Rockware Corp Rockbox SPS-100 Technical Training Manual

Industrial bar code label printing system serial print server

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ROCKWARE CORP

Industrial Bar Code Label Printing System

Overview .............................................................................................................................. 2

A) Configuration ................................................................................................................... 3

B) Installation ....................................................................................................................... 6

C) Mission Control................................................................................................................ 7

D) Studio............................................................................................................................... 9

E) Print On Demand............................................................................................................ 12

F) View and Configure from a Remote Computer.............................................................. 13

G) System Backup and Restoration .................................................................................... 14

H) System Troubleshooting ................................................................................................ 15

TECHNICAL TRAINING GUIDE

Serial Print Server

ROCKBOX ™

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Page 1: Table Of Contents
ROCKWARE CORP Industrial Bar Code Label Printing System Serial Print Server TECHNICAL TRAINING GUIDE Overview ..........................2 A) Configuration ........................3 B) Installation ........................6 C) Mission Control........................ 7 D) Studio..........................9 ...
Page 2: Overview
Technical Training Guide Overview The SPS‐100 Serial Print Server is a combination of industrial hardware and software to provide dynamic bar code label printing that can be triggered by an in‐process PLC (Programmable Logic Controller). This guide is intended to aid in configuration, installation, label design, and troubleshooting of the Rockbox. The SPS‐100 is powered by 110 VAC and is equipped to handle up to 4 independent industrial printers via RS‐232 Serial interface. This guide is intended to aid in the configuration, installation, label design, and troubleshooting of the Rockbox. Below lists terminology and definitions used throughout this guide. Term Definition Rockbox Refers to the SPS‐100 hardware and overall system. PLC Refers to the PLC providing the print trigger bit and label number register. Network Refers to the common Ethernet network the PLC and the Rockbox are connected to. Studio Refers to the application intended for label and template creation and modification. The executable file for this application is SPS100_Studio and is stored in the C:\Rockware directory of the Rockbox. Mission Control Refers to the application intended for reading values from PLC and for printing labels automatically and manually. The executable file for this application is SerialPrint.exe and is stored in the C:\Rockware directory of the Rockbox. Remote Computer Refers to a desktop or laptop computer that is permanently or temporarily connected to the Network and connects to Rockbox via Remote Desktop and the Studio application. Magic.Stick USB Flash Drive used for system file backup Database MS SQL Server Express database used for storing configuration setting and label formatting. Back‐up Files (.bak) are used to backup and restore data. See Network diagram below for general system layout. USB to RS232 Converter (One Per Channel) ...
Page 3: A) Configuration
Technical Training Guide A) Configuration Rockbox SPS‐100s can be ordered completely preconfigured. Below are instructions for manually configuring. 1. Connect keyboard and mouse to available two available USB ports and connect a monitor to the VGA port on back on the Rockbox. 2. Press Power Button on front of the Rockbox. Figure 1 3. Set IP Address and subnet mask to a unique address compatible with the triggering PLC. o Double click Network Connections shortcut on the desktop. (See Figure 1) o Right click on Local Area Connection and left click Properties. (See Figure 2) o Left click on Internet Protocol (TCP/IP) and left click Properties. (See Figure 3) o Manually set IP Address and Subnet Mask to allow Ethernet communication to PLC and computers on the local network. (See Figure 4) Figure 2 Figure 3 Figure 4 4. Configure OPC Server software KepserverEx to allow reading of print trigger bit and Figure 5 label number register from PLC. ...
Page 4 Technical Training Guide Figure 6 Figure 7 Figure 8 Channel Device 5. Configure SPS‐100 Comport Channels and Maintenance Functions. o Left Click on Mission Control tab in task bar (See Figure 9). Click on Settings Button in Mission Control (See Figure 10). Figure 10 Figure 9 o Enter Password (sps is default) (See Figure 11). Make modifications where needed. Click SAVE DATA when finished with modifications (See Figure 12). Figure 11 ...
Page 5 Technical Training Guide Figure 12 Save Modifications Click to modify PLC Addresses for Trigger and Label Number Frequency of Auto Backups Backup File Location and Name Number of Days to Store Error Log Messages Password used System Wide. Default is sps. Comport Number. If Channel not used enter N/A. Comport Setting. Make sure Printer dip switches match SPS‐100 settings for each Channel. Channel ID that can be used to identify what Channel was used to print each specific label Normally COM8 Normally COM7 ...
Page 6: B) Installation
Technical Training Guide B) Installation The Rockbox can be installed inside a well ventilated electrical cabinet or mounted externally (See Figure 14c). A 110 VAC power source is required. Clean power and surge protection is recommended to prevent device failures due to inconsistent power quality. There are four USB to RS‐232 Serial converters that are plugged into the back of the Rockbox. Predefined USB ports have corresponding COM number labels to identify which Comport each USB port connects to (See Figure 14a). Connect serial cables from corresponding printers to applicable USB to RS‐232 Serial converters (See Figure 14b). Keyboard, mouse, and monitor are optional and do not need to be connected for the Rockbox to be operational. Remote Desktop can be set up on another computer connected to the network to allow monitoring and troubleshooting of the system. See Section F) View and Configure from a Remote Computer for more detail on using Remote Desktop Figure 14a Figure 14b Comport Labels Figure 14c Revision 1.0 ‐ 6 of 15 ...
Page 7: C) Mission Control
Technical Training Guide C) Mission Control Mission Control is the application that monitors changes in print trigger and label numbers from the PLC and sends applicable label strings to each printer when triggered. This application must be running at all times. Anytime a configuration or PLC Address change is made, Mission Control will need to be restarted. If Mission Control is inadvertently or purposely shutdown it can be restarted by double clicking the desktop icon shown in Figure 15. Figure 15 Start and Stop OPC Reading and Writing Enable/Disable Number of Times Function Buttons Windows Task Last attempted Error during Ran and Successful Status Figure 16 Manager Time Stamp Execution Executions Last Printed Label ...
Page 8 Technical Training Guide the Error text box there may be a configuration issue that will prevent automatic printing. (See Figure 16) To view Actual PLC values for each Channel, left click the View Button. If there is a network related error, a Kepserver configuration error, or a PLC Address error, the Quality of the specific value will display “BAD”. If the value is being read properly then the Quality will display “GOOD”. If displayed values match actual values in the PLC, then all networking and OPC configuration has been completed successfully. (See Figure 17) Figure 17 Maintenance – Database Backup and Deletion of Error Log Maintenance functions include database backup and deletion of error log. The number of Scans (planned executions), the number of Executions (successful executions), and the Time Stamp of the last Maintenance event occurrence is displayed in the Maintenance text boxes. If there is an error there will be a red “Error” message in the Error text box. Errors usually are a result of database backup locations being set to directories that don’t exist. The Back‐up File Location can be changed in Settings along with the frequency of Back‐up execution and the length of time to save Error Log Messages. (See Figure 16 and Figure 12) Last Printed Label The Last Printed Label for each Channel is displayed at the bottom of the Mission Control Page. This can be used as a troubleshooting tool to view exactly what gets sent to the printer including Time Stamps and dynamic text that may change from one label to the next. (See Figure 16) Task Manager Enable/Disable The Windows Task Manager is disabled on start up to prevent Mission Control from being shutdown without knowledge of the password through Windows. The Windows Task Manager can be enabled by clicking the Task Manager Button and entering the correct system password. The Windows Task Manager can be disabled again by doing the same. (See Figure 16) Revision 1.0 ‐ 8 of 15 ...
Page 9: D) Studio
Technical Training Guide D) Studio The Rockware SPS‐100 X4 Studio is a standalone application to provide an interface for creating labels and label templates. Left click the Studio Button (See Figure 16) to open or double click on the desktop icon shown in Figure 18. The system password is required to open this application. SPS100_Studio.exe is the executable file for the Studio application found in the C:\Rockware directory on the Rockbox. This file can run on any computer connected to the same network with a windows operating system and .NET Framework 3.5 or higher. See Section F) View and Configure from a Remote Computer for more detail. Figure 18 Select Template Click to SAVE DATA after Export all View, Delete to use for label. View, Add, creating a new label or Click to start label formats Error Log Modify, modifying an existing New Label to a text file Delete label Delete Label Templates Figure 19 Select Label to modify , delete, or view ...
Page 10 Technical Training Guide There are 12 reserved bracketed words that can be used to create dynamic labels. The following 10 Dynamic Text reserved words are label specific and can only be used with Template labels. [TEXT1] [TEXT2] [TEXT3] [TEXT4] [TEXT5] [TEXT6] [TEXT7] [TEXT8] [TEXT9] [TEXT10] Placing any of these reserved words in a label template will replace “[TEXT#]” with the text stored for each Dynamic Text field for each label into the template when each label is printed. The following two reserved bracketed words can be used for Template or Ad‐Hoc labels. [ID] [TIMESTAMP] Placing [ID] into a Template or Ad‐Hoc label replaces “[ID]” with the Channel ID that is entered in Settings for each Channel when the label is printed. This word is intended to identify which Channel printed each specific label in multi‐channel systems. Placing [TIMESTAMP] replaces [TIMESTAMP] with the current Time Stamp of the Rockbox when each label is printed. The Rockbox Time can be modified by double clicking the time displayed in the bottom right hand corner of the task bar and making the required adjustments. The Time Stamp is printed on the label and/or bar code in the following format: ddmmyyhhnnss d = day m = month y = year h = hour n = minutes s = seconds Labels and templates can be added or changed anytime and changes will immediately take place the next time a print trigger event occurs. ...
Page 11 Technical Training Guide Template Creation and Modification To add, modify, or delete templates, left click the Templates Button (See Figure 19). See Figure 20 for detail on Template Design Page. Click to SAVE DATA after Export all creating a new template template or modifying an existing formats to a Click to start template text file Figure 20 New Template Select Template to modify, delete, or view Delete Label Name for Template Identification Dynamic Text insertion Template Time Stamp formatting insertion including ...
Page 12: E) Print On Demand
Technical Training Guide E) Print On Demand To manually print labels to test comport communications, to test a label format, or to batch print, left click the Print On Demand Button (See Figure 16). Any label format loaded into the SPS‐100 database can be retrieved from PLC ID # ‐ Label Name pull‐downs. Text can be typed or copy and pasted into the white Label Editor and can be printed on any of the four available channels that are connected to a printer. This is a good way to test label formatting prior to running live. It also is a good way to ensure Channel/COM configuration is correct. Batch printing can be performed by specifying the Quantity of Labels and specifying the Time (Seconds) Between Labels prior to left clicking Print. (See Figure 22) Click to send Label Editor String to Figure 22 Click to pull in Label Printer Select Label Label Editor can type Used for Batch Printing copy or paste inside editor Revision 1.0 ‐ 12 of 15 ...
Page 13: F) View And Configure From A Remote Computer
Technical Training Guide F) View and Configure from a Remote Computer F) View and Configure from a Remote Computer Once configured and connected to the network, Windows Remote Desktop can be used on a stationary Once configured and connected to the network, Windows Remote Desktop can be used on a stationary or mobile computer connected to the network to log on to the Rockbox for troubleshooting or or mobile computer connected to the network to log on to the Rockbox for troubleshooting or configuration changes. Enter the IP Address assigned to the Rockbox into the Computer Text Box and configuration changes. Enter the IP Address assigned to the Rockbox into the Computer Text Box and left click Connect (See Figure 23). Enter trtguest as User Name and leave the Password blank. When left click Connect (See Figure 23). Enter trtguest as User Name and leave the Password blank. When finished working on Rockbox, DO NOT Log Off or Shutdown the Rockbox. Left click Start and left click finished working on Rockbox, DO NOT Log Off or Shutdown the Rockbox. Left click Start and left click Disconnect (See Figure 24). Logging off or shutting down Rockbox will prevent SPS‐100 from functioning. Disconnect (See Figure 24). Logging off or shutting down Rockbox will prevent SPS‐100 from functioning. Figure 23 User Name: trtguest User Name: trtguest Password: [blank] Password: [blank] ...
Page 14: G) System Backup And Restoration
Technical Training Guide G) System Backup and Restore Backup The SPS‐100 database is backed up automatically during Maintenance events. See Section C) Mission Control ‐ Maintenance – Database Backup and Deletion of Error Log for more detail. The default location for this backup is set to the D drive which is the Magic.Stick that comes with the Rockbox. This is done to preserve data in the event of a hard drive failure. The file name and location of all backups will be what is set in the Back‐Up File listed in Settings (See Figure 12). The file should have a .bak extension. A backup file can be created manually be left clicking the Backup DB Button (See Figure 16). Enter the directory and the file name of the backup file in the input box and click OK (See Figure 26). The default backup file will be the Back‐Up File listed in Settings. Backing up to this file will overwrite the existing backup file saving the most recent updates. Figure 26 Restoration In the event a Rockbox needs to be replaced with another unit, a backup file can be restored on any unit to restore all configurations and label formatting data. Follow the below instructions to restore a database. 1. Plug in Magic.Stick with database back‐up file into new Rockbox. Only one Magic.Stick can be entered into a Rockbox at any given time. Remove any other Magic.Sticks prior to plugging in. 2. Left click the Restore DB Button (See Figure 16) 3. Enter system password which should be “sps” unless otherwise changed. 4. Select the back‐up file and left click Open. Shutdown and restart Mission Control to complete. (See Figure 27) Figure 27 Revision 1.0 ‐ 14 of 15 ...
Page 15: H) System Troubleshooting
Technical Training Guide H) System Troubleshooting Power Error If the computer will not power up there could potentially be a power supply, motherboard, or hard drive issue. Try powering up from a different power source. If it doesn’t start, remove the Magic.Stick and plug into a spare Rockbox SPS100. Follow instructions for restoring the system back‐up file in Section G) System Backup and Restore – Restoration. If the Rockbox is still under warranty, send to Rockware Corp for repair. Network Error If there are issues reading PLC trigger and Label Number values there potentially could be a network error. Click settings Network errors will occur if the IP Address of the Rockbox does not match the IP Address of the PLC or if the IP Address of the Rockbox is a duplicate IP with another device on the network. To determine if there is successful network communication: 1. Left click Start. 2. Left click Run. 3. Type “Ping “ and the IP Address of the PLC from the Rockbox. If there is no communication than there will either be a “Request Time Out” or another “Communication Related Error”. 4. Type “Ping “ and the IP Address of the Rockbox from a Remote Computer. If there is no communication than there will either be a “Request Time Out” or another “Communication Related Error”. 5. Reset and recheck IP Addresses along with the functionality of any network switches across the network if Ping checks are not successful. Kepserver Channel or Device Configuration Error If there are issues reading PLC Trigger and Label Number values there potentially could be a Kepserver configuration error. Make sure the Channel has the correct device driver assigned for the specific make and model of the PLC type being used. Make sure the Device has the correct IP Address and IP Address configuration for the PLC type being used. See Section A) Configuration – Item 4 for more detail. Comport/Channel Error If there are no issues reading the PLC Trigger and Label Number values and labels do not print there could potentially be a comport configuration problem. Make sure the correct COM# is entered for each channel being used in Settings. Also make sure that the Baud Rate, Parity, Data Bits, and Stop Bits match how the printer is configured. Printer settings are usually set via dip switches. COM errors will show up ...