BestCode Series 8:Technical ManualV1.06 Series 8 CIJ Technical ManualVolume 1.06, April 15th, 2015For Replacement Guides:CIJ Technical Manual: 41-0001-01 CIJ Operator’s Guide: 41-0002-01Copyright BestCode 2011-2015 ObjectiveThis manual serves as a guide for operating the Series 8 Continuous Ink Jet printer Series. All maintenance should be performed by a trained technician.If lost, duplicate manuals are available online in hard and soft copy.How to use this manualIn the electronic version, the table of contents can be used to navigate the manual. By clicking on the Section or Subsection in the table of contents, the manual will automatically jump to that page. Contents Objective 5Section 1 15General Information 15BestCode Series 8 System 16How to use this Manual 18Safety Information 18Section 2 21System Overview and Detailed Specifications 21Controller 22Printhead 23Consumable and Delivery 24Tank Capacity 24Bottle Size 24Fluid Consumption 25Speed Tables and Descriptions 29Product Dimensions 31Controller 31Printhead 3190° Printhead 32Peripherals Shaft Encoder 32Fluidic Diagram 33Block Diagram & Valve Locations 34Section 3 35Detailed System Setup 35Mounting Controller & Printhead 37Height limitations 37Carts 38Stainless Steel Cart - 40-0001-01 38Poly Cart – 40-0002-01 39Stands 40Printhead Floor Stand – 40-0003-01 40Conveyor Side Mount – 40-0004-01 41Printhead Mount 42Clamp 25-0033-02 & Spud 22-0069-01 42Section 4 43Commission System 43Commission System 45System Installation 45Controller Mounting 45Printhead Mounting 46Fluid System Commissioning 48Install/use BestCode Peripherals 54Installing bulkhead connectors 54Configuring Peripheral Devices 57Section 5 62System Operation 62Basic Navigation 64Turning Power On/Off 64Add Ink / Solvent. 65Starting/Stopping Jet. 66Selecting message for printing 67Section 6 68User Interface Operation 68Operation Basics 70Home Screen 71Main screen Menus and Indicators 71Sign In 72Help 73Print Enable 74Solvent Tank Status 75Ink Tank Status 75Printing Message 76Count 76Message Select 79Adjust 81Clean 83Setup 85Service Screen 86Creating Messages 93 Creating a Text Field 94Adding an AutoCode Field 95Adding a User Defined Field 114Adding a Graphic Field 116Moving Fields inside Editor 117Font Features 120Settings 122Advanced Editor Features 132Section 7 138Firmware and PC Tools 138Download Firmware and PC Tools 139Formatting USB for Firmware and PC Tools 139USB Folders 140How to update Firmware via J-Link / Board Recovery 140How to update Firmware via USB Load 142BestTools 144Fonts 144Keyboard 151Translations 156Graphics 162Remote Communication Protocol 167Communication Description Overview 167Resource Requirements 167Serial COM port access 168Ethernet port access 169Interface Commands 171Command Usage 173Software Screenshot 174Section 8 176Maintenance 176Maintenance Intervals 177Ink Filters Replacement Instructions 178Air Filter Replacement Instructions 183Printhead Maintenance 186Back Flush Nozzle 186Printhead Clean 188 Section 9 190Technical Operation and Troubleshooting 190Fluidic Diagrams 191General Flow Paths 191Standard “Run” Operation 192Flush Start / Stop and Printhead Clean Function Flow 195External Peripheral Schematics 196Alarm Beacon 196Shaft Encoder 196Parallel 196Ethernet 197Photocell 197Auxiliary 197Serial 198USB 198............................................................................................................................................................198Collector Information 199Wiring information 200Troubleshooting 203Software 203J-link Error (IP/TCP Error) 203Message not supported 203Controller 206Fluidic 208Printhead 215Section 10 220Service Routines and Parts 220Warranty Information 221Fluidic Service Routines 224Cleaning the Viscometer 228Main Pump Replacement 232Solenoid valve replacement 239Ink Swap or Longterm Storage Flush 244Electronic Components 247Main Board 247Fan 249 Front Door 250Display Assembly 250Power Supply 251Electronic Service Routines 252Replacing the Power Supply 252Touchscreen Replacement 257Touch Screen Calibration 259Printhead Components 261Printhead 261Printhead Service Routines 264Drop Generator Replacement 264Changing or Cleaning Nozzle 268Jet Alignment 277Modulation Calibration 287Fluidic Components 295Fluidic Compartment 295Tube Push Fittings 303Section 11 304Specific Application Setup 304Large Drop Printing 305Traversing 306Fundamental Traversing Features 306Integrating an existing Traversing system 307Meter Marking Applications 308Non-encoder applications 308Encoder applications 308Repeat Print (Pills Packs, etc) 309Non-Encoder Applications 309Encoder Applications 310 Section 1General Information BestCode Series 8 SystemThe BestCode Series 8 CIJ printers are technologically innovative systems for providing state-of-the art tracking and coding information. The Series 8 consists of a family of 8 CIJs, each with a range of special features. The charts below illustrate the primary differences between each machine, and highlights features such as speed, filter life, and templates.Model 82 86 88 88HS 88SF 88SPScreen 10.4” LCD with Touch ScreenPower 100-240Vac50-60Hz3A MAXStorage 4GByte Solid State Drive, 16 MByte Flash, 128 MByte RAM, USB Interface (thumb drive)Machine Interface RS232, EthernetEnclosure Stainless Steel EnclosureEnclosure Rating IP 55 IP 55 IP 65 IP 65 IP 65 IP 65 IP 65Air Filter MERV 8 MERV 13Inks MEK, Ethanol, Acetone, Blend, Plastic, Glass Bottle, Security, Canning, Flexible Food Grade MEK White, Acetone White Speed Ink Filter Air Filter Filter Size Hours LifeModel Drop Frequency Speed 2.5” 1 year 4000 8000 1 Year82 65 65kHZ Faster * * * *86 65 65kHZ Fastest * * * *88 65 65kHZ Ultra-Fast * * *88HS 50 73kHZ Ultra-Fast * * *88SF 65 65kHZ Ultra-Fast * * *88SP 65 65kHZ Ultra-Fast * * * Templates 5 7 9 12 16 19 25 32 2L7 3L7 4L7 2L9 3L9 2L12 5L582 * * * * * * * * * 86 * * * * * * * * * * * * 88 * * * * * * * * * * * * * * *88HS * * * * * * * * * * * * * * *88SF * * * * * * * * * * * * * * *88SP * * * * * * * * * * * * * * *Message PrintingMaximum Number of Fields 30Maximum Characters per field 100Maximum Print Rasters 16000 Maximum Print Length 320in (8.1m) How to use this ManualThis manual is used as a reference guide for training, setup, commissioning, machine and software maintenance, and troubleshooting of Series 8 CIJ printers. This manual provides specific machine specifications for each of the Series 8 family members, as well as peripheral items used with the machine. This manuals details software functions and features, navigation of the user interface, suggested maintenance routines, and breakdowns of indicators and warnings encountered in the entirety of the user interface. This manual provides instruction for operating the machine, and performing routine machine functions, including; safely adding ink and solvent, Operating the Print Jet, Selecting and editing messages, Cleaning, Replacing Electronic, Fluidic, and print head components.Follow all Safety instructions and exercise common sense while performing any service, maintenance, commissioning, part replacement, or troubleshooting.
Safety Information
PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY GLASSES WHEN HANDLING INKS AND SOLVENTS.
PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY GLASSES DURING FLUIDIC MAINTENANCE.
PERSONAL INJURY: INKS AND SOLVENTS ARE POISONOUS, DO NOT INGEST.
PERSONAL INJURY: DO NOT USE SOLVENT TO WASH INK FROM SKIN. IF EXPOSED, GENTLY RINSE AREA WITH SOAPY WATER. IF IRRITATION PERSISTS, SEEK MEDICAL ATTENTION.
EQUIPTMENT DAMAGE: DO NOT ADD FLUIDS UNLESS INSTRUCTED BY INDICATORS.
EQUIPTMENT DAMAGE: THE PRINTHEAD MUST BE DRY BEFORE STARTING PRINTER.
EQUIPTMENT DAMAGE: THE PRINTHEAD SHOULD NEVER BE COMPLETELY SUBMERGED IN SOLVENT.
FIRE HAZARD: INKS AND SOLVENTS ARE HIGHLY FLAMMABLE. NO SMOKING OR OPEN FLAMES NEAR PRINTER OR FLUID STORAGE.
ELECTRICAL SHOCK: DISCONNECT MAIN POWER CABLE PRIOR TO SERVICING MACHINE.
ELECTRICAL SHOCK: NEVER RUN MACHINE WHILE ELECTRONICS COMPARTMENT DOOR IS OPEN.
Section 2
System Overview and Detailed Specifications
Controller
Item Number Description Part Number
1 10.4” Touch Interface 20-0014-01
2 BestCode Series 8 Cabinet 20-0001-07
3 Fluidic Service Entry Door 25-0004-06
4 Air Filter Service Entry Door *
5 Printhead 20-0016-01
Printhead
Item Number Description Part Number
1 Front Cover 22-0039-02
2 Positive Deflection Plate *
3 Phase Detector *
4 Charge Electrode 22-0012-03
5 Drop Generator Kit 20-0008-01
6 Front Cover Fastener 22-0015-05
7 Ground Plate *
8 Drop Return System 20-0010-01
SPECIAL
* Parts integral to tray Printhead Tray Assembly 20-0009-01
Consumable and Delivery
Bottle Size
Tank Capacity
Ink: 1.7 Liters
Solvent: 2.7 Liters
Ink Bottle
Capacity: 32 oz (946ml) Delivery: Foil Puncture
Solvent Bottle
Capacity: 32 oz (946ml) Delivery: Foil Puncture
Fluid Consumption
Number of Drops Consumed per Font
Font Avg Drops Characters per Liter of Ink
5 8 142,469,879
7 11 103,614,457
9 19 59,987,317
12 30 37,991,967
16 53 21,504,887
19 85 13,408,929
25 130 8,767,377
32 190 5,998,731
Notes:
• Changing Speed, Width, or Gap has no effect on number of characters per liter.
• Increasing Bold reduces the number of characters per liter..
o Bold 2 will have half the characters of
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