the bottom of the UI.
Note: A popup box will confirm the location and name of the screenshot file after it has been
created.

Screenshot Creation

(2) Create a service backup to export the screenshot, see page 18-7.
End of procedure.

18-26 EPT026795 Issue 17 June 2020

PART 19 : ADVANCED SOFTWARE SETTINGS

CONTENTS
Page
INTRODUCTION .................................................................................................................... 19-3
PRINT HEAD MANUAL MODE .............................................................................................. 19-3
INK SYSTEM MANUAL MODE .............................................................................................. 19-5
INK DETAILS .......................................................................................................................... 19-6
i-Tech Module ................................................................................................................... 19-6
Ink Cartridge ...................................................................................................................... 19-8
Make-up Cartridge ............................................................................................................ 19-9
Ink Details .......................................................................................................................... 19-10
PRINTER HARDWARE SETTINGS ......................................................................................... 19-11
Print Head ......................................................................................................................... 19-11
Nozzle Size (μm) ................................................................................................................ 19-11
Conduit Length (m) ............................................................................................................ 19-11
Printhead Series ................................................................................................................ 19-11
Duo Print Head .................................................................................................................. 19-11
Modulation Frequency (kHz) ............................................................................................. 19-11
Modulation Mode .............................................................................................................. 19-12
Ink Container ..................................................................................................................... 19-12
Pump Type ........................................................................................................................ 19-12
Flush Valve Type ............................................................................................................... 19-12
Starting Mode .................................................................................................................... 19-12
Warm-up Mode ................................................................................................................. 19-13
Wake-up Mode .................................................................................................................. 19-13
Enable/Disable Wake-up Mode ........................................................................................ 19-13
Set a Custom Wake-up Mode Interval .............................................................................. 19-14
Ink System ......................................................................................................................... 19-15
ITM Type Required ............................................................................................................ 19-15
Use Default ITM Life .......................................................................................................... 19-15
GUTTER PUMP SETTINGS ................................................................................................... 19-16
DIAGNOSTIC TESTS ............................................................................................................. 19-17

EPT026795 Issue 17 June 2020 19-1

ADVANCED SOFTWARE SETTINGS

THIS PAGE INTENTIONALLY LEFT BLANK

19-2 EPT026795 Issue 17 June 2020

ADVANCED SOFTWARE SETTINGS

INTRODUCTION
This chapter describes the settings that are available on the printer’s Advanced screen. Many of
these settings can only be adjusted with the use of an Engineer’s USB key.

PRINT HEAD MANUAL MODE

CAUTION: Risk of damage to printer’s ink system

Do not use print head manual mode unless trained. In-proper use of print head
manual mode will damage the printer.

To manually control the print head:

(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Print head manual mode.
(3) The settings described below are available for adjustment. Make a note of the settings
before changing them.
Note: Settings for Jet 1 and Jet 2 will be available on printers equipped with an i-Pulse Duo
print head.

Table 1: Print Head Manual Mode Settings

Setting Name Description

Skip next flush Tick the tick box to skip the flush sequence when the printer
is next shut down and re-started.
CAUTION: If the tick box is selected and the
printer is shut down, re-start the
printer as soon as possible.
Otherwise ink will dry up and block
the gutter and nozzle.

EPT026795 Issue 17 June 2020 19-3

ADVANCED SOFTWARE SETTINGS

Table 1: Print Head Manual Mode Settings

Setting Name Description

Sequence to Sequence the printer to one of the following states:

Sequence on - The ink jet will sequence on and start

running. When the printer receives a valid encoder and print
trigger signal the printer will print.

Sequence off - The print head will be flushed and the printer
will shut down.

Pause printing - Printing will be paused, power to the

deflector plates will be stopped.

Fast shutdown - The printer will skip the flush routine and
quickly shut down.

Jet running - The printer will sequence to jet running. No

phasing or power to the deflector plates are present.

Phase locked - The printer will sequence to phase locked.

Modulation and charging will be present, but no power to
the deflector plates.
Heater state Enable or disable the heater on the drop generator
assembly.
Auto modulation start voltage Set the start voltage that the printer will start from when
looking for a modulation peak.
Temperature (°C) Displays the temperature of the drop generator assembly.
Temperature set point (°C) Change the temperature set point of the drop generator
assembly.

(4) Remove the engineer’s USB key from the printer or TouchScreen.
End of procedure.

19-4 EPT026795 Issue 17 June 2020

ADVANCED SOFTWARE SETTINGS

INK SYSTEM MANUAL MODE

CAUTION: Risk of damage to printer’s ink system

Do not use ink system manual mode unless trained. In-proper use of ink system
manual mode will damage the printer.

To manually control the ink system:

(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Ink system manual mode.
(3) The settings described below are available for adjustment. Make a note of the settings
before changing them.

Table 2: Ink System Manual Mode Settings

Setting Name Description

Feed valve closed/open Tick the tick box to close/open the valve that feeds ink to
the print head.
Viscometer valve closed/open Tick the tick box to close/open the valve that feeds ink to
the viscometer.
Bleed valve closed/open Tick the tick box to close/open the bleed valve.
Make-up valve closed/open Tick the tick box to close/open the make-up valve.
Nozzle valve closed/open Tick the tick box to close/open the nozzle valve in the print
head.
Wash valve closed/open Tick the tick box to close/open the wash valve.
Pump state Displays the status of the ink pump.
Current pressure (mBar) Displays the ink system pressure.
Pressure set point (mBar) Adjust the ink system pressure set point.
Current pump speed (rpm) Displays current ink pump speed in rpm.
Speed set point (rpm) Adjust the ink pump speed.
Gutter dry alert enabled Enable or disable the gutter dry alert.
Gutter pump speed set point Adjust the gutter pump speed.
(rpm)
Gutter pump speed (rpm) Displays current gutter pump speed in rpm.
Gutter pump enabled Enable or disable the gutter pump.

(4) Remove the engineer’s USB key from the printer or TouchScreen.
End of procedure.

EPT026795 Issue 17 June 2020 19-5

ADVANCED SOFTWARE SETTINGS

INK DETAILS
To view the Ink details screen, select Home > Setup > Advanced > Ink details.
The ink details screen displays information stored in RFID tags on the printer’s consumable items.
Engineers certified by Domino can use an engineer’s USB key to adjust the grace period that the
printer will continue to run for after an ITM expiry date. The engineer’s USB key can also be used
to adjust the notice period given before an item is due to expire.

i-Tech Module
The i-Tech module screen is used to view ITM information and adjust the ITM grace period.
To access the i-Tech module screen:
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Ink details > i-Tech module.
(3) The settings described below are available to view or adjust.

Table 3: i-Tech Module Settings

Setting Name Description

Capacity Displays the capacity of the ITM.

Serial number 1 Displays the serial number of the first printer that the ITM
was fitted to.
Timestamp 1 Displays the time that the ITM was fitted to the printer the
printer described in the Serial number 1 setting.
Serial number 2 Displays the serial number of the second printer that the ITM
was fitted to.
Timestamp 2 Displays the time that the ITM was fitted to the printer the
printer described in the Serial number 2 setting.
Life data Displays technical informatory about the ITM.

ADVANCED SOFTWARE SETTINGS

Ink Details
The ink details screen is used to view information about the ink system configuration and adjust
the ink system configuration.
To access the ink details screen:
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Ink details > Makeup cartridge.
(3) The settings described below are available to view or adjust.

Table 6: Ink Cartridge Settings

Setting Name Description

Current ink Select which type of ink that the printer is configured to use.
If an ink cartridge of a different type is inserted into the
printer a red alert will be displayed and the printer will not
run.
Ink version Displays ink version information.
Wash type Displays the type of wash that is compatible with the
currently selected ink type.
Make-up type Displays the type of make-up that is compatible with the
currently selected ink type. If a make-up cartridge of a
different type is inserted into the printer a red alert will be
displayed and the printer will not run.
Class Displays the ink system class.
System Displays the ink system type.
Use default viscosity setting Use the default ink viscosity setting, or de-select the tick
box to manually adjust the target ink viscosity.
Target viscosity (cP) Manually adjust the target ink viscosity.
Depletion mode Enable or disable depletion mode.

When the ITM is due for replacement at a standard service

interval, the user will be informed to remove the ink cartridge
and allow the ITM to use all the existing ink before the unit is
replaced. This “Depletion mode” minimizes the amount of
ink wasted when the ITM unit is finally replaced.

(4) Remove the engineer’s USB key from the printer or TouchScreen.
End of procedure.

19-10 EPT026795 Issue 17 June 2020

ADVANCED SOFTWARE SETTINGS

PRINTER HARDWARE SETTINGS

The hardware screen is used to view and adjust the printer’s hardware configuration. These
settings are defined at the factory, but can be changed by an engineer if the printer’s hardware is
changed in the field.
The settings and fields available on the Hardware screen are described below.
To access the Hardware screen select Home > Setup > Advanced > Hardware.
An engineer’s USB key is required to change any setting on this screen.

Print Head
This setting defines the type of print head, nozzle size and conduit length installed on the printer.
This setting is defined at the factory but can also be changed by an engineer in the field.
To change the print head setting:
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Hardware.
(3) Select the Print head drop down setting and select the correct print head, nozzle size and
conduit length combination.
(4) Remove the engineer’s USB key.
End of procedure.

Nozzle Size (μm)

This field displays the size of the nozzle installed in the print head. To change this field, the
Printhead setting must be changed.

Conduit Length (m)

This field displays the printer’s conduit length. To change this field, the Printhead setting must be
changed.

Printhead Series
This field displays the print head series. To change this field, the Printhead setting must be
changed.

Duo Print Head

This setting displays if the print head is a duo or not. To change this field, the Print head setting
must be changed.

Modulation Frequency (kHz)

This setting displays the current modulation frequency.

EPT026795 Issue 17 June 2020 19-11

ADVANCED SOFTWARE SETTINGS

Modulation Mode
This setting allows the modulation mode to be changed between auto and fixed. During normal
operation it is recommended to leave the modulation mode set to auto.
To change the modulation mode:
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Hardware.
(3) Select the Modulation mode setting and select the required value.
(4) Remove the engineer’s USB key.
End of procedure.

Ink Container
This field displays the type of container that the printer uses to store ink.

Pump Type
This setting defines the type of ink pump that the printer is fitted with. This setting must match the
ink pump that is fitted to the printer or the pump will not work correctly.
For details on pump replacement, see page 16-51.

Flush Valve Type

This setting enables a newer type of flush valve to be used in Ax-Series printers. The default
software setting is “EPT034806”. This setting which will work with new and older flush valve
hardware types.
The flush valve type setting is important for Duo print heads which require a physical EPT034806
flush valve and the correct matching software setting.
The flush valve type setting “EPT024821” is for older flush valve hardware types. If this setting is
selected the printer’s flushing routine will change because of different flow efficiencies.
To change the flush valve software type:
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Hardware.
(3) Select the Flush valve type setting and select the required value.
(4) Remove the engineer’s USB key.
End of procedure.

Starting Mode
This field displays the printer’s starting mode. This field cannot be changed in the current
software version.

19-12 EPT026795 Issue 17 June 2020

ADVANCED SOFTWARE SETTINGS

Warm-up Mode
Warm-up mode can be used in cold or harsh environments to reduce condensation inside print
head. Condensation inside the print head can cause EHT trips to occur.
When warm-up mode is enabled, the ink jet will automatically sequence to jet running when the
standby button is pressed. This encourages the ink, ink system, and print head to warm up prior
to printing.
To enable or disable warm-up mode:
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Hardware.
(3) Tick or untick the Warm-up mode tick box.
(4) Remove the engineer’s USB key.
End of procedure.

Wake-up Mode
Wake-up mode ensures the ink remains at a good viscosity inside the printer during long periods
of idle time. When this setting is enabled, the wake-up routine will run the printer’s main pump for
2-3 minutes every 20 minutes to agitate the ink. The 20 minute interval value can be changed if
required.

Enable/Disable Wake-up Mode

Setting Name Explanation

Factory default Set the wake-up mode to the factory default setting.
On Enable wake-up mode.
Off Disable wake-up mode.

EPT026795 Issue 17 June 2020 19-13

ADVANCED SOFTWARE SETTINGS

Set a Custom Wake-up Mode Interval

19-14 EPT026795 Issue 17 June 2020

ADVANCED SOFTWARE SETTINGS

Ink System
This setting defines the type of ink system that the printer is fitted with. Unless the printer’s
hardware has been changed, or the ink system type has been set wrong, it is note recommended
to change this setting.
To change the ink system setting:
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Hardware.
(3) Select the Ink system drop down setting.
(4) Select the ink system type.
(5) Remove the engineer’s USB key.
End of procedure.

ITM Type Required

This field displays the type of ITM that the printer uses.
• ITM02 / ITM06 = ITM Type 2 or ITM Type 6, used in printers equipped with a standard ink
system.
• ITM03 = ITM Type 3, used in printers equipped with a heavy duty ink system.

Use Default ITM Life

In harsh environments, it maybe necessary to replace the ITM more frequently. The default life for
all ITMs installed in the printer can be reduced. This will ensure the ink filters stay cleaner to
improve print quality in harsher environments.
Note: This will reduce the lifetime of any ITM installed in the printer. The ITM life cannot be
increased again.
To increase the frequency of ITM changes (reduce default ITM life):
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen, select Home > Setup > Advanced > Hardware.
(3) De-select the Use default ITM life tick box.
(4) Adjust the ITM life (hours/months) settings:

ITM life (hours) Set the total life in months for an ITM type 2, 3 and 4.
ITM life (months) Set the total life in ink jet running hours for an ITM type 6.

(5) Remove the engineer’s USB key.

End of procedure.

EPT026795 Issue 17 June 2020 19-15

EPT026795 Issue 17 June 2020 20-1

ADJUSTMENT SETTINGS

THIS PAGE INTENTIONALLY LEFT BLANK

20-2 EPT026795 Issue 17 June 2020

ADJUSTMENT SETTINGS

INTRODUCTION
This chapter describes the settings that are available on the printer’s “Adjustment” screen. Many
of these settings can only be adjusted with the use of an Engineer’s USB key.

BUP Time
To view the BUP time, select Home > Setup > Adjustment.
The break up time (BUP time) displays the time (in microseconds) from the point that the ink
begins to break up into drops to the point that the ink drops are detected in the phase detector.

Charge Electrode

Break up Time
(BUP Time)

Phase Detector

To ensure a drop of ink is successfully charged, the ink drop must break off within the charge
electrode slot. The position of the jet break up will move during normal operation due to changes
in ink viscosity, temperature and print head elevation. The BUP time is adjusted by changing the
modulation voltage. When the printer’s modulation mode is set to “Auto”, the printer will measure
the BUP time and use this value to set the modulation voltage.
Note: It is recommended to leave the modulation mode in Auto during normal operation.

EPT026795 Issue 17 June 2020 20-3

ADJUSTMENT SETTINGS

Airdryer / Positive Air Pump

A positive air pump (if fitted) pumps air from the printer cabinet into the print head. This creates
positive air pressure inside the print head to keep dust and other contaminants out. For more
information, see page 9-4.
An air drier removes moisture from factory supplied air before air is fed into the printer cabinet and
print head. For more information, see page 9-8.
The airdryer / positive air pump setting enables an engineer to enable or disable the software that
controls the air drier and positive air pump.
To set the airdryer / positive air pump setting:
(1) Insert an engineer’s USB key into a USB slot on the TouchScreen or printer cabinet.
(2) Select Home > setup > Adjustment > Installation.
(3) Select the Airdryer / Positive air pump drop down setting.
(4) Select Installed or Not present.
(5) Remove the engineer’s USB key.
End of procedure.

EPT026795 Issue 17 June 2020 20-7

ADJUSTMENT SETTINGS

Airdryer Mode
An air drier removes moisture from factory supplied air before air is fed into the printer cabinet and
print head. For more information, see page 9-8.
The airdryer mode setting defines when the air drier will start and stop running.
To set the airdryer mode:
(1) Insert an engineer’s USB key into a USB slot on the TouchScreen or printer cabinet.
(2) Select Home > setup > Adjustment > Installation.
(3) Select the Airdryer mode drop down setting and select one of the modes described in the
table below.
Table 3: Airdryer Mode Settings

Mode Name Description

Standard Mode The air dryer will start running as soon as the ink jet starts running. The
air dryer will stop when the printer is sequenced off.
Extended Mode The air dryer will start running during the software loading process when
the printer is switched on. The air dryer will only stop when the printer is
shut down.
(4) Remove the engineer’s USB key.
End of procedure.

20-8 EPT026795 Issue 17 June 2020

ADJUSTMENT SETTINGS

INSPECTION
The inspection screen contains settings that allow the printer’s service date to be checked and
changed. The printer’s replacement history can also be viewed on this screen.

Service Interval Requires Key

Changing the date that the printer requires a service normally requires the use of an Engineer’s
USB key. The “Service Interval requires key” setting enables an engineer to unlock the “Next
service” setting to allow any user to change the printer’s next service date.
To change the service interval requires key setting:
(1) Insert an engineer’s USB key into a USB slot on the TouchScreen or printer cabinet.
(2) Select Home > Setup > Adjustment > Inspection.
(3) Select or de-select the Service interval requires key tick box.
(4) Remove the engineer’s USB key.
End of procedure.

Next Service/Hours to Next Service

This setting displays either the date that the next service is required, or number of hours until the
next service is required. Changing the value normally requires an engineer’s USB key, however
the setting can be unlocked to allow any user to change it, see the previous procedure for more
information.
To change the next service/hours to next service setting:
(1) Insert an engineer’s USB key into a USB slot on the TouchScreen or printer cabinet.
(2) Select Home > Setup > Adjustment > Inspection.
(3) Select the Next Service/Hours to next service value.
(4) Enter a new value and select Save.
(5) Remove the engineer’s USB key.
End of procedure.

Service Time Mode

This setting changes the way in which the “Next service” value is displayed and set. The “Next
service” value can be shown as a specific date or as the number of hours before the next service
is required.
To change the service time mode:
(1) Insert an engineer’s USB key into a USB slot on the TouchScreen or printer cabinet.
(2) Select Home > Setup > Adjustment > Inspection.
(3) Select the Service time mode drop down setting and select either Date or Hours.
(4) Remove the engineer’s USB key.
End of procedure.

EPT026795 Issue 17 June 2020 20-9

ADJUSTMENT SETTINGS

View Replacement History

When certain parts of the printer are replaced, details of the replacement can be saved to create a
history which may be useful when diagnosing printer faults.
Note: The replacement history may not be accurate if the log has not been kept up to date
by those working on the printer.
To view the replacement history:
(1) Select Home > Setup > Adjustment> Inspection > View...
(2) The following information will be displayed:
• Date of replacement.
• Spare part name.
• Operator.
• Notes.
(3) Select Save to exit the replacement history screen.
End of procedure.

Update Replacement History

To update the replacement history:
(1) Select Home > Setup > Adjustment > Inspection > Add...
(2) Select the Replaced part drop down setting and select one of the following options:
• Air filter.
• Air drier.
• Pump.
• PSU.
• Electronics board set.
(3) Select Operator name and enter your name.
(4) Select Notes and enter any useful notes about the replaced part.
End of procedure.

20-10 EPT026795 Issue 17 June 2020

PART 21 : DIAGRAMS

CONTENTS
Page
EXTERNAL CONNECTIONS .................................................................................................. 21-3
Ax150i ............................................................................................................................... 21-3
Ax350i/Ax550i ................................................................................................................... 21-4
CABINET DIMENSIONS ......................................................................................................... 21-5
Ax150i ............................................................................................................................... 21-5
Ax350i ............................................................................................................................... 21-6
Ax550i ............................................................................................................................... 21-7
PRINT HEAD DIMENSIONS ................................................................................................... 21-8
i-Pulse ............................................................................................................................... 21-8
i-Pulse Duo ........................................................................................................................ 21-9
i-Pulse RS with 60μ Nozzle ............................................................................................... 21-10
i-Pulse RS with 75μ Nozzle ............................................................................................... 21-11
TOUCHSCREEN DIMENSIONS ............................................................................................. 21-12
Remote TouchScreen 7" ................................................................................................... 21-12
Remote TouchScreen 10" ................................................................................................. 21-12
CABINET LABELS .................................................................................................................. 21-13
External Printer Configuration Label ................................................................................. 21-13
Internal Printer Configuration Label .................................................................................. 21-14
Ax150i External Connections Label .................................................................................. 21-15
Ax350i/Ax550i External Connections Label ...................................................................... 21-16
INK SYSTEM DIAGRAMS ...................................................................................................... 21-17
Standard Ink System ......................................................................................................... 21-17
Heavy Duty Ink System ..................................................................................................... 21-18
Distribution Block Component Diagram ........................................................................... 21-19
Distribution Block Piping Diagram .................................................................................... 21-20
ELECTRONICS SYSTEM OVERVIEW DIAGRAM .................................................................. 21-21
Main PCB Overview .......................................................................................................... 21-22
Main PCB Component Locations ..................................................................................... 21-24
Main PCB LED Indication .................................................................................................. 21-27
Product Detect / Shaft Encoder PCBA Layout ................................................................. 21-28
Product Detect/Shaft Encoder Connectors (J3, J5) ...................................................... 21-29
Internal Interface to Main PCB (J4) ............................................................................... 21-29
i-Pulse Print Head PCBA ................................................................................................... 21-30
Conduit Connector (J1) ................................................................................................ 21-31
Charge and Strobe Connector (J2)................................................................................ 21-32
Drop Generator Assembly Connector (J3) ................................................................... 21-32
Phase Sensor Input Connector (J4)............................................................................... 21-33
EHT Trip Sensor Input Connector (J5) .......................................................................... 21-33

EPT026795 Issue 17 June 2020 21-1

DIAGRAMS

THIS PAGE INTENTIONALLY LEFT BLANK

21-2 EPT026795 Issue 17 June 2020

DIAGRAMS

EXTERNAL CONNECTIONS
Ax150i
* - Standard Fit.
** - Pack Option.

Product Detect /
Shaft Encoder*
Alarm
Connector**

Beacon
Product Detect / Connector**
Shaft Encoder*

Ethernet**

RS232**

USB Type A**

GPIO**

Ax150i External Connections Left View

Power
Connector*

Ax150i External Connections Rear View

EPT026795 Issue 17 June 2020 21-3

DIAGRAMS

Ax350i/Ax550i
* - Standard Fit.
** - Pack Option.
Product Sensor /
Shaft Encoder*

TouchScreen Product Sensor /

Connector* Shaft Encoder*

Extended GPIO**

GPIO**

RS232** Beacon
Connector**

Alarm
Connector**
Ethernet**

Powered
HMI** USB Type A**

Control
Port**

Power
Connector*

Ax350i/Ax550i External Connections

21-4 EPT026795 Issue 17 June 2020

DIAGRAMS

CABINET DIMENSIONS
Ax150i

373mm
400mm 394mm

Ax150i Cabinet Dimensions

873mm

Ax150i Cabinet Dimensions With Open Doors

EPT026795 Issue 17 June 2020 21-5

DIAGRAMS

Ax350i

411mm
430mm 381mm

Ax350i Cabinet Dimensions

1018mm

Ax350i Cabinet Dimensions With Open Doors

21-6 EPT026795 Issue 17 June 2020

DIAGRAMS

Ax550i

411mm
430mm 381mm

Ax550i Cabinet Dimensions

1018mm

Ax550i Cabinet Dimensions With Open Doors

EPT026795 Issue 17 June 2020 21-7

DIAGRAMS

PRINT HEAD DIMENSIONS

i-Pulse

65mm (2.56")
Minimum bend
radius.

21.5mm
(0.85")
221.5mm (8.72")

135mm (5.31")

50mm (2.0") 50mm (2.0")

i-Pulse Print Head Dimensions

21-8 EPT026795 Issue 17 June 2020

DIAGRAMS

i-Pulse Duo

65mm (2.56")
Minimum bend
radius.

28mm
(1.10")
255mm (10")

3.30mm
(0.13")
7.60mm
(0.30")
148mm (5.83")

57mm (2.24") 49.7mm

(1.96")

i-Pulse Duo Print Head Dimensions

EPT026795 Issue 17 June 2020 21-9

DIAGRAMS

i-Pulse RS with 60μ Nozzle

70mm minimum inside bend

radius for a fixed installation.
150mm best radius for a
continuous flex installation
72.5mm
243.1mm

111.5mm

Ø 40mm

i-Pulse RS Print Head Dimensions

21-10 EPT026795 Issue 17 June 2020

DIAGRAMS

i-Pulse RS with 75μ Nozzle

70mm minimum inside bend

radius for a fixed installation.
150mm best radius for a
continuous flex installation
72.5mm
251.6mm

120mm

Ø 40mm

i-Pulse RS Print Head Dimensions

EPT026795 Issue 17 June 2020 21-11

DIAGRAMS

TOUCHSCREEN DIMENSIONS
Remote TouchScreen 7"

232mm
307mm 75mm

Remote TouchScreen 7" Dimensions

Remote TouchScreen 10"

160mm

245mm 50mm

Remote TouchScreen 10" Dimensions

21-12 EPT026795 Issue 17 June 2020

DIAGRAMS

CABINET LABELS
External Printer Configuration Label

External Printer Configuration Label

EPT026795 Issue 17 June 2020 21-13

DIAGRAMS

Internal Printer Configuration Label

21-14 EPT026795 Issue 17 June 2020

DIAGRAMS

Ax150i External Connections Label

EPT026795 Issue 17 June 2020 21-15

Ax350i/Ax550i External Connections Label
21-16

DIAGRAMS
EPT026795 Issue 17 June 2020

Ax350i/Ax550i External Connections Label

INK SYSTEM DIAGRAMS
EPT026795 Issue 17 June 2020

Standard Ink System

Ink Pump Gear (Dye low flow)
Ink Cooler
(in intermediate zone)

Pressure Bleed
Transducer Valve
1 2
Blue
Stripe 2
Wash Ink
Valve Temp
1
Damper

2 1
Jet Pump
Feed ø 0.5mm
Red Valve
2
Stripe Ø 0.3mm
Make-up Restrictor

DIAGRAMS
Valve
1
Nozzle
Valve Gutter
Vacuum
Flush Transducer Pump Viscometer
NRV Valve

PRV (80 mBar)

1 2

8 7 6 5 4 3 2 1
Print Head

MU Ink
Cartridge Cartridge

No Viscometer
Stripe

Gutter
MU Filter
Filter Main Ink
Filter
Peltier MU
Recovery
MUM ITM Type 2
21-17

Vent
Heavy Duty Ink System
21-18

Heavy Duty Ink Pump (EPT015770) Ink Cooler

(in intermediate zone)

Pressure
Bleed Line Transducer Bleed
Blue Stripe Valve

Ink
Dampers Temp
Feed
Valve Wash
Feed Filter
10 Micron Valve
Jet Pump
ø 0.5mm

Ø 0.3mm
Red Stripe
Feed Line

Restrictor
Make-up
Valve
Viscometer
Vacuum Valve
Nozzle Flush Line Transducer
Valve

DIAGRAMS
Green Stripe
Diaphragm
Flush NRV Gutter Pump

PRV (80 mBar)

Print Head

V is
6 5 4 3 2 1

com
8 7
Line No Stripe
Gutter Return

ete
MU
EPT026795 Issue 17 June 2020

Ink

r
Cartridge Cartridge

100 Micron
MU Screen Filter
Filter Main Ink
Peltier MU Gutter Filter 5
Recovery Filter Micron
0.5mm
MUM Restrictor

Vent
ITM Type 3
Distribution Block Component Diagram
EPT026795 Issue 17 June 2020

The image below shows a standard ink system distribution block. Heavy duty ink system distribution blocks are fitted with two dampers.
Ink Cooler
1 PSI PRV

Damper
Feed Filter
Gutter Ink Pressure
Vacuum Sensor
Sensor

DIAGRAMS
Flush NRV

Gutter
Pump

Bleed Solenoid
(Orange Wires)
Make-up Solenoid Feed Solenoid Wash Solenoid Ink Temperature Viscometer Solenoid
(Red Wires) (Green Wires) (Yellow Wires) Sensor (Blue Wires)
21-19
DIAGRAMS

Distribution Block Piping Diagram

The gutter pipe is a clear pipe but has a different colour stripe depending on the nozzle size and
conduit length:
• 60μ or 75μ nozzle with 3m conduit - Clear pipe.
• 60μ or 75μ nozzle with 6m conduit - Clear pipe with violet stripe.
• 40μ or 50μ nozzle with 3m or 4m conduit - Clear pipe with black stripe.
Flush Pipe Feed Pipe Red
Green Stripe Stripe
Gutter Pipe

Vent Pipe Bleed Pipe Viscometer Pipe

Viscometer Pipe Peltier Blue Stripe Output
Output

Pump Output
Large Pipe

Pump Input
Small Pipe

Viscometer Pipe
Input

21-20 EPT026795 Issue 17 June 2020

DIAGRAMS
ELECTRONICS SYSTEM OVERVIEW DIAGRAM
EPT026795 Issue 17 June 2020 21-21
DIAGRAMS

Main PCB Overview

Battery Back
Up

Low Voltage
Modulation PSU
Print head Connector
Settings

Non
Replaceable
Fuses

High Voltage
PSU
Connectors

Main PCB
Status LEDs

Processor
and RAM

TouchScreen
USB Ports Socket

SIM Card and SD

Card Socket

Main PCB Front View

21-22 EPT026795 Issue 17 June 2020

DIAGRAMS

Main PCB Rear View

Main PCB Ink System Electronic Connections

Main PCB Rear View

EPT026795 Issue 17 June 2020 21-23

DIAGRAMS

Main PCB Component Locations

EPT026795 Issue 17 June 2020 21-27

DIAGRAMS

Product Detect / Shaft Encoder PCBA Layout

Product Detect / Shaft Encoder PCBA

Top View

Product Detect / Shaft Encoder PCBA

Bottom View

Product Detect / Shaft Encoder PCBA

Switch Configuration

21-28 EPT026795 Issue 17 June 2020

DIAGRAMS

Product Detect/Shaft Encoder Connectors (J3, J5)

Table 3: J3 andJ5 Pin Out

Pin Signal Description

1 EXT_+24V +24V Supply

7 6
2 GND Ground 8
3 1
3 INPUT_PD+ Product Detect (+)
5 4
4 INPUT_PD- Product Detect (-) 2

5 INPUT_SE_A+ Encoder Channel A (+)

6 INPUT_SE_A- Encoder Channel A (-) J3 and J5 Connections
(external view)
7 INPUT_SE_B+ Encoder Channel B (+)
8 INPUT_SE_B- Encoder Channel B (-)

Internal Interface to Main PCB (J4)

This connector provides internal communication between the product detect / shaft encoder
PCBA and the main PCB. Connect it to J1503 on the printer’s main PCB.
Connector type: 10-way vertical box header (SMT).

2 4 6 8 10

1 3 5 7 9

J4 Connections
(external view)

Table 4: J16 Pin Out

Pin PD/SE PCBA Signal Main PCB Signal

1 +24V +24V_INT_A
2 +24V +24V_INT_A
3 GND GND
4 PD Product Detect
5 GND GND
6 SE_A Encoder A
7 GND GND
8 SE_B Encoder B
9 GND GND
10 +5V +5V_FUSED

EPT026795 Issue 17 June 2020 21-29

DIAGRAMS

i-Pulse Print Head PCBA

Print Head PCBA

Top View

Print Head PCBA

Bottom View

21-30 EPT026795 Issue 17 June 2020

DIAGRAMS

Conduit Connector (J1)

Connector type: 22-way vertical box header (SMT).

2 4 6 8 10 12 14 16 18 20 22
1 3 5 7 9 11 13 15 17 19 21

J1 Connections
(external view)

Table 5: J1 Pin Out

Pin Signal

1 EHT_TRIP_DP
2 EHT_TRIP_DN
3 PHASE_ENABLE_DP
4 PHASE_ENABLE_DN
5 PHASE+
6 PHASE-
7 TEMP_PH+
8 TEMP_PH-
9 SOL_PH
10 SOL_PH_RTN
11 STROBE_DP
12 STROBE_DN
13 HEATER
14 HEATER_RTN
15 -12V
16 +12V
17 -12V_RTN (GND)
18 +12VRTN (GND)
19 MOD_IN
20 MOD_RTN
21 CHARGE_IN
22 CHARGE_RTN (GND)

EPT026795 Issue 17 June 2020 21-31

DIAGRAMS

Charge and Strobe Connector (J2)

Connector type: 4-way vertical box header (SMT).

2 4
1 3

J2 Connections
(external view)

Table 6: J2 Pin Out

Pin Signal

1 STROBE_RTN
2 STROBE
3 NOT_CONNECTED
4 CHARGE

Drop Generator Assembly Connector (J3)

Connector type: 8-way vertical box header (SMT).

2 4 6 8
1 3 5 7

J3 Connections
(external view)

Table 7: J3 Pin Out

Pin Signal

1 MOD_RTN
2 MOD
3 SOL_PH_RTN
4 SOL_PH
5 TEMP_PH-
6 TEMP_PH+
7 HEATER_RTN
8 HEATER

21-32 EPT026795 Issue 17 June 2020

DIAGRAMS

Phase Sensor Input Connector (J4)

Connector type: Vertical SMT Micro Miniature Coax Jack

1
2 3
J4 Connections
(external view)

Table 8: J3 Pin Out

Pin Signal

1 PHASE_IN+
2 GND
3 PHASE_IN-

EHT Trip Sensor Input Connector (J5)

Connector type: Vertical SMT Micro Miniature Coax Jack

1
2 3

J5 Connections
(external view)

Table 9: J3 Pin Out

Pin Signal

1 EHT_TRIP+
2 GND
3 GND

EPT026795 Issue 17 June 2020 21-33

DIAGRAMS

THIS PAGE INTENTIONALLY LEFT BLANK

21-34 EPT026795 Issue 17 June 2020

CONTINUOUS PRINTING PACK

PART 22 : CONTINUOUS PRINTING PACK

CONTENTS
Page
INTRODUCTION .................................................................................................................... 22-3
INSTALLATION ...................................................................................................................... 22-3
HOME SCREEN FEATURES .................................................................................................. 22-4
Label Length and Print Speed Statistics ........................................................................... 22-4
Current Printing Label View ............................................................................................... 22-5
Reset Counter ................................................................................................................... 22-6
LABEL CREATOR FEATURES ............................................................................................... 22-8
Initial Canvas Width Setting .............................................................................................. 22-8
Label Measurement Ruler and Label Width Value ............................................................ 22-9
X (mm) (Element Position Setting) ..................................................................................... 22-10
Label .................................................................................................................................. 22-11
Use Alternative Numerals .................................................................................................. 22-12
CONTINUOUS BACKGROUND COUNTING ......................................................................... 22-13
PRINT OPTIMISATION SETTINGS ........................................................................................ 22-14
Distance Interval Adjustment ............................................................................................ 22-14
Space Repeat Adjustment ................................................................................................ 22-15
LUA SCRIPT .......................................................................................................................... 22-16
Import LUA Script Files ..................................................................................................... 22-16
Behavioural Configuration ................................................................................................. 22-16
Reset Script Variables ....................................................................................................... 22-16
ADDITIONAL RASTERS ......................................................................................................... 22-17

EPT026795 Issue 17 June 2020 22-1

CONTINUOUS PRINTING PACK

THIS PAGE INTENTIONALLY LEFT BLANK

22-2 EPT026795 Issue 17 June 2020

CONTINUOUS PRINTING PACK

INTRODUCTION
Note: Available for Ax350i/Ax550i printers only.
Software requirements: Version 01.00.28 or higher.
The continuous printing pack installs additional features for printing long labels on high speed
continuous print surfaces, such as cable, wire and extrusion applications.
The continuous printing pack adds the following features to the printer:
• Improved visibility of long labels on the user interface home screen.
• Current speed and maximum speed values visible on the user interface home screen.
• Quick access to reset counter functions.
• Quick access to print optimisation settings to enable the pitch/gap between labels to be
easily adjusted.
• Additional label creator features specifically designed to create long labels.
• Additional rasters for high speed printing.
• Lua script engine.
The items listed in the table below are contained in the continuous printing pack:

Table 1: Continuous Printing Pack Contents

Quantity Item Description

1 USB Software Key

INSTALLATION
To install the continuous printing pack on the printer:
(1) Insert the continuous printing pack USB into a USB port on the printer cabinet or
TouchScreen.
(2) On the TouchScreen, wait for the install prompt to appear. Or, select Home > Setup > Packs
management.
(3) Select the appropriate Install button.
(4) Follow the on screen instructions.
(5) Remove the continuous printing pack USB.
(6) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

EPT026795 Issue 17 June 2020 22-3

(2) Select Reset counter.

Reset Counter Button

22-6 EPT026795 Issue 17 June 2020

CONTINUOUS PRINTING PACK

(3) Select one of the three icons illustrated below:

Icon Description

Reset the counter to the counter’s start value.

If there is more than one counter in the label, reset all counters to
their start values.

Reset the counter to a new user specified value.

End of procedure.

EPT026795 Issue 17 June 2020 22-7

CONTINUOUS PRINTING PACK

LABEL CREATOR FEATURES

The label creator contains additional features to help users create long labels. The additional
features are described on the next few pages of this document.

Initial Canvas Width Setting

The initial canvas width setting defines the width of the label creator’s canvas area. This setting is
specified when a new label is created.
To specify the Initial canvas width setting:
(1) From the TouchScreen’s Home Screen, select Label creator.
(2) Select Blank.
(3) Select the Label name text box.
(4) Use the on screen keyboard to enter a name which the label design will be saved as.
(5) Select the green Tick icon.
(6) Select the Initial canvas width (mm) setting and enter the initial canvas width value.

Initial Canvas Width (mm) Setting

(7) Select the icon to configure more label layout settings. Or, select Create label to
continue to the label creator.
End of procedure.

22-8 EPT026795 Issue 17 June 2020

CONTINUOUS PRINTING PACK

Label Measurement Ruler and Label Width Value

The label creator contains a metric ruler above the canvas area. The ruler enables the user to
accurately place elements in the label design. The label width is also displayed on the label
creator screen.

Ruler

Label
Width

Label Creator Screen

EPT026795 Issue 17 June 2020 22-9

CONTINUOUS PRINTING PACK

X (mm) (Element Position Setting)

The X (mm) setting enables the user to position an element at a specific location in the label. The
X (mm) value is measured from the left side of the label to the left side of the element.
Note: Some X (mm) values may not be possible. If the user specified X (mm) value is in
between two print strokes, the printer will choose the closest possible X (mm) value.
The screen shot below illustrates a text element with an X (mm) value of 95mm.

X (mm) Setting

To position a label element using the X (mm) setting:

(1) Select an element in the label.
(2) In the label creator’s side bar, select the Element menu and select Edit.
(3) Scroll down to the X (mm) setting and select it.
(4) Enter a new X (mm) value.
(5) Select the green Save icon to save the change.
End of procedure.

22-10 EPT026795 Issue 17 June 2020

CONTINUOUS PRINTING PACK

Label
Each label can be saved with it’s own distance interval value.
This setting defines the distance between each print on the print surface. The distance interval is
measured in mm from the start of one label to the start of the next label.
Distance Interval

Distance Interval Measurement

When the label is sent to print, this value will overwrite the current distance interval that is set on
the print optimisation screen (page 22-14), and the print trigger screen (page 4-54). Also, if the
print trigger is set to external, the print trigger will automatically change to internal.
To set the label’s distance interval setting:
(1) In the label creator’s side bar, select the Label menu and select Continuous.
(2) Tick the Enable tick box.
(3) Select the Distance interval (mm) setting and change the value.
Note: Ensure the Distance interval (mm) value is greater than the label width.

To adjust the distance interval setting:

(1) From the Home screen, select Print optimisation.
(2) Select the Distance interval (mm) setting and change the value.

Distance Interval (mm) Setting

End of procedure.

22-14 EPT026795 Issue 17 June 2020

CONTINUOUS PRINTING PACK

Space Repeat Adjustment

Note: This setting is only available when the label’s repeat mode setting is set to Counted or
Continuous, see page 5-31.
The space repeat setting enables the user to quickly adjust the distance between repeating
labels.
If the label’s Repeat spacing mode is set to Space by pitch; The Space repeat setting will adjust
the distance in mm between the start of one repeating label and the start of the next repeating
label.
If the label’s Repeat spacing mode is set to Space by gap; The Space repeat setting will adjust the
distance in mm between the end of one repeating label and the start of the next repeating label.
Pitch

Gap

Space by Pitch or Space by Gap

To adjust the space repeat setting:

(1) From the Home screen, select Print optimisation.
(2) Select the Space repeat (mm) setting and change the value.
(3) Select Save.

Space repeat (mm) Setting

End of procedure.

EPT026795 Issue 17 June 2020 22-15

CONTINUOUS PRINTING PACK

LUA SCRIPT
Import LUA Script Files
Script elements written in LUA programming language can be imported into the printer using the
file manager. Once imported, the script element can then be added into the label design, see
page 5-51.
To import a script:
(1) Save the script file to a USB drive.
(2) Insert the USB drive into a USB slot on the TouchScreen or printer cabinet.
(3) On the TouchScreen, select Home > Setup > File manager.
(4) Open the USB folder.
(5) Copy the script file and navigate to the Scripts folder.
(6) Select Paste.
End of procedure.

Behavioural Configuration
The settings on the behavioural configuration screen define the loop time of specific scripts.
To set the loop time of a specific script:
(1) Select Home > Setup > Global print settings > Behavioural configuration
(2) Select Add new script
(3) Configure the following settings:

Setting Name Description

Script path Enter the location of the script file.

Instance name Enter the name of the script file.
Loop time (ms) Define the loop time.

End of procedure.

Reset Script Variables

To reset scripts:
(1) Select Home > Setup > Global Print Settings > Content.
(2) Select Reset All to reset persistent script variables.
End of procedure.

22-16 EPT026795 Issue 17 June 2020

EPT026795 Issue 17 June 2020 23-9

CABLE AND WIRE SECTOR

ACCESSORIES
Print Head Cooling Device
The print head cooling device is an optional accessory available for i-Pulse RS Print Heads. It is
designed to protect the print head from high temperature environments when the print head is
installed close to a very hot extruder.

23-10 EPT026795 Issue 17 June 2020

CABLE AND WIRE SECTOR

INKS
The tables below list the most commonly used inks for each application in the cable and wire
sector.

Standard Inks

Ink Type WDB Colour Other Information

2BK842 W52 - 110 - 2KN Black Pigmented ink designed for zero
offset of plasticised PVC.
2WT854 N/A White Low transfer, fast-drying ink with
excellent PE and PVC adhesion.
2WT843 W92 - 110 - 3P White Low transfer, fast-drying ink with
excellent PE and PVC adhesion.
2WT840 5P White Our best general purpose white ink.
2WT860 N/A White Fast drying bright white ink for PVC
and extruded products. High
temperature resistant (20 min at
300 °C).

Inks for PVC

Ink Type WDB Colour Other Information

2BK842 W52 - 110 - 2KN Black Pigmented ink designed for zero
offset of plasticised PVC.
2WT843 W92 - 110 - 3P White Low transfer, fast-drying ink with
excellent PE and PVC adhesion.
27T851 W52 - 110 - 6 PVC White High opacity fast drying ink for PVC
or rubber.
2BL841 W52 - 110 - 25K Light Blue High contrast pigmented fast drying
cable ink.
2OR844 W92 - 110 - OR Orange Pigmented low transfer fast dry
cable ink.

EPT026795 Issue 17 June 2020 23-11

CABLE AND WIRE SECTOR

Inks for PE

Ink Type WDB Colour Other Information

2WT843 W92 - 110 - 3P White Low transfer, fast-drying ink with

excellent PE and PVC adhesion.
2BK124 W82 - 100 - IP Black General purpose, fast drying ink.
Excellent on plastics plus ketone
free. Alternative to 1BK111.
2YL812 W82 - 110 - 6KN Yellow General purpose ink for opaque
printed codes, good for PE.
2WT854 N/A White General purpose ink for opaque
printed codes, good for PE.

Inks for PA and PP

Ink Type WDB Colour Other Information

2WT850 W72 - 110 3K White Use 2WT840/254WT where

possible. Some existing 253WT
users may prefer to use 2WT580
where the end user properties have
been proven.
2BK106, W52 - 100 - 1K Black Food oil resistant ink.
2BK119,
2BK130

Inks for EPDM (Vulcanisation Resistant)

Ink Type WDB Colour Other Information

2WT851 W52 - 110 - 6 PVC White High opacity fast drying ink for PVC
or rubber.
2GR846 W52 - 100 - 174 Green Pigmented low transfer fast drying
ink.

23-12 EPT026795 Issue 17 June 2020

CABLE AND WIRE SECTOR

Inks for Teflon

Ink Type WDB Colour Other Information

2BK106, W82 - 100 - 1K - Black Food oil resistant black ink.

2BK119, Black
2BK130
2BK842 W52 - 110 - 2KN - Black Black pigmented ink designed for
Black zero offset of plasticised PVC.
2OR844 W92 - 100 - OR Orange Pigmented low transfer fast dry
orange cable ink.

EPT026795 Issue 17 June 2020 23-13

CABLE AND WIRE SECTOR

THIS PAGE INTENTIONALLY LEFT BLANK

23-14 EPT026795 Issue 17 June 2020

PART 24 : KOMAX M1630 JET

CONTENTS
Page
INTRODUCTION .................................................................................................................... 24-3
KOMAX M1630 JET FEATURE OVERVIEW ........................................................................... 24-4
KOMAX MODE QUICKSTEP INTERFACE ............................................................................. 24-5
Home Screen ..................................................................................................................... 24-5
Test Print ........................................................................................................................... 24-8
KRPC & POPP Interface Pack ........................................................................................... 24-9
Select Machine ............................................................................................................. 24-9
STAND-ALONE MODE QUICKSTEP INTERFACE .................................................................. 24-11
Home Screen ..................................................................................................................... 24-11
SECURITY .............................................................................................................................. 24-13
Log In ................................................................................................................................ 24-13
Log Out .............................................................................................................................. 24-13
INK JET THROW DISTANCE SETUP ..................................................................................... 24-14

EPT026795 Issue 17 June 2020 24-1

KOMAX M1630 JET

THIS PAGE INTENTIONALLY LEFT BLANK

24-2 EPT026795 Issue 17 June 2020

KOMAX M1630 JET

INTRODUCTION
The Komax M1630 Jet is a re-branded Ax350i that is designed for the Komax OEM. In most cases
the M1630 Jet will be integrated with a Komax wire processing machine on a cable or wire
production line.

Komax M1630 Jet

EPT026795 Issue 17 June 2020 24-3

KOMAX M1630 JET

KOMAX M1630 JET FEATURE OVERVIEW

The Komax M1630 Jet is always equipped with an i-Pulse RS print head with a 40 or 60 micron
nozzle.
Although the M1630 Jet is physically identical to the Ax350i, there are a number of user interface
differences which are described in this chapter. The table below gives a brief overview of the
Komax M1630 Jet’s different features.
Notes: (1) The printer’s Komax software is not separately available as an upgrade pack. Komax
software is installed on the printer at manufacture.
(2) Komax M1630 Jet printer software can be updated with the standard Ax-Series .upg
files.
(3) The printer’s Komax software is stored on the smart card (SIM). If the printer requires a
new main PCB, the smart card (SIM), SD card and conduit jumpers must be
transferred to the new main PCB.

Komax M1630 Jet

Description
Features

Komax Mode User Optimised user interface mode for printer integration with Komax
Interface wire processing machines, see page 24-5.
TopWin Interfaces Pack Enables integration with komax wire processing machines that
(KRPC/POPP) use KRPC or POPP communication protocols. Only available
when the printer is operating in Komax Mode, see page 24-9.
Stand-alone Mode User Optimised user interface mode for stand-alone printer
Interface applications. This mode is similar to the standard Ax-Series user
interface, see page 24-11.
Security Essential security mode is enabled on the printer as standard.
Only two login profiles are available, see page 24-11.
Standard Connectivity The Komax M1630 Jet is equipped with the following connectivity
Packs packs as standard:
• Status Pack, see page 7-22.
• RS232 Pack, see page 7-29.
• Comms Pack, see page 7-35.
Standard Performance The Komax M1630 Jet is equipped with the green pack as
Packs standard, see page 8-38.

24-4 EPT026795 Issue 17 June 2020

KOMAX M1630 JET

KOMAX MODE QUICKSTEP INTERFACE

The Komax mode interface is optimised for operation with Komax wire processing machines.
When Komax mode is enabled, setup and printing data is automatically sent from the wire
processing machine to the M1630 Jet via RS232 or TCP/IP communication.

Home Screen
When starting the printer in Komax mode, the following Home Screen is displayed.
1 2 3 2 1

5
6
7

8
9

18 17 16 15 14 13 12

QuickStep Home Screen

Item Setting Name Explanation

1 Information Bar Displays printer information.

2 Start/Stop Buttons Toggle jet sequences (On/Off)
3 Status Tab Displays printer status and alerts. If more than one alert is
present, the highest priority alert is displayed.
If an alert is displayed, select the Status Tab to show
more information and to clear the alert.

EPT026795 Issue 17 June 2020 24-5

KOMAX M1630 JET

Item Setting Name Explanation

4 Connection Displays the name of the machine that the printer is

connected to.
5 Ink Displays the type of ink that the printer is configured for.
6 Make-up Displays the type of make-up that the printer is
configured for.
7 System Information and Opens a window which displays the following
Pack Overview information:
• Current printer IP address.
• Current communication protocol.
• Software version.
• KRPC & POPP Interface Pack installation status.
• Green Pack installation status.
• Enhanced function status.
8 Test Print Select a test label that will print when the Single Print
button on the printer cabinet is pressed. Also, select the
print trigger and encoder input method.
See “Test Print” on page 24-8.
9 Select Machine Note: This setting is only available if the KRPC &
POPP Interface Pack is installed.
Select the machine the printer is integrated with from a
list.
See “KRPC & POPP Interface Pack” on page 24-9.
10 Stand-alone Mode Change the user interface to Stand-alone mode.
See “STAND-ALONE MODE QUICKSTEP INTERFACE”
on page 24-11.
11 Lock Log the user out from the printer.
Disconnect the TouchScreen from the printer.
Change the user’s password.
Lock the screen to prevent accidental changes.
12 Date / Time Displays the current system date / time.
13 Setup Open the Setup screen.
Note: The Editor Defaults and IO Port setup screen
options are not available on an M1630 Jet.
14 Production Line Setup Open the Production Line Setup screen.
Note: When operating in Komax mode, it is not
necessary to setup the settings on this
screen. The production line setup settings will
be transmitted to the printer from the Komax
wire processing machine.
15 Label Name Displays the name of the label which is currently loaded.

Note: The KRPC & POPP Interface Pack tick box on the System Information and Pack
Overview window indicates if the pack is installed.
KIMI communication protocol is normally used for communication with Komax wire processing
machines. However, some Komax machines use KRPC or POPP protocols. KRPC and POPP
protocols are available on the printer if the KRPC & POPP interface pack is installed.
If a graphic or logo is part of the label, Komax machines using the POPP protocol will send a
command to print logos that are saved in the printer’s internal memory.
Select Machine
When the KRPC & POPP interface pack is installed on the printer, the Select Machine setting will
be available on the Komax mode home screen.
The Select Machine setting enables the user to select the model name of the machine the printer
is integrated with from a list. This ensure the printer uses the correct communication protocol to
integrate with the Komax wire processing machine.
To select the machine that the printer is integrated with:
(1) Select Home > Select Machine.
(2) Select the model name of the machine that the printer is integrated with.

Machine Selection List

EPT026795 Issue 17 June 2020 24-9

KOMAX M1630 JET

(3) If communication protocol used by the machine is POPP, the Activate Local Printer Function
window will open. This window displays the Automatic Alternating Mirror Print tick box.
When the box is ticked the printed label will continuously alternate between mirrored and
standard orientation until the box is deselected.

Label 1 Label 2 Label 3 Label 4 Label 5

Tick Box Selected

Label 1 Label 2 Label 3 Label 4 Label 5

Tick Box Not Selected

(4) Select OK to confirm the selection and return to the Home screen. Or select Cancel to
disregard the selection and return to the Home screen.
End of procedure.

24-10 EPT026795 Issue 17 June 2020

KOMAX M1630 JET

STAND-ALONE MODE QUICKSTEP INTERFACE

The stand-alone mode QuickStep interface is optimised for operation of the M1630 Jet when the
printer is not integrated with any other Komax machines.

Home Screen
When starting the printer in Stand-alone mode, the following Home Screen is displayed.
1 2 3 2 1

14 13 12 11 10 9 8

QuickStep Home Screen

Item Setting Name Explanation

1 Information Bar Displays printer information.

EPT026795 Issue 17 June 2020 24-11

KOMAX M1630 JET

Item Setting Name Explanation

5 Label Finder Find a saved label from the printer’s label store to
preview, print or edit.
6 Komax Mode Change the user interface to Komax mode. When the
printer is in Komax mode, all label data is sent to the
printer from the Komax machine.
See “KOMAX MODE QUICKSTEP INTERFACE” on
page 24-5.
7 Lock Log the user out from the printer.
Disconnect the TouchScreen from the printer.
Change the user’s password.
Lock the screen to prevent accidental changes.
8 Date / Time Displays the current system date / time.
9 Setup Open the Setup screen.
Note: The Editor Defaults and IO Port setup screen
options are not available on an M1630 Jet.
10 Production Line Setup Open the Production Line Setup screen.
11 Label Name Displays the name of the label which is currently loaded.
12 Print optimisation Access the print optimisation settings.
13 Printer Name Displays the name of the printer that the user interface is
connected to.
The name can be changed by selecting Home > Setup >
System information and changing the Printer name
setting.
14 Home Button Press the Home Button at any time to return to this Home
Screen.

24-12 EPT026795 Issue 17 June 2020

KOMAX M1630 JET

SECURITY
When the printer starts up or re-boots, the operator level user will always automatically log into
the printer.
The log in and log out procedures are only required when changing between the operator level
user and the supervisor level user.

User Group Password Explanation

operator KO Operator access to the settings required for normal

printer operation.
supervisor KS Supervisor access to all printer settings.

End of procedure.

Log Out
To log out:
(1) Select the Padlock icon in the bottom right corner of the user interface.
(2) Select Log out.
End of procedure.

EPT026795 Issue 17 June 2020 24-13

KOMAX M1630 JET

INK JET THROW DISTANCE SETUP

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Note: Configuration of this setting is required in stand-alone mode only. In Komax mode, the
recommended throw distance in 2mm for all nozzle diameters.
The throw distance setting is used to define the distance between the bottom of the print head
and the print surface.
Tools required: Metric ruler.
To setup the throw distance:
(1) Measure the distance between the bottom of the print head and the print surface.
(2) If it is possible, position the print head at the recommended distance away from the print
surface as described in the table below.
Note: The nozzle diameter of the printer can be found on the TouchScreen by selecting
Home > Setup > System information and viewing the Nozzle diameter (μm) value.

Recommended Throw Distance Recommended Throw Distance

Nozzle Diameter
(Stand-Alone Mode) (Komax Mode)

60 micron 8mm 2mm

40 micron 4mm 2mm

24-14 EPT026795 Issue 17 June 2020

PART 25 : HD INK SYSTEM FIELD CONVERSION
KIT

CONTENTS
Page
INTRODUCTION .................................................................................................................... 25-3
Ax350i/Ax550i Kit Contents .............................................................................................. 25-3
Required Tools and Equipment ......................................................................................... 25-4
INSTALLATION ...................................................................................................................... 25-5
Flush Ink System ............................................................................................................... 25-5
Replace Ink Pump ............................................................................................................. 25-10
Install Second Damper ...................................................................................................... 25-15
Configure Software ........................................................................................................... 25-20
Install Make-up Module (MUM) ......................................................................................... 25-21
Install ITM .......................................................................................................................... 25-23
Install Ink and Make-up Cartridge ..................................................................................... 25-26
Prime Ink System .............................................................................................................. 25-29

EPT026795 Issue 17 June 2020 25-1

HD INK SYSTEM FIELD CONVERSION KIT

THIS PAGE INTENTIONALLY LEFT BLANK

25-2 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

INTRODUCTION
The HD ink system field conversion kit is designed to convert a standard ink system to heavy duty
(Opaque) ink system.
Notes: (1) There is no kit available to convert a heavy duty ink system back to a standard ink
system.
(2) Refer to the Ax-Series Spares and Accessories Catalogues for part numbers.

Ax350i/Ax550i Kit Contents

The items listed in the table below are contained in EPT046571 - HD ink system field conversion
(Ax350i/Ax550ii) kit:

Table 1: EPT046571 - HD Ink System Field Conversion (Ax350i/Ax550) Kit Contents

Quantity Item Description

1 ITM Type 3
1 ITM and MUM Base Plate
1 Gear Pump Opaque
1 Damper Assembly
1 Damper Bracket Assembly
2 M3x8 SS Torx Screw with Captive Washer
1 LLDPE Tubing 8mm
1 LLDPE Tubing 6mm
1 PTFE Tubing 1/8

EPT026795 Issue 17 June 2020 25-3

HD INK SYSTEM FIELD CONVERSION KIT

Required Tools and Equipment

The tools and equipment listed below are also required to install the HD ink system field
conversion kit:
• Make-up Module (MUM) - P/N EPT009810SP
• Flush Manifold Assembly - P/N EPT025259
• At least 1350ml of wash that is compatible with the current ink
• At least 1350ml of wash that is compatible with new ink
• Empty Make-up Cartridge
• Empty Ink Cartridge
• Engineer’s USB Key
• T20 Torx Driver
• T10 Torx Driver
• 7mm Nut Spinner
• 6mm Hex Key
• Lint Free Paper Towel.

25-4 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

INSTALLATION
Complete all of the procedures in this chapter to install the HD ink system field conversion kit.

Flush Ink System

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

CAUTION: Risk of damage to printer’s ink system

It is essential to flush the printer when converting the ink system from standard to
heavy duty. If the ink system is not flushed it is likely that damage will occur to the
main ink pump and ink system components.

CAUTION: Risk of damage to printer’s ink system

Do not allow foreign objects to enter the ITM or ink block. Observe good
cleanliness procedures.

CAUTION: Hazardous chemicals. Risk of environmental damage.

Waste ink and make-up are hazardous to the environment. Follow local waste
disposal regulations to safely dispose of waste ink, make-up and other
contaminated items

Required tools and equipment: Flush manifold assembly (P/N EPT025259), empty make-up
cartridge, empty ink cartridge, 1350ml of wash that is compatible with the current ink, 1350ml of
wash that is compatible with new ink, lint free paper towel.
To flush the ink system:
(1) If the printer is on, press and hold the standby button for 2 seconds and wait for the printer
to shut down.
(2) Disconnect the power lead from the rear of the printer.
(3) Open the front access door to the main ink compartment.
(4) Remove the ink and make-up cartridges.
(5) Remove the ITM and MUM.

EPT026795 Issue 17 June 2020 25-5

HD INK SYSTEM FIELD CONVERSION KIT

(6) Place lint free paper towel on top of the level sensor modules to catch excess fluid. Use
wash to remove any dried residual ink from the distribution block valve face.

Cleaning the Distribution Block

(7) Fit the flushing rig assembly onto the distribution block and insert the drain pipe into an
empty wash bottle.

Flushing Rig and Empty Wash Bottle Connected to Distribution Block

(8) Remove the holster from the print head by pressing in the two holster retaining clips and
withdrawing the holster.
(9) Rinse the print head gutter with wash solution.

25-6 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

(10) Connect the flushing rig input pipe to the gutter pipe in the print head.

Flushing Rig Input Pipe Connected to Gutter Pipe

(11) Insert the other end of the input pipe into a bottle containing 900ml of wash solution that is
compatible with the current ink type.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

Do not connect the input pipe to a bottle containing more than 900ml of wash
solution. Otherwise too much wash will be drawn into the ink system and the ink
viscosity will become too thin.

Wash Bottle Connected to Print Head Gutter

EPT026795 Issue 17 June 2020 25-7

HD INK SYSTEM FIELD CONVERSION KIT

(12) Reconnect the power lead to the rear of the printer.

(13) Press and hold the standby button for 2 seconds and wait for the printer to start up.
(14) On the TouchScreen select Home > Setup > Wizards > Ink flushing.
(15) Select Minimal Flush: Future inks will be similar to existing.
(16) Select the Next Screen icon eight times to move to step nine of the ink flushing wizard.

(17) Select Begin Flush.

(18) Wait for the flush process to complete.
(19) Remove the full wash bottle from the flushing rig assembly, empty it according to local
waste disposal regulations and reconnect it to the flushing rig assembly.
(20) Disconnect the input pipe connected to the gutter pipe in the print head.
(21) Rinse the print head gutter with wash solution.
(22) Reconnect the input pipe to the print head gutter pipe.
(23) Insert the other end of the input pipe into a bottle that contains a mix of 450ml wash solution
compatible with the old ink type, and 450ml wash solution compatible with the new ink
type.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

Do not connect the input pipe to a bottle containing more than 900ml of wash
solution. Otherwise too much wash will be drawn into the ink system and the ink
viscosity will become too thin.

(24) Select the Next Screen icon eight times to move to step 17 of the ink flushing wizard.

(25) Select Begin Flush.

CAUTION: Risk of sending ink viscosity outside of printer operating limit.

Do not connect the input pipe to a bottle containing more than 900ml of wash
solution. Otherwise too much wash will be drawn into the ink system and the ink
viscosity will become too thin.

(32) Select the Next Screen icon eight times to move to step 25 of the ink flushing wizard.

(33) Select Begin Flush.

25-8 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

(34) Wait for the flush process to complete.

(35) Select the Next Screen icon two times.

(36) Select the Complete icon.

EPT026795 Issue 17 June 2020 25-9

HD INK SYSTEM FIELD CONVERSION KIT

Replace Ink Pump

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10 torx driver, 7mm nut spinner and lint free paper towel.
To replace the ink pump:
(1) Connect the 8mm and 6mm pipes from the kit to the new opaque ink pump.

Ink Pump Pipes

25-10 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

(2) Remove the vanity cover inside the printer cabinet.

Vanity Cover Removal

(3) Remove the 2 nuts that secure the LSM and move the LSM to one side.

LSM Removal

(4) Place lint free paper towel underneath the ink block to absorb ink that may leak.

EPT026795 Issue 17 June 2020 25-11

HD INK SYSTEM FIELD CONVERSION KIT

(5) Disconnect the two pipes from the bottom of the ink block.

Pipe Disconnection

(6) Use a T10 torx driver to open the access panel to the rear ink compartment.

Ink Compartment Access

25-12 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

(7) Disconnect the ink pump cable.

Ink Pump Cable Disconnection

(8) Use a 7mm nut spinner to remove the nuts that secure the ink pump to the printer cabinet
chassis.
Note: Place lint free paper towel in the bottom left corner of the cabinet to catch dropped
nuts.

Ink Pump Nut Removal

EPT026795 Issue 17 June 2020 25-13

HD INK SYSTEM FIELD CONVERSION KIT

(9) Remove the ink pump from the printer cabinet.

Ink Pump Removal

(10) Refit the new opaque ink pump in the reverse order of removal.
End of procedure.

25-14 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

Install Second Damper

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

WARNING: Pressurised ink system. Risk of ink spray.

Shut down the printer and disconnect the power cable to de-pressurise the ink
system before removing the ITM.

Required tools: T10, T20 torx driver and lint free tissue.
Printers equipped with a standard ink system are fitted with one damper. Printers equipped with a
heavy duty ink system are fitted with two dampers.

Double Damper Ink Block

To install the second damper:

(1) Use a T10 torx driver and the two screws from the kit to attach the new damper to the
mounting bracket.

Damper and Damper Bracket

EPT026795 Issue 17 June 2020 25-15

HD INK SYSTEM FIELD CONVERSION KIT

(2) Use a T20 torx driver to attach the new mounting bracket and damper to the ink block as
illustrated below.

Damper Bracket Attachment

(3) Place lint free tissue underneath the damper to catch any ink which may leak out of the
damper or connecting pipes.
(4) Disconnect the damper feed pipe at the ink block.

Damper Feed Pipe Disconnection

25-16 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

(5) Connect the pipe from the top fitting on the original damper to the bottom fitting on the new
damper.

Damper Pipe Connection

(6) Connect the new PTFE pipe from the kit to the top fitting on the new damper.

Damper Pipe Connection

EPT026795 Issue 17 June 2020 25-17

HD INK SYSTEM FIELD CONVERSION KIT

(7) Connect the other end of the new pipe to the ink block damper feed fitting.

Damper Pipe Connection

(8) Replace the base ITM and MUM baseplate with the new baseplate included in the kit.
Note: Take care to correctly refit the Peltier condenser vent tube in the rear right corner of
the baseplate.

ITM and MUM Baseplate Replacement

25-18 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

(9) Replace the ink system vanity shield.

Vanity Cover Replacement

End of procedure.

EPT026795 Issue 17 June 2020 25-19

HD INK SYSTEM FIELD CONVERSION KIT

Configure Software
Required tools: Engineer’s USB key
To configure the printer’s software for the new ink system ink system:
(1) Insert an engineer’s USB key into a USB port on the TouchScreen or printer cabinet.
(2) On the TouchScreen select Home > Setup > Advanced > Hardware.
(3) Scroll down the Pump type and select EPT015570.
(4) Select Ink system and select Opaque.
(5) Tick the Wake-up mode enabled tick box.
(6) Select Home > Setup > Advanced > Ink details > Ink details > Current Ink.
(7) Select the new ink type from the drop down list.
(8) Remove the engineer’s USB key.
(9) Select Home > Setup > Production line setup > Power options > Restart and wait for the
printer to restart.
End of procedure.

25-20 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

Install Make-up Module (MUM)

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Risk of damage to printer’s ink system.

Do not allow foreign objects to enter the make-up module or ink block. Observe
good cleanliness procedures.

CAUTION: Hazardous chemicals. Risk of environmental damage.

The used ITM and paper towel contain residual chemicals which are hazardous to
the environment. Follow local waste disposal regulations to safely dispose of the
used ITM and paper towels.

To install the MUM:

(1) Insert the make-up recovery tube into the MUM and push the MUM’s manifold pipes into
the ink block.

MUM Installation

EPT026795 Issue 17 June 2020 25-21

HD INK SYSTEM FIELD CONVERSION KIT

(2) Tighten the thumb screw that secures the MUM to the printer cabinet.

MUM Replacement

(3) Dispose of contaminated paper towels and the old MUM by following local waste disposal
regulations.
End of procedure.

25-22 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

Install ITM
WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

CAUTION: Hazardous chemicals. Risk of environmental damage.

Used paper towels will contain chemicals that are hazardous to the environment.
Follow local waste disposal regulations to safely dispose of used paper towels.

Tools required: Paper towels (or similar) and wash.

To install the ITM:
(1) Unpack the new ITM and remove the sealing strip that protects the ITM manifold pipes.

Removing the ITM Sealing Strip

EPT026795 Issue 17 June 2020 25-23

HD INK SYSTEM FIELD CONVERSION KIT

(2) Place paper towel (or similar) under the ITM manifold pipes and lubricate the pipes with
wash.

Washing the ITM manifold pipes

(3) Insert the ITM between the retaining clips and firmly push the ITM manifold pipes into the
ink block.

Inserting the ITM

25-24 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

WARNING: Pressurised ink system. Risk of ink spray.

When replacing the ITM, ensure the retaining clips are fully engaged.

(4) Continue pushing until the retaining clips engage with a click.

Retaining Clip Engaged Retaining Clip Not Engaged

(5) Close the printer ink cabinet.

(6) Dispose of used paper towels by following local waste disposal regulations.
End of procedure.

EPT026795 Issue 17 June 2020 25-25

HD INK SYSTEM FIELD CONVERSION KIT

Install Ink and Make-up Cartridge

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

(2) Insert a 6mm hex key into the top of the cartridges and twist to break the sealing tabs.
Remove the sealing tab.

25-26 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

(3) Push the make-up cartridge onto the make-up module manifold and push the ink cartridge
onto the ITM.

Make-up Cartridge Ink Cartridge

Installation Installation

(4) Rotate the ink cartridge clockwise and the make-up cartridge anti-clockwise, ensuring that
the label is facing towards you.

Make-up Ink
Cartridge Cartridge

Ink and Make-up Cartridge Replacement

EPT026795 Issue 17 June 2020 25-27

HD INK SYSTEM FIELD CONVERSION KIT

(5) Check inside the printer for leaks.

(6) Shut the ink compartment access door.
End of procedure.

25-28 EPT026795 Issue 17 June 2020

HD INK SYSTEM FIELD CONVERSION KIT

Prime Ink System

WARNING: Hazardous Chemicals. Risk of eye and skin damage.

Wear appropriate protective equipment such as gloves and glasses when near the
printer. Contact with chemicals can cause skin or eye damage. Refer to Safety
Data Sheet.

Note: The ink priming will take 12 minutes to complete

Before starting this procedure, ensure that the ink and make-up levels are at least half full. This
will be indicated by yellow or green make-up and ink level icons on the information bar on the
TouchScreen screen.
To prime the ink system:
(1) On the TouchScreen, select Home > Setup > Wizards > Ink priming.
(2) Select Start ink priming.
(3) Select Complete when the ink priming process is finished.
End of procedure.

EPT026795 Issue 17 June 2020 25-29

HD INK SYSTEM FIELD CONVERSION KIT

THIS PAGE INTENTIONALLY LEFT BLANK

25-30 EPT026795 Issue 17 June 2020

PART 26 : ITM TYPES

CONTENTS
Page
INTRODUCTION .................................................................................................................... 26-3
ITM TYPE 2 (STANDARD INK SYSTEM) ................................................................................ 26-6
Description ........................................................................................................................ 26-6
ITM TYPE 3 (HEAVY DUTY INK SYSTEM) ............................................................................. 26-7
Description ........................................................................................................................ 26-7
ITM TYPE 6 (STANDARD INK SYSTEM - RUN TIME) ........................................................... 26-8
Description ........................................................................................................................ 26-8
ITM Type 6 Run Time Expiry ............................................................................................. 26-9
18 Month Alert ................................................................................................................... 26-9
ITM ALERTS ........................................................................................................................... 26-10
First (350 Hour) Alert ......................................................................................................... 26-10
Second (8 Hour) Alert ........................................................................................................ 26-10
Final (0 Hour) Alert ............................................................................................................. 26-10
ITM SETTINGS ....................................................................................................................... 26-11
Set Default ITM Life (For Harsh Environments) ................................................................. 26-11
Set Remaining ITM Life (For Warranty Replacement) ....................................................... 26-12
ITM Life Remaining Alert Hours ........................................................................................ 26-13

EPT026795 Issue 17 June 2020 26-1

ITM TYPES

THIS PAGE INTENTIONALLY LEFT BLANK

26-2 EPT026795 Issue 17 June 2020

ITM TYPES

INTRODUCTION
Inside the printer cabinet, printing ink and make-up is filtered and mixed in a replaceable reservoir
called the ITM. The ITM location is highlighted below.

The ITM is fitted with an electronic tag that stores data Including:
• The ITM type.
• ITM fluid capacity
• Serial number of printers that the ITM was installed in.
• Time and date that the ITM was first installed.
• ITM life data.
• ITM grace period (length of time the ITM will continue to operate for after expiry).
Communication between the ITM’s electronic tag and the printer is made using RFiD via the
printer’s RFiD reader (QMM). The QMM location is illustrated below.

EPT026795 Issue 17 June 2020 26-3

ITM TYPES

The ink level in the ITM is measured by the printers level sensor module (LSM).

Level Sense Module

(LSM

26-4 EPT026795 Issue 17 June 2020

ITM TYPES

The illustration below is an annotated top down cutaway view of an ITM.

A B C D E F

G H I

Item Description Item Description

A Output to Gear Pump and Ink Cooler F Return from temp sensor, jet pump
and viscometer
B Return from Print Head Gutter G Gutter Filter
C Return from Peltier Condensor H Main Ink Filter
D Output to temp sensor, jet pump and I Input from Ink Cartridge
viscometer
E Return from Gear Pump and Ink -
Cooler

EPT026795 Issue 17 June 2020 26-5

ITM TYPES

ITM TYPE 2 (STANDARD INK SYSTEM)

Description
ITM02 is used in printers equipped with a standard ink system only. It is designed for use with
dye-based inks. Maximum volume is 0.825 litres.

A side cut away for the ITM02 is illustrated below.

Main Ink
Filter

26-6 EPT026795 Issue 17 June 2020

ITM TYPES

ITM TYPE 3 (HEAVY DUTY INK SYSTEM)

Description
ITM03 is used in printers equipped with a heavy duty ink system only. It is designed for
pigmented/opaque and carbon black ink types. Maximum volume is 0.666 litres.

The ITM03 contains a break up nozzle. The break up nozzle is designed to agitate heavier ink
particles that settle at the bottom of the ITM.

Main Ink
Filter

Break Up Nozzle

EPT026795 Issue 17 June 2020 26-7

ITM TYPES

ITM TYPE 6 (STANDARD INK SYSTEM - RUN TIME)

Description
ITM Type 6 is used in printers equipped with a standard ink system only. It is designed for use
with a commercially restricted list of dye-based inks. The ITM Type 6 is only available to approved
distribution channels. Maximum volume is 0.825 litres.
Notes: (1) The ITM Type 6 can only be used in printers that are running software version
1.39.1202 and above.
(2) The ITM Type 6 is not valid for printers equipped with an i-Pulse Duo print head.
(3) The ITM Type 6 is not valid for printers equipped with an i-Pulse RS print head with
40 μ nozzle.

The ITM Type 6 is intended for customers with low production/low print rates. It is designed to
reduce the printer operating costs for these customers.
Low production/low print rates are defined as:
• Running the printer for up to 1900 hours per year.
• Printing up to 3000 codes per hour.
• Printing up to 5.7 million codes per year.
The ITM Type 6 can be moved from one printer to another compatible Ax-Series printer. When
moved from one printer to another, the remaining percentage of the ITM life will be preserved.

26-8 EPT026795 Issue 17 June 2020

ITM TYPES

ITM Type 6 Run Time Expiry

The default lifetime of an ITM Type 6 is 3500 run time hours.
Run time hours are defined as time when:
• The printer is ready to print (printing).
• Jet running.
• Phase locked.
Run time hours does not include time when the printer is:
• Idle.
• sequencing on/off.
• in wake-up mode.
• shut down.
By default, if the available run time hours are completely consumed within one year, the ITM will
switch from calculating expiry as run time hours to a calendar date one year after the ITM was
installed. For example, within the 1st year of the ITM’s life, if the ITM’s remaining hours drops
below 350 and there are more than 37 days of the year left, the remaining run time hours will be
converted to days. The ITM will then mirror the behaviour of a calendar based ITM Type 2 for the
remainder of it’s life.
The ITM Type 6 will expire after 2.5 years of calendar time usage, even if the remaining run time is
greater than 0 hours. However, if it becomes impossible to use the remaining run time hours
within 2.5 years, for example there are 2000 run time hours left, but the ITM has been installed for
2 years and 4 months, the ITM will switch to calendar mode and the printer will show an ITM
expiry date instead of run time hours. The first and second amber run time alerts will precede the
final 2.5 year expiry alert. After which the grace period will be allowed. After the grace period has
expired, a red alert will be raised.

18 Month Alert
An amber alert will be triggered after 18 months of use. This is to advise the user that the ink
quality may be degrading and to monitor print quality. This alert can be cleared by the user but will
be raised again once per month.

EPT026795 Issue 17 June 2020 26-9

ITM TYPES

This alert is intended to inform the customer to check

This alert is intended to inform the customer/operator

that they should prepare to change the ITM.
Grace period 120 Adjust the length of the grace period.

End of procedure.

EPT026795 Issue 17 June 2020 26-13

ITM TYPES

THIS PAGE INTENTIONALLY LEFT BLANK

26-14 EPT026795 Issue 17 June 2020

Common questions

Accessing the electronic compartment of a printer poses several safety risks, particularly the risk of electric shock due to high voltage electricity . To mitigate this risk, always disconnect the mains power supply before accessing the compartment . Additionally, the printer contains electrostatic sensitive components, so precautions against ESD (electrostatic discharge) should be taken. This includes wearing an ESD wristband grounded to the earth and avoiding clothing that can generate static electricity . Wear appropriate personal protective equipment to avoid chemical hazards when applicable .

When replacing the ink feed filter, first power down the printer by holding the standby button for 2 seconds and disconnect the power lead . After removing the distribution block, locate and remove the feed filter secured by T10 torx screws . Ensure all personnel wear protective equipment to guard against chemical exposure and follow precautions against pressurized ink . Refit the filter and block in reverse order and prime the ink system using on-screen instructions .

Correct ink jet alignment is significant to ensure that ink is accurately deposited, preventing wasted ink and ensuring high-quality print output . To achieve proper alignment, use tools like a magnifying eye glass and align based on a visual inspection of the ink jet entering the gutter. If misalignment is detected, adjust with a 1.5mm hex driver or Tx8 torx driver as needed . Continuous monitoring and adjustments according to detailed alignment procedures are crucial for maintaining system integrity and performance .

To edit a label's print settings using the label creator, follow these key steps: First, open the label that requires editing if it is not already open . Next, in the label creator’s side menu, select the Label tab, then the Settings menu . Adjust the settings such as Forward and Reverse offset, Inverse mode, Reverse mode, or Repeat mode as needed . After making the necessary changes, select the Save icon to save the settings .

Reverse mode can be configured by selecting the Reverse mode drop-down setting in the label creator's Settings menu . Options include 'On - Always,' where the design is reversed at all times; 'On - Counted,' where reversal occurs for a specified number of prints; and 'On - GPI/User Port,' where the design reverses when an input pin is activated . The 'Off' setting will not reverse the design . Each option affects how the label is printed and can impact production depending on the required label orientation .

When using Invert mode, consider that this setting is used to invert an individual label design. It's essential for setting labels on traversing lines and inverting them for a set number before reverting back . Note that if the printer is equipped with a GPIO or extended IO pack, this setting can be triggered by activating an assigned input pin . Also, while a global invert setting is available, it does not count the number of inverted prints or allow inversion to be triggered by a user port .

The Nozzle Unblocking procedure involves selecting Home > Setup > Wizards > Nozzle unblocking on the TouchScreen and following on-screen instructions to start the procedure . This helps clear any blockages in the nozzle. The associated risks include exposure to hazardous chemicals, thus necessitating the use of protective equipment like gloves and eye protection . Running the unblocking wizard more than twice may thin the ink viscosity beyond operational limits, requiring additional maintenance steps .

To set up Repeat mode for a label design, first open the label in the label creator if it's not already open . Select the Label tab in the side menu and then choose the Settings menu . From there, select the Repeat mode drop-down setting; options include 'Off,' 'Counted,' or others based on the number of repeats required . Configuring Repeat mode allows the label design to be printed repeatedly after a single print trigger or continuously, thus improving printing efficiency for repetitive labels .

Integrating a status pack with a printer enhances connectivity by providing additional external connections, such as a 5-way socket for a beacon and a 7-way plug for an alarm . This facilitates better status monitoring of the printer's operations and enables alerts or notifications through external devices when the printer needs attention . Installing this involves adding a status PCBA and connecting it to the printer’s main PCB, enhancing the printer’s capability to communicate and display real-time status .

To prepare for installing a DCI Port Kit on an Ax350i/Ax550i, ensure the printer is off by holding the standby button for 2 seconds . Disconnect the power lead to eliminate electric shock risk . Use the T10 torx driver to remove screws from the rear panel, being cautious of high voltage and electrostatic sensitive components . Wearing ESD protection and ensuring the work area is free from electrostatic build-up enhances safety during installation .

Ax Series User Guide EPT034331 3
No ratings yet
Ax Series User Guide EPT034331 3
42 pages
A-Series GP Printer: Operation and Maintenance Manual
No ratings yet
A-Series GP Printer: Operation and Maintenance Manual
182 pages
Manual A Series Ingles
No ratings yet
Manual A Series Ingles
296 pages
Domino Ax-Series User Guide
No ratings yet
Domino Ax-Series User Guide
48 pages
Domino User Manual
100% (2)
Domino User Manual
288 pages
A-Series Spare Parts Catalogue
100% (3)
A-Series Spare Parts Catalogue
137 pages
A320i A420i A520i Product Manual Touchscreen Variant English EPT006508 2
100% (4)
A320i A420i A520i Product Manual Touchscreen Variant English EPT006508 2
249 pages
A-Series Plus Printer Manual
No ratings yet
A-Series Plus Printer Manual
337 pages
Markem-Imaje 9450 Service Manual
100% (1)
Markem-Imaje 9450 Service Manual
302 pages
Markem-Imaje 9040 Printer Manual
100% (1)
Markem-Imaje 9040 Printer Manual
222 pages
Domino A Series Quality Codes Guide
No ratings yet
Domino A Series Quality Codes Guide
11 pages
Domino A Series Printer Quality Codes
No ratings yet
Domino A Series Printer Quality Codes
14 pages
Markem-Imaje 9450 Service Manual
100% (2)
Markem-Imaje 9450 Service Manual
298 pages
A-Series i-Tech Spares Catalogue
No ratings yet
A-Series i-Tech Spares Catalogue
115 pages
VJ100 Series Scratch Pad Test Sequences
No ratings yet
VJ100 Series Scratch Pad Test Sequences
2 pages
A-Series Spare Parts Catalogue
100% (1)
A-Series Spare Parts Catalogue
137 pages
21 Aa Videojet 1530 Service Manual en
No ratings yet
21 Aa Videojet 1530 Service Manual en
296 pages
Markem-Imaje 9450 Parts Catalog
100% (1)
Markem-Imaje 9450 Parts Catalog
84 pages
Service Manual-VIDEOJET
100% (1)
Service Manual-VIDEOJET
360 pages
9028 Printer Service Manual
100% (3)
9028 Printer Service Manual
194 pages
361869-21 AE - Videojet 1210 - 1510 Service Manual
No ratings yet
361869-21 AE - Videojet 1210 - 1510 Service Manual
318 pages
Videojet 1610 Service Manual 1610 E
100% (1)
Videojet 1610 Service Manual 1610 E
249 pages
User Manual: 9400 Series
100% (1)
User Manual: 9400 Series
235 pages
Domino A120 Printer Manual Guide
50% (2)
Domino A120 Printer Manual Guide
4 pages
Markem-Imaje 9040 Printer Manual
No ratings yet
Markem-Imaje 9040 Printer Manual
138 pages
F500 Service Manual en V2.0
100% (4)
F500 Service Manual en V2.0
97 pages
Domino A120 Inkjet Printer Overview
67% (3)
Domino A120 Inkjet Printer Overview
4 pages
Markem Image Book For Service Engineers 2200 - v3.3
88% (8)
Markem Image Book For Service Engineers 2200 - v3.3
535 pages
Domino Ax Series User Manual
100% (1)
Domino Ax Series User Manual
175 pages
8900 Link
0% (1)
8900 Link
189 pages
SmartLase C150/C350 User Manual
100% (1)
SmartLase C150/C350 User Manual
44 pages
01 Aa Videojet 1580 Service Manual Us
82% (11)
01 Aa Videojet 1580 Service Manual Us
191 pages
KGKJET CCS-R Printer Manual
No ratings yet
KGKJET CCS-R Printer Manual
257 pages
1280, 1240 Technical Training Guide - 01 - AA
No ratings yet
1280, 1240 Technical Training Guide - 01 - AA
212 pages
Manual Linx 89xx
100% (2)
Manual Linx 89xx
410 pages
Videojet 3330/3130 System Overview
100% (1)
Videojet 3330/3130 System Overview
72 pages
5800 User Manual 10041241 EN
100% (1)
5800 User Manual 10041241 EN
168 pages
5902 A320i A420i Product Manual English EDP002568 2
71% (7)
5902 A320i A420i Product Manual English EDP002568 2
0 pages
Dataflex Plus Service Manual
80% (5)
Dataflex Plus Service Manual
243 pages
Maintenance Manual 7900 MM en Iss1 Ebook
No ratings yet
Maintenance Manual 7900 MM en Iss1 Ebook
530 pages
Linx 7300 Maintenance Manual
63% (8)
Linx 7300 Maintenance Manual
512 pages
Smartlase C150/C350 User Manual
100% (1)
Smartlase C150/C350 User Manual
138 pages
KGK JET CCS3000 Communication Manual
50% (6)
KGK JET CCS3000 Communication Manual
196 pages
Videojet 1880 Series Service Manual
100% (1)
Videojet 1880 Series Service Manual
255 pages
Videojet 1240, 1280, 1580 Operator Manual
100% (3)
Videojet 1240, 1280, 1580 Operator Manual
25 pages
9029 - Instruction Manual (Eng)
100% (2)
9029 - Instruction Manual (Eng)
18 pages
1040.7983 - alphaJET 5-EN
No ratings yet
1040.7983 - alphaJET 5-EN
220 pages
Markem-Imaje 9040 Parts Catalog
No ratings yet
Markem-Imaje 9040 Parts Catalog
53 pages
9028 Printer Service Manual Overview
No ratings yet
9028 Printer Service Manual Overview
176 pages
A-Series i-Tech Printer Training Manual
No ratings yet
A-Series i-Tech Printer Training Manual
388 pages
May in Domino
100% (1)
May in Domino
52 pages
A-Series Plus Printer Safety Guide
No ratings yet
A-Series Plus Printer Safety Guide
52 pages
Inks and Fluids Safety Guidelines
No ratings yet
Inks and Fluids Safety Guidelines
54 pages
Domino G-Series Printer Manual
No ratings yet
Domino G-Series Printer Manual
188 pages
T110/T210 Inkjet Printer Manual
No ratings yet
T110/T210 Inkjet Printer Manual
84 pages
EPT053091 Issue 2 Jan 2020 English Gx-Series Product Manual Linked
No ratings yet
EPT053091 Issue 2 Jan 2020 English Gx-Series Product Manual Linked
213 pages
Domino A Series Manual 202332910340
No ratings yet
Domino A Series Manual 202332910340
339 pages
XENONS User Manual Overview
No ratings yet
XENONS User Manual Overview
46 pages
Domino Printer Operation and Safety Guide
43% (7)
Domino Printer Operation and Safety Guide
42 pages
Domino Printer Operation and Safety Guide
No ratings yet
Domino Printer Operation and Safety Guide
42 pages
Modbus-Rtu Danfoss fc302
100% (1)
Modbus-Rtu Danfoss fc302
39 pages
Delta DVP-MC Catalog 20180614 AutoVina
No ratings yet
Delta DVP-MC Catalog 20180614 AutoVina
8 pages
Modbus VLT2800
100% (1)
Modbus VLT2800
35 pages
KTB S09 Operating Instructions for Sigma 688
No ratings yet
KTB S09 Operating Instructions for Sigma 688
70 pages
0 BA C1370 C1340 Komax HMI EN
No ratings yet
0 BA C1370 C1340 Komax HMI EN
52 pages
MNQF Entry Criteria Overview
No ratings yet
MNQF Entry Criteria Overview
6 pages
Sterilization and Bacterial Isolation Techniques
No ratings yet
Sterilization and Bacterial Isolation Techniques
6 pages
Understanding Clinical and Managerial KPIs
No ratings yet
Understanding Clinical and Managerial KPIs
71 pages
Hydrostatics Principles and Problems
No ratings yet
Hydrostatics Principles and Problems
5 pages
Morgan Clinical Anaesthesiology 6th Ed 7
No ratings yet
Morgan Clinical Anaesthesiology 6th Ed 7
31 pages
Understanding Computer Threats
No ratings yet
Understanding Computer Threats
9 pages
Pohon Masalah Waham Curiga dalam Keperawatan
No ratings yet
Pohon Masalah Waham Curiga dalam Keperawatan
5 pages
BYD Battery-Box Premium Manual LVL 15.4
No ratings yet
BYD Battery-Box Premium Manual LVL 15.4
37 pages
Wipro's Transformative HR Policies Explained
No ratings yet
Wipro's Transformative HR Policies Explained
3 pages
School Physical Education Inspection Report
No ratings yet
School Physical Education Inspection Report
9 pages
Offshore Lifting Regulations Overview
No ratings yet
Offshore Lifting Regulations Overview
3 pages
Impact of Mother's Voice on Premature Infants
No ratings yet
Impact of Mother's Voice on Premature Infants
8 pages
APU Features and Functions Overview
No ratings yet
APU Features and Functions Overview
27 pages
Laser Photo Tachometer DT-2234BL Specs
No ratings yet
Laser Photo Tachometer DT-2234BL Specs
2 pages
Open Channel Flow Analysis and Solutions
100% (4)
Open Channel Flow Analysis and Solutions
39 pages
2023+Pressure+Canning AA
No ratings yet
2023+Pressure+Canning AA
2 pages
Women with Autism: Online Community Insights
No ratings yet
Women with Autism: Online Community Insights
21 pages
Maxillary Ameloblastoma Review: Diagnosis & Characteristics
No ratings yet
Maxillary Ameloblastoma Review: Diagnosis & Characteristics
10 pages
Overview of Aquatic Toxicology Effects
No ratings yet
Overview of Aquatic Toxicology Effects
177 pages
India Dairy Industry Economic Overview
No ratings yet
India Dairy Industry Economic Overview
13 pages
Investigating Osmosis in Beetroot
No ratings yet
Investigating Osmosis in Beetroot
10 pages
Understanding Foot and Mouth Disease
No ratings yet
Understanding Foot and Mouth Disease
92 pages
Enhanced CAR-T Cell Potency via Solupore
No ratings yet
Enhanced CAR-T Cell Potency via Solupore
19 pages
Skilled Occupational Therapy Documentation
No ratings yet
Skilled Occupational Therapy Documentation
2 pages
Checklist Occupied PDF
50% (2)
Checklist Occupied PDF
2 pages
QHDC Premium Retail Trolleys Baskets Spares
No ratings yet
QHDC Premium Retail Trolleys Baskets Spares
16 pages
Purpose of C.H.I.L.D. Foundation
No ratings yet
Purpose of C.H.I.L.D. Foundation
2 pages
Stroop Test Report for Ahsan Ali
No ratings yet
Stroop Test Report for Ahsan Ali
8 pages
Nav Arch Content Handout Complete
No ratings yet
Nav Arch Content Handout Complete
70 pages
Scaling A Start-Up
No ratings yet
Scaling A Start-Up
7 pages