CoPilot Gemini Industrial Inkjet Printing System User Guide PDF

CoPilot Gemini ™ Industrial Inkjet Printing System User Guide 2005559 – Rev B – 4/14/23 2005559 – Rev B – 4/14/23 CoPilot Gemini Industrial Inkjet Printing System User Guide Revised 4/14/2023 P/N 2005559 – Rev B Copyright and Trademarks Copyright ©2023 Squid Ink Manufacturing. All rights re...

CoPilot Gemini ™ Industrial Inkjet Printing System User Guide 2005559 – Rev B – 4/14/23 2005559 – Rev B – 4/14/23 CoPilot Gemini Industrial Inkjet Printing System User Guide Revised 4/14/2023 P/N 2005559 – Rev B Copyright and Trademarks Copyright ©2023 Squid Ink Manufacturing. All rights reserved. All trademarks and brand names are the property of their respective owners. Squid Ink Manufacturing 7041 Boone Avenue North Brooklyn Park, MN 55428 Phone: 763-795-8856, Fax: 763-795-8867, Toll Free: 800-877-5658 www.squidink.com 2005559 – Rev B – 4/14/23 2005559 – Rev B – 4/14/23 Contents We Help Companies Deliver Products to the World ............................... 11 Abbreviations & Terminology ................................................................. 13 Safety ....................................................................................................... 15 Warnings ..................................................................................................................... 15 Understanding Safety Notifications ............................................................................. 16 General Precautions ................................................................................................... 16 Liability ........................................................................................................................ 17 Introduction ............................................................................................. 19 General System Description ....................................................................................... 19 System Components ................................................................................................... 21 System Dimensions .................................................................................................... 22 Controller Dimensions .........................................................................................................22 Printhead Dimensions .........................................................................................................23 System Specifications ................................................................................................. 24 Software Specifications ............................................................................................... 25 Options........................................................................................................................ 26 Installation and Setup ............................................................................. 27 General Recommendations ........................................................................................ 27 Vibration and Movement .....................................................................................................27 Material Handling ................................................................................................................27 Grounding ...........................................................................................................................28 AC Power ............................................................................................................................28 Work Area ...........................................................................................................................28 Maintenance Access ...........................................................................................................28 Printhead Overview ..................................................................................................... 29 Printhead Front Components ..............................................................................................29 Printhead Rear Components ...............................................................................................29 Controller Overview..................................................................................................... 30 Controller Front View...........................................................................................................30 Controller Rear View ...........................................................................................................30 Mounting ..................................................................................................................... 31 2005559 – Rev B – 4/14/23 Mounting the Printhead .......................................................................................................31 Mounting the Controller .......................................................................................................32 Attaching an Optional Cable Protection Bracket ..................................................................33 Mounting a Photocell ...........................................................................................................34 Distance from Substrate ......................................................................................................36 Mounting to a Floor Stand ...................................................................................................37 Conveyor Mounting Bracket ................................................................................................38 Rotating or Tilting the Printhead ..........................................................................................39 Cable Connections ...................................................................................................... 40 Connecting Photocell Trigger ..............................................................................................40 Connecting Optional Encoder..............................................................................................41 Custom Triggering Device ...................................................................................................42 Printhead Data Cables ........................................................................................................43 Connecting Additional Printing Systems ..............................................................................44 Optional Low Ink Warning Devices ......................................................................................45 Connecting to a Desktop Computer.....................................................................................46 Connecting to a Local Area Network ...................................................................................47 USB Port ..................................................................................................................... 48 Optional Four Port USB Hub ...............................................................................................49 Power Supply .............................................................................................................. 50 Ink Supply ................................................................................................................... 51 Inks and Fluids ....................................................................................................................51 Cartridge Ink System ...........................................................................................................52 Installing the Ink or Fluid Cartridge ......................................................................................53 Initial Startup ............................................................................................................... 54 Commission the Printhead .......................................................................................... 54 Software .................................................................................................. 55 Software Map .............................................................................................................. 55 Video Tutorial .............................................................................................................. 56 Home Screen .............................................................................................................. 57 Zoom Screen............................................................................................................... 58 Info Screen .................................................................................................................. 59 Message Screen ......................................................................................................... 60 Delete .................................................................................................................................60 2005559 – Rev B – 4/14/23 Message Screen Remote Server ................................................................................ 61 Settings Screen ........................................................................................................... 62 Line Speed ..........................................................................................................................63 Distance to Trigger ..............................................................................................................65 Print Direction......................................................................................................................66 Encoder...............................................................................................................................67 Repeat and Squid Connect Trigger Settings .......................................................................68 Counters .............................................................................................................................70 Spit Settings ........................................................................................................................71 Barcode Validation ..............................................................................................................73 USB Load............................................................................................................................74 Reset ..................................................................................................................................76 CoPilot Gemini Settings ......................................................................................................77 Printhead Temperature .......................................................................................................78 Wireless Interface ...............................................................................................................79 Static IP Address.................................................................................................................83 Calibrating the Touchscreen................................................................................................84 Remote Database Server ....................................................................................................85 Set Date ..............................................................................................................................87 Set Time..............................................................................................................................88 Custom Keyboard ...............................................................................................................89 Peak Encoder Speed ..........................................................................................................91 Language ............................................................................................................................92 Print Engine Alignment ........................................................................................................94 User Data .................................................................................................................... 96 Temperature Warning Screens ................................................................................... 97 Sleep Screen............................................................................................................... 99 Software Setup ...................................................................................... 101 Entering the Proper Settings ..................................................................................... 101 Operation ............................................................................................... 103 Before First-Time Use ............................................................................................... 103 Startup ...................................................................................................................... 103 Creating a Print Message .......................................................................................... 104 Transferring a Print Message .................................................................................... 104 Loading a Print Message .......................................................................................... 105 2005559 – Rev B – 4/14/23 Printing a Message ................................................................................................... 106 Correcting Image Alignment ...................................................................................... 107 Changing an Ink Cartridge ........................................................................................ 108 Powering Off ............................................................................................................. 109 Maintenance .......................................................................................... 111 Understanding Gemini Maintenance ......................................................................... 111 Needed for Maintenance of a CoPilot Gemini ........................................................... 115 Checking Mounting Hardware and Connections ....................................................... 115 External Cleaning ...................................................................................................... 115 Cleaning the Nozzle Faceplate ................................................................................. 116 Flushing the Printhead .............................................................................................. 118 Purging the Printhead ............................................................................................... 126 Commissioning the Printhead ................................................................................... 130 Printhead Storage/Idle Time Guidelines.................................................................... 132 Preparing a CoPilot Gemini for Shipping................................................................... 133 Preparing a Printhead for Shipping....................................................................................133 Preparing a Controller for Shipping ...................................................................................135 Preparing a CoPilot Gemini for Storage .................................................................... 136 Preparing a Printhead for Storage .....................................................................................136 Preparing a Controller for Storage .....................................................................................141 Preparing an Unfinished Ink Cartridge for Short-Term Storage .........................................141 Troubleshooting .................................................................................... 143 Parts List ............................................................................................... 145 Printhead Exploded View .......................................................................................... 145 Controller – Exploded View ....................................................................................... 148 Replaceable Parts ..................................................................................................... 150 Mounting Hardware ................................................................................................... 151 Floor Stand Mounting Systems .........................................................................................152 Conveyor Mounting Systems.............................................................................................153 Updates.................................................................................................. 155 System Updates ........................................................................................................ 155 Applying System Updates from USB .................................................................................155 User Guide Updates.................................................................................................. 157 2005559 – Rev B – 4/14/23 Product Warranty .................................................................................. 159 Warranty Statement .................................................................................................. 159 Warranty Period ........................................................................................................ 159 Printheads ................................................................................................................. 159 Repairs...................................................................................................................... 159 Print Quality .............................................................................................................. 159 Shipping Policy.......................................................................................................... 159 Exclusions ................................................................................................................. 159 Warranty Procedures ................................................................................................ 160 Warranty within 60 days of invoice ............................................................................ 160 Warranty 60 days to 1 year from invoice ................................................................... 160 Warranty Eligibility..................................................................................................... 160 Limited Warranty ....................................................................................................... 160 Disclaimer of Damages ............................................................................................. 161 Technical Support ................................................................................. 163 2005559 – Rev B – 4/14/23 10 We Help Companies Deliver Products to the World 2005559 – Rev B – 4/14/23 We Help Companies Deliver Products to the World 11 We Help Companies Deliver Products to the World Thank you for choosing the Squid Ink CoPilot Gemini Industrial Inkjet Printing System for your marking and coding needs. Squid Ink is part of Engage Technologies, an ISO 9001-2015 certified company that has steadily built a solid reputation for quality since 1991. Engage is known for providing rugged, durable, reliable packaging equipment to help companies deliver their products to the world. Each Engage Technologies company – Squid Ink, Eastey, and American Film & Machinery (AFM), focuses on a different part of the packaging section of the production line. Squid Ink (www.SquidInk.com) Coding and marking equipment, inks, and fluids for product identification and traceability Eastey (www.Eastey.com) Automated shrink wrapping and bundling, automated case sealing, case erecting and product handling AFM (www.AFMSleeves.com) Automated shrink sleeve labeling equipment, tamperevident banding equipment, shrink tunnels and shrink sleeve consumables When you purchase your packaging equipment from the Engage Technologies family of companies, you can feel confident that you have a machine that is first in quality and built to last. Thank you for choosing us for your packaging needs. 2005559 – Rev B – 4/14/23 12 We Help Companies Deliver Products to the World 2005559 – Rev B – 4/14/23 Abbreviations & Terminology 13 Abbreviations & Terminology The following abbreviations are used throughout this User Guide: Abbreviation Meaning Abbreviation Meaning C Celsius P/N Part Number CE Meets safety, health, and environmental requirements of the European Union PDF417 A barcode format cm Centimeters PNP Positive-Negative-Positive dpi Dots per inch QR A barcode format EAN-8 A barcode format RJ12 Registered Jack 12 EAN-15 A barcode format SCC-14 28 A barcode format F Fahrenheit SCC-14 ITF A barcode format FAT32 A USB format SSCC-18 A barcode format fpm Feet per minute SSID Service Set Identifier ft Feet TUV Meets the requirements of the German Equipment and Product Safety Act GB Gigabytes UCC-128 A barcode format GND Ground UDP User Datagram Protocol GUI Graphic User Interface UPC-A A barcode format Hz Hertz USB Universal Serial Bus IP Internet Protocol VAC Volts Alternating Current IT Information Technology W Watts LED Light-Emitting Diode WiFi Wireless networking technology ml Milliliters ° Degrees m Meters ‘ Feet MicroQR A barcode format “ Inches min Minutes < Less than mm Millimeters > Greater than MSI A barcode format # Number NPN Negative-Positive-Negative % Percent NTFS A USB format 2005559 – Rev B – 4/14/23 14 Abbreviations & Terminology 2005559 – Rev B – 4/14/23 Safety 15 Safety Follow these safety practices when installing, operating, and maintaining the CoPilot Gemini printing system. Warnings • Use proper lifting techniques: When unpacking and setting up the Printer, use proper lifting techniques. Avoid overreaching and leaning over while handling the Printer and accessories. • Wear proper PPE: When installing, maintaining, and operating the Printer, wear safety glasses, gloves, and protective clothing. • Power source: Ensure that the electrical power source is properly wired and grounded. Ensure that the power source complies with all safety regulations and codes applicable to the installation location. • Shut down for maintenance. Turn off and unplug the printing system while servicing and performing maintenance. NOTE: Some service and maintenance procedures require the power to be left on. During such procedures, carefully follow the safety instructions. • Use proper inks and fluids: Use only Squid Ink Manufacturing ink or other Squid Ink Manufacturing approved fluids. • Use only as described: The Squid Ink CoPilot Gemini Printer uses an Ink Cartridge system. Do not open or use the Ink Cartridge in any way other than normal installation. • Flammability: Keep all fluids away from open flame and excessive heat, as they may be flammable. • Skin damage: Avoid prolonged contact with skin. Fluids can be washed away with soap and water. • Eye damage: Do not look directly into the Printhead. If fluids make eye contact, flush immediately with water and receive appropriate medical attention. • Dispose of all fluids properly: Never pour fluids into a sink, sewer, or drain. Dispose of fluids in accordance with all ordinances and regulations pertaining to fluid disposal. 2005559 – Rev B – 4/14/23 16 Safety Understanding Safety Notifications WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. ATTENTION: Indicates a hazardous situation which, if not avoided, could result in property damage only. General Precautions When installing, operating, and maintaining the CoPilot Gemini, observe these cautions. WARNING: Health Hazard Some inks may be a health hazard with prolonged exposure. Ensure that the area has adequate ventilation. WARNING: Electrical Hazard Do not open cover. No user-serviceable parts inside. WARNING: Electrical Ground Hazard Ensure that unit is properly grounded. WARNING: Keep Dry Keep the equipment dry and indoors. CAUTION: Fire Hazard Inks, cleaners, internal flush fluids, and storage fluids may be flammable. Use caution and keep away from flame. CAUTION: Environmental Hazard Inks, cleaners, internal flush fluids and storage fluids may be harmful to the environment. Dispose of properly. 2005559 – Rev B – 4/14/23 Safety 17 Liability The CoPilot Gemini Industrial Inkjet Printing System has been designed for safe operation under normal conditions. However, unauthorized modifications, improper operation, or carelessness can result in serious injury to the user or damage to equipment. The manufacturer or its agents and representatives assume no responsibility or liability for the following: • Injury or equipment damage due to improper use of the machine. • Problems or hazards resulting from failure to operate or maintain the equipment as specified in this User Guide. • Equipment modifications that have not been authorized in writing by Squid Ink. • Abuse, unauthorized tampering with the system or attempting to perform repairs beyond the scope of what is described in this User Guide. • Electrical interference, hot-plugging of Printheads, or improper/ungrounded power sources. • Use of unauthorized inks and/or fluids, including inks and fluids from Squid Ink that are inconsistent with the systems and uses described in “Inks and Fluids” on page 51. • Use of unauthorized wipes on Printhead Nozzles. Any of the above misuses will void any and all warranties. Further, Engage Technologies, Squid Ink, or their agents and representatives shall not be held liable for lost profits, incidental or consequential damages, attorney fees, or similar expenses that may result from such misuse. Refer to the Product Warranty on page 159 for further information. Always use the equipment in a manner consistent with the instructions in this User Guide. 2005559 – Rev B – 4/14/23 18 Safety 2005559 – Rev B – 4/14/23 Introduction 19 Introduction General System Description The CoPilot Gemini printing system is designed to print superior quality high-resolution characters on a variety of porous and non-porous surfaces. The CoPilot Gemini system consists of a Controller with a Touchscreen user interface and a Printhead that uses a Squid Ink CoPilot Max Ink Cartridge. The Printhead has two Print Engines which “stitch together” the upper and lower halves of a print message into a single printed image. The Upper Print Engne is controlled through the PH1 Data Input and is maintained using the PH1 Print Engine Isolation Button and PH1 Drain Tube. The Lower Print Engine is controlled through the PH2 Data Input and is maintained using the PH2 Print Engine Isolation Button and PH2 Drain Tube. Front View Ink or Fluid Cartridge Rear View Upper Print Engine (PH1) Purge Button Print Engine Isolation Buttons Lower Print Engine (PH2) Data Inputs Drain Tubes For a more thorough understanding of how to control ink flow through the CoPilot Gemini during maintenance, see “Understanding Gemini Maintenance” on page 111. Messages for the CoPilot Gemini are created and edited using Orion™ software. Messages are then loaded onto the Controller through an Ethernet connection or from a USB device. Refer to the Orion™ Software User Guide for more information. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial 2005559 – Rev B – 4/14/23 20 Introduction environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area may also cause harmful interference. If so, the user will be required to correct the interference at his or her own expense. 2005559 – Rev B – 4/14/23 Introduction 21 System Components The CoPilot Gemini printing system consists of the following items: Part Controller Part Number Description 2005077 CoPilot Gemini Controller 2005550 CoPilot Gemini Printhead – Oil-Based 2005551 CoPilot Gemini Printhead – Solvent-Based 2004187 Power Supply Cord for Controller Data Cable 2003921 Printhead Data Cable – 36 in (91.4 cm) (one for each Printhead) Optional 10’ (304.8 cm) available Mount Varies Mounting Hardware (optional) Sensor 1602018 Photocell Assembly (trigger) Encoder 1604177 Encoder Assembly Kit (optional) Alarm Beacon 2003975 Low Ink Warning Beacon (optional) USB Hub 2004242 USB Hub (optional) Ink Cartridge Varies Ink Cartridge Printhead Power Cable IMPORTANT: If you purchased an optional level of Orion™ that allows connecting to multiple Printers, a Download Instructions card is included in the shipping carton. Do not throw this card away. The card contains the Orion license number required for downloading Orion and connecting the CoPilot Gemini printing system. If there is no card, you can still download Orion and connect to a single printer. If there are problems, call Customer Service at 800-877-5658. 2005559 – Rev B – 4/14/23 22 Introduction System Dimensions Controller Dimensions Top View Bottom View Side View Front View 2005559 – Rev B – 4/14/23 Introduction 23 Printhead Dimensions Right View Front View Left View Rear View Bottom View 2005559 – Rev B – 4/14/23 24 Introduction System Specifications Print Technology Piezo impulse Printhead technology Maximum Print Height 5.6” 14.2 cm Maximum Message Length 120” 304.8 cm Maximum Throw Distance 0.19” 48.3 mm Drop Size 42 pL Vertical Print Resolution 360 dpi Maximum Print Speed At 300 dpi Horizontal Resolution 110 fpm 33.5 m/min At 150 dpi Horizontal Resolution 220 fpm 67.1 m/min Time and Date Internal real-time clock with battery backup Product Sensor External Photocell trigger or optional Encoder Communication Interface One USB host and one Ethernet input Main PCB (Part #1440019) Circuit Board Weight TQ Module (Part #2004000) Controller 3.2 lbs 1.45 kg Printhead 7.1 lbs 3.22 kg Ink Cartridge (Full) 1.2 lbs 0.54 kg Electrical Requirements 100–240 VAC, 50/60 Hz, 65 W maximum Operating Temperature 34 - 104 °F (1 - 40 °C) Storage Environment 34 - 122 °F (1 - 50 °C) Substrate Capabilities Porous and non-porous applications Ink Capabilities Oil-based and solvent-based Ink System Active Ink Control System 500 ml Cartridge Message alert on Touchscreen Low Ink Indicator Optional Low Ink Alarm Beacon Agencies Agency Certifications Safety Emissions/ Immunity 2005559 – Rev B – 4/14/23 CE, FCC, and ICES Certified US UL 62368-1 Canada CAN/CSA 62368-1 Europe EN 62368-1 US FCC Part 15, EN 61000-6-4 & EN 61000-6-2 Canada ICES-3 Europe EN 61000-6-4 & EN 61000-6-2 Introduction 25 Software Specifications Time and Date Multiple formats including: 1,2,4, -digit year, 1,2-digit month, 3 letter month, custom month string, 1 letter day of month (Korean), 2-digit day of month, 1-digit day of week, 1,3 letter day of week, 2digit week of year, 3 digit Julian year, 1 letter hour, (a-x), 2-digit hour 12 or 24, 2-digit minute, 2 digit second, 1,2 letter meridians (A/P, AM/PM), custom week string. Counters Supports 16 counters, one of which can be a daily counter. Shift Codes Four programmable shift codes with automated rollover. Barcodes Code 39, Interleaved 2 of 5, UPC-A, EAN-8, EAN-13, Code 128, UCC-128, SCC-14 ITF, SCC-14 28, SSCC-18, MSI, DataMatrix, QR, MicroQR and PDF417 bar codes standard. Fonts Arial (regular and bold), Courier, Tahoma (regular and bold), and Lucida resident fonts for use in variable data elements. Static elements in any Windows® font. Printing Features Reverse, Rotate, Repeat, Invert Message Storage Capacity 1024 Messages. Capacity to store more than 1024 messages based on the message complexity up to 1 GB free space. Logos and Graphics Orion™ software supports most image file types Languages English, Spanish, German, Chinese, Japanese, Korean, Russian, and Polish. 2005559 – Rev B – 4/14/23 26 Introduction Options Part Number Description Purpose Dependent on ink STARTER KIT Includes ink, cleaner and flush, Printhead wipes, hand cleaner, and latex gloves. 1604177 ENCODER ASSEMBLY KIT For operation with variable speed Conveyors. 2003927 LOW INK ALARM BEACON ASSEMBLY Alerts when ink levels become low. 2003975 AUDIBLE LOW INK WARNING ASSEMBLY Alerts when ink levels become low. 2004194 BARCODE LASER SCANNER Allows scan and print message retrieval. 2004242 USB HUB Enables connection of multiple USB devices to the Controller’s USB Port. 2005559 – Rev B – 4/14/23 Installation and Setup 27 Installation and Setup General Recommendations Vibration and Movement The CoPilot Gemini “stitches” together two parts of a print message. This requires consistent alignment of the two Print Engines in relation to one another. If the Printhead is moved – even slightly – the two Print Engines can lose their alignment, and the user will need to readjust that alignment in “Settings.” To avoid this, ensure that the Printhead is positioned so that it will not be easily bumped by products passing on the Conveyor or by individuals or equipment on the factory floor. Additionally, Squid Ink recommends mounting the Printhead and Controller to a Conveyor Mount or, if the Conveyor is prone to significant vibration, a Floor Stand that is bolted to the floor. Both of these accessories are available from Squid Ink (see “Floor Stand Mounting Systems” on page 152 and “Conveyor Mounting Systems” on page 153). Material Handling A critical item for consistently superior quality printing is material handling. This is an area controlled by the customer and the installer. Always use adequate Conveyor Product Guides and ensure that they are installed and maintained properly. Incorrect or inconsistent product handling will cause print quality problems, maintenance problems, and could lead to Printhead damage. The customer is responsible for maintaining proper material handling equipment. Properly Installed and Maintained Conveyor Guides Conveyor Guides 2005559 – Rev B – 4/14/23 28 Installation and Setup Grounding To further improve print quality and protect the system from static electricity, install a 0.25" (or wider) ground braid between the Controller and earth ground. AC Power In some locations where the printing system is installed, AC power may be subject to line noise, brownouts, and blackouts. If line noise, brownouts, or blackouts occur on a regular basis, a good-quality line conditioner or Uninterruptible Power Supply (UPS) should be installed to ensure data integrity. In many cases, these devices may not be necessary; it is acceptable to start an installation without them. However, if system lockups or occasional distorted print occurs, the first corrective measure should be to isolate and clean up the AC power. Work Area The CoPilot Gemini may occasionally require commissioning, flushing, or purging due to environmental contaminants collecting on the Nozzle Faceplate. Commissioning, flushing, and purging require the use of clean, Non-abrasive, Lint-free Wipes (Part #2005470) that will become soiled with ink during use. A small Cabinet or Box near the Printer to store the Wipes and to keep them clean is recommended. A small Waste Receptacle is also recommended for soiled Wipe disposal. All supplies listed in “Needed for Maintenance of a CoPilot Gemini” on page 115 should be readily available in the work area. Maintenance Access When planning the installation, allow for easy access to the Printheads so that cleanup and maintenance can be done conveniently. ATTENTION: Avoid operating the Printhead without ink. Doing so results in more purge ink being required to re-commission the Printhead. Always purge and commission solvent inks before attempting to print messages. 2005559 – Rev B – 4/14/23 Installation and Setup 29 Printhead Overview Printhead Front Components Nozzle Faceplate Upper Print Engine (PH1) Lower Print Engine (PH2) Printhead Rear Components Ink Cartridge (not included) Purge Button Power Indicator Light PH2 Data Port: Lower Print Engine PH2 Isolation Button: Lower Print Engine PH2 Ink Drain Tube: Lower Print Engine PH1 Data Port: Upper Print Engine PH1 Isolation Button: Upper Print Engine PH1 Ink Drain Tube: Upper Print Engine 2005559 – Rev B – 4/14/23 30 Installation and Setup Controller Overview Controller Front View Touchscreen Photocell/Encoder IN Port Photocell/Encoder OUT Port to Daisy Chain Printers Ethernet Port Power Switch Power Cord Receptacle Fuse: (4A Fast Blow Schurter 0034.1521) Controller Rear View Printhead 1 Data Cable Port Printhead 2 Data Cable Port 2005559 – Rev B – 4/14/23 USB Port Label Installation and Setup 31 Mounting Each installation is unique, and Squid Ink Manufacturing cannot anticipate customer requirements for attaching Mounting Brackets to the production line. Squid Ink recommends using a Floor Stand Mounting System (see “Floor Stand Mounting Systems” on page 152) or Conveyor Mounting Assembly (see “Conveyor Mounting Systems” on page 153) for mounting the CoPilot Gemini printing system. Follow the installation instructions for the specific mounting system ordered with your Printer. ATTENTION: Use only the supplied Mounting Screws to attach the Printhead and Controller to the Mounting Brackets. Using Mounting Screws other than those supplied by Squid Ink Manufacturing can result in damage to the Printhead or the Controller. Mounting the Printhead Printhead Mounting Bracket Supplied Mounting Screws Supplied Mounting Screw Mounting Arm 2005559 – Rev B – 4/14/23 32 Installation and Setup Mounting the Controller There are two M6 mounting holes located on the bottom of the Controller. Use these holes and the supplied Mounting Screws to attach the Controller to the Mounting Bracket. ATTENTION: Use only the supplied Mounting Screws to attach the Controller to the Mounting Brackets. Using Mounting Screws other than those supplied by Squid Ink Manufacturing can result in damage to the Controller. Controller Supplied Mounting Screws 2005559 – Rev B – 4/14/23 Installation and Setup 33 Attaching an Optional Cable Protection Bracket An optional Cable Protection Bracket (Part Number: 2005083) can be easily installed before attaching the Controller to a Floor Mount or Conveyor Mount. Controller Attaching a Cable Protection Bracket Screw from Controller Cable Protection Bracket Supplied Mounting Screws (can go through the Platform of the Mount and the Cable Protection Bracket) 2005559 – Rev B – 4/14/23 34 Installation and Setup Mounting a Photocell A Photocell (Part Number 1602018) can be mounted to the left or right side of the Printhead using a Photocell Mounting Bracket. Mount the Photocell on the upstream side of the Printhead so that it detects the product before it reaches the Printhead. Photocell Correctly Mounted Photocell for left-to-right product flow Photocell Mounting Bracket Photocell Correctly Mounted Photocell for right-to-left product flow Photocell Mounting Bracket 2005559 – Rev B – 4/14/23 Installation and Setup 35 Choosing the Correct Photocell Mounting Bracket To ensure optimal performance of the Photocell, it is important to select the correct Photocell Mounting Bracket for the intended situation. The matrix below shows the various Bracket Assembly options. Situation Part Number Illustration Straight / Down / Turn Mount Straight Mount Conveyor Mount 2005031 2005051 2005031 2005051 2005051 2003083 � � 2003377 � � 1603005 � � 1603007 � � 2005559 – Rev B – 4/14/23 36 Installation and Setup Distance from Substrate Generally, the closer the Printhead is to the print surface (substrate), the better the print quality. The recommended distance between the Nozzle Faceplate and the print surface is 0.125” (3.2 mm). Throw distances greater than 0.125” (3.2 mm) are possible but print quality may be affected. Recommended Distance from Substrate: 0.125 " (3.2 mm) Printhead Print Surface Print Engines 2005559 – Rev B – 4/14/23 Installation and Setup 37 Mounting to a Floor Stand When using a Floor Stand Mount, screw the bottom of the Controller to the upper shelf bracket, and attach the Printhead to the arm of the Mount. Front View (Conveyor Side) Rear View (User Side) Controller Printhead Floor Stand Floor Stand Mounting System (Part Number 2005031) 2005559 – Rev B – 4/14/23 38 Installation and Setup Conveyor Mounting Bracket When using a Conveyor Mounting Bracket, screw the bottom of the Controller to the upper shelf bracket, and attach the Printhead to the arm of the Mount. Controller Printhead Conveyor Mounting Bracket Conveyor Mounting Assembly (Part Number 2005051) 2005559 – Rev B – 4/14/23 Installation and Setup 39 Rotating or Tilting the Printhead The Printhead can be mounted in a rotated or tilted orientation. This is useful when printing on an incline Conveyor or vertical web. The Printhead can be rotated 90° counterclockwise (Ink Cartridge side facing downward) or 45° clockwise (Ink Cartridge side angled upward) when viewed from the rear of the Printhead. Do not rotate the Printhead 90° clockwise. NOTE: When rotating the Printhead counterclockwise, do not exceed 90°. Ensure that the unit is level from front to back or tilted slightly downward 45° 90° Sideshooter Mode The Printhead can be tilted from 0° to 90° pointing down (downshooter mode). The Printer will not print pointing upward. 90° Straightshooter Mode Downshooter Mode 2005559 – Rev B – 4/14/23 40 Installation and Setup Cable Connections Connecting Photocell Trigger The Photocell notifies the Controller when a product is about to pass in front of the Printhead. Connect the Photocell signal cable to the IN Connection on the Controller Front Panel. IN Connection Photocell Controller Front Panel 2005559 – Rev B – 4/14/23 Installation and Setup 41 Connecting Optional Encoder An Encoder (Part Number 1604177) sends continuous information to the Controller about the speed of the Conveyor. When using a variable speed Conveyor, an Encoder is needed to coordinate the timing of printing with the timing of the passing products. An Encoder uses a wheel that touches the Conveyor Belt and sends electronic pulses to the Controller with real time information on the distance that the Conveyor has moved at any given instant, regardless of changes in Conveyor speed. NOTE: For best results, mount the Encoder as close to the Printhead as possible. Encoder Data Connect the optional Encoder and Photocell trigger to an RJ12 Adapter Cable (Part Number 2003864). Connect the Adapter Cable to the IN connection on the front of the Controller. IN Connection RJ12 Adapter Cable Encoder Photocell Controller Front Panel 2005559 – Rev B – 4/14/23 42 Installation and Setup Custom Triggering Device Some applications may require the use of a site-specific triggering device. Use the following pin assignments on the RJ12 Connector (Part Number 2003864) to install a custom triggering mechanism. NOTE: Site-specific or unusual devices should only be connected by trained and qualified personnel. If in doubt, contact your Squid Ink distributor. On the RJ12 Connector, connect Pin 4 to an NPN sinking open-collector output with Pin 5 acting as ground. When using a relay, connect the relay across Pins 4 and 5. The relay should be normally open, and should close when activated. CAUTION: Do not apply external voltage to any pins on the RJ12 Connector. The Fuse can be accessed by removing the AC Cord and sliding the tab outward. 2005559 – Rev B – 4/14/23 Installation and Setup 43 Printhead Data Cables Ensure that the Controller Power Switch is turned OFF and the Controller is disconnected from the power source before connecting a Printhead. ATTENTION: Connect the Printhead only to a corresponding Controller. Connecting a Printhead to an inappropriate Controller may damage the Printhead and void the warranty. The rear of the Controller contains two Data Connections labeled PRINTHEAD 1 and PRINTHEAD 2, which correspond to the two Print Engines in the Printhead. The PRINTHEAD 1 Port on the Controller should be connected using a Data Cable to the PH1 Port on the rear of the Printhead to control the Upper Print Engine. The PRINTHEAD 2 Port on the Controller should be connected using a Data Cable to the PH2 Port on the rear of the Printhead to control the Lower Print Engine. Data Port: Lower Print Engine Data Port: Upper Print Engine Data Cables Controller Printhead NOTE: The Gemini will not function properly if only one Print Engine is connected to the Controller or if the Print Engines are connected to the wrong Ports on the Controller. The Data Cable also carries power from the Controller to the Printhead. 2005559 – Rev B – 4/14/23 44 Installation and Setup Connecting Additional Printing Systems Connecting a second CoPilot Gemini system allows two different messages to be printed on the same box at the same time – for example, when printing on both sides of a box. If using a second CoPilot Gemini printing system, connect an RJ12 Sensor Cable between the first and second CoPilot Gemini Controllers. Connect the Sensor Cable from the “OUT” Connection Port on the first Controller to the “IN” Connection on the second Controller. To Connect Additional Printing Systems in a Daisy Chain: 1. Connect an RJ12 Sensor Cable (Part Number 2003588) between the first and second Controllers. 2. Connect the Sensor Cable from the OUT Connection on the first Controller to the IN Connection on the second Controller. First Controller Sensor Cable OUT Sensor Cable IN Second Controller Theoretically, an infinite number of printing systems can be attached using the IN and OUT Data Connections in a daisy chain. However, the number of Printers connected through a single triggering device is limited by the specific installation and use. Other Squid Ink printing systems may also be connected downstream from the Controller. For example, another CoPilot Gemini, a CoPilot Max, an AutoPilot, and an SQ-2 printing system could be attached to a single triggering device. 2005559 – Rev B – 4/14/23 Installation and Setup 45 Optional Low Ink Warning Devices An optional Low Ink Warning Beacon (Part Number 2003927) can be connected to the CoPilot Gemini Controller USB Port. An optional Audible Low Ink Warning Device (Part Number 2003975) is also available. An optional Four Port USB Hub (Part Number 2004242) can be used to connect both of these low ink warning devices at once. The Low Ink Warning Beacon is useful for alerting operators that ink is running low before missed prints or Printhead damage occurs due to lack of ink. Low Ink Warning Beacon Audible Low Ink Warning Device Mounting Bracket Mounting Bracket USB Port Controller Since each installation is unique, Squid Ink cannot anticipate an ideal location for the Low Ink Warning Beacon. The Beacon includes a generic Mounting Bracket. Mount the Low Ink Warning Beacon within 5 feet (1.5 meters) of the Controller. 2005559 – Rev B – 4/14/23 46 Installation and Setup Connecting to a Desktop Computer A desktop computer can be connected to the Controller, enabling the user to create and download messages using Orion software. To connect to a desktop computer, connect an Ethernet Cable to the Ethernet Port on the Controller and to the Ethernet Port on the computer. Desktop Computer Ethernet Cable Ethernet Port Controller 2005559 – Rev B – 4/14/23 Installation and Setup 47 Connecting to a Local Area Network A Local Area Network (LAN) can be connected to the Controller, allowing the user to connect multiple Controllers to a network-connected PC running Orion software. To connect to a Local Area Network, plug the Network Cable into the Ethernet Port on the Controller. Local Area Network Ethernet Cable Ethernet Port Controller 2005559 – Rev B – 4/14/23 48 Installation and Setup USB Port The USB Port located on the front of the Controller can be used to connect to a variety of USBsupported devices such as a wireless network adapter antenna, Low Ink Alarm Beacon, scanner, or removable USB storage device. The maximum current available on the USB Port is 900 mA. USB Port Controller A removable USB Drive can be used to load messages from Orion and to install Printer firmware and software updates. NOTE: The USB format must be FAT32 or NTFS. The USB button on the Settings screen is enabled when a USB Drive is connected to the USB Port. The USB Load screen opens automatically if a USB Drive is connected during startup. 2005559 – Rev B – 4/14/23 Installation and Setup 49 Optional Four Port USB Hub The Controller contains one USB Port. The optional Four Port USB Hub (Part Number 2004242) provides three connections for USB devices. Low Ink Warning Beacon USB Hub Power Supply USB Drive USB Wireless Adapter Four-Port USB Hub USB Cable to Controller Controller Optional Four Port USB Hub (Part Number 2004242) 2005559 – Rev B – 4/14/23 50 Installation and Setup Power Supply To Connect the Power Supply: 1. Locate the Power Cord Port on the front of the Controller. 2. Verify that the Power Switch is in the OFF position. 3. Attach the supplied Power Cord into the Power Cord Port. 4. Plug the Power Cord into a properly wired and grounded electrical outlet. Controller Power Switch Power Cord Port Power Cord 2005559 – Rev B – 4/14/23 Installation and Setup 51 Ink Supply Ink and fluids are supplied to the Printhead using a 500 ml Cartridge ink system. The Ink Cartridge has been manufactured and labeled to ensure that the correct ink is used. Ensure that the correct inks and fluids are being used with the system (see “Inks and Fluids” below). WARNING: Ink is flammable. Keep away from flames and excessive heat sources. Inks and Fluids ATTENTION: Use only the Squid Ink approved fluids for cleaning or flushing the Printhead. Using the wrong fluids may damage the equipment, cause a safety hazard, and will void the warranty. ATTENTION: For oil-based Printheads, never use External Cleaning Fluid as an Internal Flush Fluid or Storage Fluid, and never use External Cleaning Fluid on the Nozzle Faceplate. ATTENTION: Always use Non-abrasive Lint-free Wipes (Part Number 2005470) when cleaning and maintaining the Printhead. Internal Flush Fluid External Cleaning Fluid (Nozzle Area) Storage Fluid Floor and Work Area Cleaner Ink Base Ink Oil SI-PZ1060 SI-PZ1043 Part #: 2101140 SI-PZ1053 NOT near Printhead Oil (Mineral Oil Free) SI-PZ19XX SI-PZ1943 2101947 SI-PZ1053 NOT near Printhead Solvent SI-PZ32XX SI-PZ3043 2103160 SI-SB PZ STORAGE 2109008 SI-PZ3043 2005559 – Rev B – 4/14/23 52 Installation and Setup Cartridge Ink System A small tab located above the Ink Fitting prevents the wrong type of ink from being installed in the Printhead. The Ink Fitting on the front of the Ink Cartridge is color-coded to correspond with the ink type. For oil-based inks, the Ink Fitting is black. For solvent-based inks, the Ink Fitting is tan. Ink Cartridge (Rear) Ink Cartridge (Front) Tab Thumb Recess 2005559 – Rev B – 4/14/23 Tan or Black Ink Fitting Installation and Setup 53 Installing the Ink or Fluid Cartridge The Printhead is shipped from the factory with a small Shipping Cover placed over the Ink Fitting in the Ink Cartridge Bay. Remove the Shipping Cover from the Ink Fitting before installing the Cartridge. Save the Shipping Cover for future use. Printhead Shipping Cover To install an Ink Cartridge or Internal Flush Cartridge, snap the 500 ml Cartridge into position. Verify that the Cartridge is fully seated in the Printhead. Printhead Ink Cartridge Properly Seated Cartridge If using the Printhead for the first time, or if it has been idle for an extended period, commission the Printhead before use (see “Commissioning the Printhead” on page 130). 2005559 – Rev B – 4/14/23 54 Installation and Setup Initial Startup Before initial startup, double-check the installation. Verify that all components have been securely mounted and all Data and Power Cables are properly seated and connected. When all components have been properly mounted and connected, the system can be started. To start the system, turn the Power Switch located on the front of the Controller to the ON position. Power Switch Controller After the power is turned on, the system goes through a brief startup sequence lasting approximately one minute. When startup is complete, the Home screen is displayed. Home Screen Commission the Printhead Before first use, the Printhead must be commissioned. Follow the instructions in “Commissioning the Printhead” on page 130. 2005559 – Rev B – 4/14/23 Software 55 Software Software Map 56 60 62 62 96 58 62 63 65 66 67 68 70 71 73 74 76 79 83 84 85 87 88 89 91 92 94 77 78 2005559 – Rev B – 4/14/23 56 Software Video Tutorial The video below provides the basics of the software on the CoPilot Max Controller, which is very similar to the CoPilot Gemini Controller. VIDEO: Controller Screens and Navigation To see a video of this procedure, click this link: https://www.youtube.com/watch?v=XXW6yyNGhDo&list=PLQry 4D7ObPx5gph8VfxTE9tmqz1js5w_f&index=6 Or scan the QR code at right using the camera app on your mobile device. Not included in this video are software features exclusive to the Gemini: • Settings Screen 1: The Gemini has a “CoPillot Gemini Settings” button, which functions similarly to the “CoPilot Max Settings” button – taking the user to a screen used when changing Ink Cartridges and when adjusting print speed/resolution (see “CoPilot Gemini Settings” on page 77). • Settings Screen 2: Unlike CoPilot Max, Gemini has a “Print Engine Alignment” button – taking the user to a screen where they can fine tune the “stitching together” of the two parts of a print message printed by Print Engine 1 and Print Engine 2 (see “Print Engine Alignment” on page 94). 2005559 – Rev B – 4/14/23 Software 57 Home Screen The Home Screen contains the following: • A preview of the current message • The name of the current message • Product count • Ink status • Printing status If a USB Drive is plugged into the USB Port at startup, the Touchscreen will automatically display the USB Load Screen. To go the Home Screen, select Back. Message Preview Commands Current Time Home Screen Message Name Current Date Ink Status Connection Type Product Counter Printing Status Zoom 2005559 – Rev B – 4/14/23 58 Software Zoom Screen The Zoom Screen enables the user to view the print message at a larger size on screen. Zooming does not affect the print size of the message. To access the Zoom Screen from the Home Screen, select the Zoom button side of the screen. The 1 and 2 buttons indicate the active Printhead. on the right Select Full Message Width , 75%, and 100% to zoom in and out of the message. The current zoom setting button is available. Zoom Screen Full Message Width 2005559 – Rev B – 4/14/23 75% 100% Software 59 Info Screen The Info Screen provides information about the CoPilot Gemini system being used. Info Screen 2005559 – Rev B – 4/14/23 60 Software Message Screen The Message Screen contains a list of available messages. Refer to the Orion Software User Guide for information about creating messages on a PC and downloading them to the Controller. Use the Up and Down arrows or drag the scroll bar to view the list of available messages. To select a message for printing, choose the desired message and then select APPLY. Message Screen Scroll Up Delete Message Scroll Down Delete The Delete button removes a selected message from the Controller. Deleting the message only deletes the message copy in the Controller. It does not delete the message from Orion. NOTE: A message cannot be deleted if it is currently open. 2005559 – Rev B – 4/14/23 Software 61 Message Screen Remote Server If the Printer is using a remote Database Server to load messages for printing, use the keyboard on the Touchscreen to enter a message ID. Select APPLY to load the message for printing. When the message is loaded, a green checkmark is briefly displayed in the lower right corner of the screen. If the connection fails, an error message is briefly displayed. The Printer returns to the Home Screen. Message Screen with Remote Server 2005559 – Rev B – 4/14/23 62 Software Settings Screen The Settings Screen contains two pages of Printer configuration settings. Select between Settings Screen 1 and Settings Screen 2. to switch Settings Screen 1 Line Speed Distance to Trigger Encoder Print Direction Home Screen Previous Screen Settings Screen 2 Barcode Validation Repeat Trigger Spit Settings Counters Info USB Load Reset CoPilot Gemini Settings Printhead Temperature Settings Screen 2 Wireless Interface - Wifi Static IP Address Calibrate Touchscreen Remote Database Server Home Screen Previous Screen Settings Screen 2 Peak Encoder Speed Set Date Custom Keyboard Set Time Info Language Print Engine Alignment Following describes the settings accessible through the Settings Screen functions are. 2005559 – Rev B – 4/14/23 and what their Software 63 Line Speed The Line Speed Screen sets a static line speed for the Printer in feet per minute (fpm). To set the line speed, use the Plus (+) or Minus (-) buttons to increase or decrease the line speed, or move the scroll bar in either direction. The maximum line speed is 110 fpm at 300 dpi or 220 fpm at 150 dpi. Line Speed Screen Increase Line Speed (fpm) Decrease Line Speed (fpm) Line Speed Using an Encoder To use an Encoder to control line speed, select ON. Conveyor Pause Time After Which Printer Stops Decrease Pause Time Increase Pause Time Select APPLY to save changes. Select BACK to return to the previous screen. 2005559 – Rev B – 4/14/23 64 Software Encoder Timeout The Encoder Timeout (upper half of screen) is the amount of time in seconds that the Printer waits for a signal after the Encoder Wheel stops spinning. This number should be set to significantly higher than the normal pauses that the Conveyor makes while operating. If the Conveyor stops for a period longer than the “Encoder Timeout” time while printing a message or between messages, the Printer stops looking for an Encoder signal, and the message must be restarted. Use the Plus (+) or Minus (-) buttons or the slider to increase or decrease the amount of time. The default setting is 15 seconds. The maximum setting is 86400 seconds (24 hours). The amount of time is displayed in hours, minutes, and seconds. 2005559 – Rev B – 4/14/23 Software 65 Distance to Trigger Distance to Trigge