Squid Ink CoPilot 500 User Manual
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Squid Ink CoPilot 500 User Manual

Industrial inkjet printing system
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CoPilot 500
Industrial Inkjet Printing System
User Guide
2005482 Rev G –210505 - BETA

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Summary of Contents for Squid Ink CoPilot 500

  • Page 1 CoPilot 500 Industrial Inkjet Printing System User Guide 2005482 Rev G –210505 - BETA...
  • Page 2 Abbreviations & Terminology 2005995 Rev O – 210712...
  • Page 3 Industrial Inkjet Printing System User Guide For use with: • CoPilot 500 Controller, CoPilot 500 Turbo Controller, or CoPilot 500 High Speed Turbo Controller • CoPilot 500 Oil Printhead or CoPilot 500 Solvent Printhead Revised 7/12/2021 P/N 2005995 – Rev O Copyright and Trademarks Copyright ©2021 Squid Ink Manufacturing.
  • Page 4 Abbreviations & Terminology 2005995 Rev O – 210712...

  • Page 5: Table Of Contents

    Contents Abbreviations & Terminology ..............9 Safety ..................... 11 Understanding Safety Notifications ................12 General Precautions ....................12 Introduction .................... 13 General System Description ..................13 System Components ....................15 Printhead Overview ..................... 16 Controller Overview ..................... 17 System Specifications ....................18 Software Specifications ....................
  • Page 6 Custom Triggering Device ..................... 53 Printhead Data Cable ......................54 Connecting a Second Printhead ................... 55 Connecting a Second CoPilot 500 Printing System .............. 56 Connecting an Optional Low Ink Warning Beacon ..............57 Connecting to a Desktop PC ....................58 Connecting to a Local Area Network ..................
  • Page 7 Cleaning the Nozzle Faceplate ................. 119 Flushing the Printhead ....................120 Purging the Printhead of Air Bubbles ................ 123 External Cleaning ...................... 123 Preparing a CoPilot 500 for Shipping or Storage ............123 Troubleshooting ................... 127 Parts List ....................129 Replaceable Parts ..................... 129 Complete Systems ......................
  • Page 8 Cartridge Ink System ......................134 Bag Ink System ........................137 Printhead ..........................139 CoPilot 500 Controller*/CoPilot 500 HiSpeed Controller** ..........140 CoPilot 500 Turbo/CoPilot 500 HiSpeed Turbo Controller ..........141 System Updates ................... 145 Applying Updates from USB ..................145 Product Warranty ................. 147 Warranty Statement ....................

  • Page 9: Abbreviations & Terminology

    A USB format Meets safety, health, and Part Number environmental requirements of the European Union Centimeters PDF417 A barcode format CP500 CoPilot 500 Positive-Negative-Positive Dots per inch A barcode format EAN-8 A barcode format RJ12 Registered Jack 12 EAN-15 A barcode format...
  • Page 10 Abbreviations & Terminology 2005995 Rev O – 210712...

  • Page 11: Safety

    • Use only Squid Ink Manufacturing ink and Squid Ink Manufacturing approved fluids. The Squid Ink CoPilot 500 printer systems use a Cartridge Ink or Bag Ink system. Do not • open or puncture the Ink Cartridge or Ink Bag in any way other than normal installation.

  • Page 12: Understanding Safety Notifications

    Indicates a hazardous situation which, if not avoided, could result in property damage only. General Precautions When installing, operating, and maintaining the CoPilot 500, observe the following precautions. WARNING: Health Hazard Some inks and solvents may be a health hazard if exposed for too long.

  • Page 13: Introduction

    Messages for the CoPilot 500 printing systems are created and edited using PC-based Orion™ software. Messages are then loaded onto the Controller through an Ethernet connection or from a USB device.
  • Page 14 Ink Line to the Printhead. The ink is then ejected onto the substrate through the Ink Nozzles on the front of the Printhead. Because the system uses capillary action (rather than a motor) to help supply the ink to the Printhead, the CoPilot 500 is referred to as a “passive ink system.”...

  • Page 15: System Components

    The card contains the Orion license number required for downloading Orion and connecting the CoPilot 500 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.

  • Page 16: Printhead Overview

    Introduction Printhead Overview Front View Purge Tube (Capped) Nozzle Face Check Valve Photocell Mounting Bracket Holes Power & Communication Indicator LED Ink Line Rear View Fitting Hose Clamp Ink Level Signal Port Data Cable (Cartridge Only) Port 2005995 Rev O – 210712...

  • Page 17: Controller Overview

    Introduction 17 Controller Overview Front View Touchscreen Display Photocell/Encoder IN Photocell/Encoder OUT to Second CoPilot System Ethernet Port Power Switch Label with Serial Number Power Cord Port Fuse Receptacle Rear View Printhead 1 Data Cable Port Printhead 2 Data Cable Port 2005995 Rev O –...

  • Page 18: System Specifications

    Porous and non-porous applications Ink Capabilities Oil-based or solvent-based, depending on Printhead Ink System Passive Ink Control System: Squid Ink Manufacturing 500 ml cartridge or 500 ml Bag Ink systems. Low Ink Indicator Message alert on Touchscreen Optional Low Ink Alarm Beacon...
  • Page 19 100° F (37° C) 104° F (40° C) * The CoPilot 500 Controller has been replaced by the CoPilot 500 Turbo Controller. ** The CoPilot 500 HiSpeed Controller has been replaced by the CoPilot 500 HiSpeed Turbo Controller. 2005995 Rev O – 210712...

  • Page 20: Software Specifications

    Introduction Software Specifications 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, 2-digit week Time and Date 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.

  • Page 21: Component Dimensions

    Introduction 21 Component Dimensions Printhead Front View Side View Bottom View 2005995 Rev O – 210712...

  • Page 22: Controller

    22 Introduction Controller Top View Side View Front View Bottom View 2005995 Rev O – 210712...

  • Page 23: Options

    Introduction 23 Options Part Number Description Purpose Dependent Starter Kit Includes ink, cleaner and flush, Printhead on ink wipes, hand cleaner, and latex gloves. 1604177 Encoder Assembly Kit For operation with variable-speed Conveyors. 2004194 Barcode Laser Scanner Allows scan and print message retrieval. Prevents Printhead from being accidentally 2004570 Spring-Loaded Printhead Bracket...

  • Page 24: Mounting Hardware

    24 Introduction Mounting Hardware Squid Ink offers a variety of Floor Stands and Conveyor Mounts for a range of unique situations (see “Replaceable Parts” on page 129). Floor Stand Mounts isolate the CoPilot 500 from vibrations and movements of the Conveyor. Conveyor Mounts attach directly to the Conveyor.

  • Page 25: Installation And Setup

    Installation and Setup 25 Installation and Setup General Recommendations Material Handling The most 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.

  • Page 26: Work Area

    Vibration CoPilot 500 Print Engines do not de-prime easily. They are tolerant of being bumped by passing products and normal Conveyor vibrations. However, sustained, long-term vibration may lead to erratic print performance. In cases where the Conveyor is especially vibration- prone, the entire printing system should be mounted on an optional Floor Stand available from Squid Ink.

  • Page 27: Mounting

    Each installation is unique, and Squid Ink Manufacturing cannot anticipate customer requirements for attaching Mounting Brackets to the production line. Several mounting systems are available for the CoPilot 500 printing system. Follow the instructions for the specific mounting system ordered with your Printer.

  • Page 28: Mounting The Controller

    28 Installation and Setup Mounting the Controller The Controller is attached to the Mounting Bracket by inserting the two supplied Mounting Screws into the two M6 mounting holes located on the bottom of the Controller. VIDEO: Mounting the Controller To see a video of this procedure, click this link: https://youtu.be/zSjTfhCmU8M?t=49 Or scan the QR code at right using the camera app on your mobile device.

  • Page 29: Mounting Printhead(S)

    Installation and Setup 29 Mounting Printhead(s) Printhead mounting varies by situation. This section lays out some general principles for Printhead mounting. A Mounting Bracket is necessary when the Printhead is going to be printing in any direction other than straight ahead. Attaching a Mounting Bracket to the Printhead Printhead Mounting...
  • Page 30 30 Installation and Setup To Mount a Printhead on a Conveyor Mount or Floor Stand: 1. Use the supplied Screws to attach the Mounting Bracket to the downstream side of the Printhead. Attaching the Printhead to a Conveyor Mount or Floor Stand (Left-to-Right Product Flow) Printhead Mounting...

  • Page 31: Mounting The Ink System

    Installation and Setup 31 Mounting the Ink System Because the CoPilot 500 uses a passive ink system that relies on a specific relationship between the height of the Printhead and the Ink System, both of these items should be attached to the same Mount, whether that is a Conveyor Mount or Floor Stand.
  • Page 32 32 Installation and Setup 2. Use the T-Nuts and accompanying Screws to attach the Mounting Bracket (through the two vertical slots) to the Mounting Arm, and then tighten the T-Nuts. Attaching the Mounting Bracket to the Mounting Arm Cross Section of Mounting Arm Mounting Bracket Screw...
  • Page 33 Installation and Setup 33 Bag Ink System Items Needed to Mount a Bag Ink System: • Alan Wrench Phillips Head Screwdriver • To Mount a Bag Ink System: 1. Use the supplied Screws to attach the side of the Ink Tray to the Ink System Mounting Bracket.

  • Page 34: Mounting A Photocell

    34 Installation and Setup Mounting a Photocell A Photocell triggers printing when a product passes in front of it. The Photocell can be mounted directly to the Printhead using the supplied Mounting Bracket and Screws. The Photocell should be mounted on the upstream side of the Printhead so that it will “see” the product before the product passes in front of the Printhead.

  • Page 35: Distance From Substrate

    Generally, the closer the Printhead is to the surface to be printed (substrate), the better the print quality. Squid Ink recommends keeping the printed surface within 1/8” (3.2 mm) from the Nozzle Face. While throw distances greater than 1/8” (3.2 mm) are possible, print quality may be affected.
  • Page 36 36 Installation and Setup Dual Printheads with Bag Ink System Mounted on Floor Stand Printheads Bag Ink System Floor Stand Controller Assembly 2005995 Rev O – 210712...
  • Page 37 Installation and Setup 37 Printhead with Cartridge Ink System Mounted on Floor Stand Printhead Controller Floor Stand Assembly Cartridge Ink System 2005995 Rev O – 210712...

  • Page 38: Rotating Or Tilting The Printhead

    38 Installation and Setup 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° clockwise or counter-clockwise (sideshooter position) when viewed from behind the Printhead.

  • Page 39: Connecting The Ink Supply

    (Cartridge or Bag) can supply two Printheads if they are mounted at the same height. ATTENTION: Use only Squid Ink approved fluids for cleaning or flushing the Nozzle Face. Use only the appropriate cleaning or flushing fluid for the specific ink being used (see “Inks and Fluids”...
  • Page 40 40 Installation and Setup 2. Ensure that the Printhead is properly aligned to the Ink Reservoir (see “Printhead Height Relative to Ink Reservoir or Ink Pan” on page 47). 3. Ensure that the Ink Reservoir Vent Tube is uncapped for printer operation. 4.
  • Page 41 Installation and Setup 41 b. Aligning the Cartridge at a right angle to the Ink Reservoir, lower the Ink Cartridge onto the Ink Reservoir. Lowering the Ink Cartridge onto the Ink Reservoir Ink Cartridge Foil Ink Reservoir c. Rotate the Ink Cartridge 90° clockwise to thread it down into the seat of the Ink Reservoir.
  • Page 42 42 Installation and Setup VIDEO: Connecting an Ink Cartridge To see a video of this procedure, click this link: https://youtu.be/zSjTfhCmU8M?t=159 Or scan the QR code at right using the camera app on your mobile device. View Time: 2:39 – 4:11 VIDEO: Connecting the Ink Lines To see a video of this procedure, click this link: https://youtu.be/zSjTfhCmU8M?t=405...
  • Page 43 Installation and Setup 43 8. Make sure that the Printhead Purge Tube is capped for operation. 9. Connect the Low Ink Signal Wire to the RJ-12 Ink Level Signal Port on the back of the Printhead. 10. Correctly position the Printhead relative to the substrate (see “Distance from Substrate”...

  • Page 44: Bag Ink System Setup

    1. Attach the Ink Tray to the mounting hardware according to the mounting instructions. NOTE: Squid Ink offers several mounting systems. Mounting and installation may vary depending on the mounting system used. Contact your authorized Squid Ink distributor for guidance on the best mounting system for your needs.
  • Page 45 Installation and Setup 45 Fabricating an Ink Line 4. Attach one end of the fabricated Ink Line to the Ink Tray Nozzle and attach the other end to the Ink Line IN on the back of the Printhead. Printhead Connecting the Ink Tray to the Printhead Ink Line Ink Tray Ink Tray...
  • Page 46 46 Installation and Setup 5. Connect the Ink Bag to the Ink Bag Connect Fitting in the Ink Tray. WARNING: Do not squeeze the Bag like a sponge. Doing so is very hazardous, can potentially lead to personal injury, will likely damage the Print Engine, and will void the warranty.

  • Page 47: Printhead Height Relative To Ink Reservoir Or Ink Pan

    Installation and Setup 47 Printhead Height Relative to Ink Reservoir or Ink Pan The following Printhead-to-Ink Bag or Reservoir height drawings are a starting point or guideline. The heights may need to be adjusted slightly if the following problems occur: If the Bag or Reservoir is too high, the Printhead will flood with ink and the print will •...
  • Page 48 48 Installation and Setup Oil Printhead with Bag System Straightshooter Mode Printhead Printhead bottom is even with Ink Pan top Ink Pan Downshooter Mode Printhead Printhead Nozzle Face is even with Ink Pan top Ink Pan Sideshooter Mode Printhead Printhead’s lowest side is Ink Pan even with Ink Pan top 2005995 Rev O –...
  • Page 49 Installation and Setup 49 Solvent-Based Systems For solvent-based systems, the lowest surface of the Printhead should be 2” (50.8 mm) higher than the top of the Ink Reservoir (Cartridge Ink system) or Ink Pan (Bag Ink system). Solvent Printhead with Cartridge System Straightshooter Mode Printhead Printhead bottom is 2”...
  • Page 50 50 Installation and Setup Solvent Printhead with Bag System Straightshooter Mode Printhead Printhead bottom is 2” (50.8 mm) higher than Ink Pan top 2” (50.8 mm) Ink Pan Downshooter Mode Printhead Printhead Nozzle Face is 2” (50.8 mm) higher than Ink Pan top 2”...

  • Page 51: Cable Connections

    Installation and Setup 51 Cable Connections Connecting Photocell Trigger to Controller Connect the Photocell Signal Cable to the “IN” Port on the back of the Controller. Connecting a Photocell Data Connection “IN” Port Controller Back Panel Photocell 2005995 Rev O – 210712...

  • Page 52: Connecting An Optional Encoder To Controller

    52 Installation and Setup Connecting an Optional Encoder to Controller Connect the optional Encoder and Photocell trigger to the RJ12 Adapter Cable. Connect the Adapter Cable to the “IN” Port on the back of the Controller. VIDEO: Mounting and Connecting an Encoder To see a video of this procedure, click this link: https://youtu.be/zSjTfhCmU8M?t=626 Or scan the QR code at right using the camera app on your mobile...

  • Page 53: Custom Triggering Device

    Pin Assignments on the RJ12 Connector to install a custom triggering mechanism. ATTENTION: Site-specific or unusual devices should only be connected by trained and qualified personnel. Please contact your authorized Squid Ink distributor to discuss device compatibility before connecting. On the RJ12 Input Connector, connect Pin 4 to an NPN sinking open-collector output with Pin 5 acting as ground.

  • Page 54: Printhead Data Cable

    54 Installation and Setup Printhead Data Cable WARNING: Ensure that the Controller Power Switch is turned OFF and the Controller is disconnected from the power source when connecting a Printhead. VIDEO: Connecting the Data Cable To see a video of this procedure, click this link: https://youtu.be/zSjTfhCmU8M?t=1064 Or scan the QR code at right using the camera app on your mobile device.

  • Page 55: Connecting A Second Printhead

    Installation and Setup 55 Connecting a Second Printhead WARNING: Ensure that the Controller Power Switch is turned OFF and the Controller is disconnected from the power source when connecting a second Printhead. To connect a second Printhead, connect the Printhead Data Cable to PRINTHEAD 2 Port on the Controller, and connect the other end to the Printhead that will be designated “Printhead 2.”...

  • Page 56: Connecting A Second Copilot 500 Printing System

    Connecting a Second CoPilot 500 Printing System Connecting a second CoPilot 500 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 500 printing system, connect an RJ12 Sensor Cable between the first and second CoPilot 500 Controllers.

  • Page 57: Connecting An Optional Low Ink Warning Beacon

    Port Controller Since each installation is unique, Squid Ink cannot anticipate an ideal location for the Low Ink Warning Beacon. The Beacon has a generic Mounting Bracket attached to it. Mount the Warning Beacon within 5’ (1.5 meters) from the Controller.

  • Page 58: Connecting To A Desktop Pc

    58 Installation and Setup Connecting to a Desktop PC To connect to a desktop PC, connect an Ethernet Cable to the Ethernet Port on the Controller and into the Ethernet Port on the PC. Connecting to a PC Desktop PC Ethernet Cable Ethernet...

  • Page 59: Connecting To A Local Area Network

    Installation and Setup 59 Connecting to a Local Area Network The network connection is located on the Controller. To connect to a local area network, plug the Ethernet Cable into the Ethernet Port on the Controller and into the Ethernet Port on a connected PC.

  • Page 60: Usb Port

    60 Installation and Setup USB Port There is a USB Port on the back of the Controller. The USB Port can be used for a variety of USB-supported devices such as a WiFi Adapter Antenna, Low Ink Warning Beacon, Scanner, or removable USB Drive.

  • Page 61: Optional Four Port Usb Hub

    Installation and Setup 61 Optional Four Port USB Hub There is only a single USB Port on the Controller. However, the CoPilot 500 is not limited to a single USB device. The optional Four Port USB Hub (Part Number 2004242) can provide three points of entry for USB devices.

  • Page 62: Power Supply

    62 Installation and Setup Power Supply The Power Cord Receptacle is located on the back of the Controller. Plug the supplied Power Cord into the Power Cord Receptacle, making sure the Power Switch is in the OFF position, and plug the other end of the Power Cord into a properly wired and grounded electrical outlet. Plugging in the Power Cord Controller Power Cord...

  • Page 63: Commissioning The Printhead

    Installation and Setup 63 Commissioning the Printhead If the printing system is new or has been idle for an extended period, the Printhead must be commissioned (primed) to remove potential air bubbles from the Printhead Nozzles. Air bubbles can lead to dropouts or poor print quality. ATTENTION: To avoid scratching the Printhead Faceplate, use only non-abrasive lint-free wipes (Part Number 2007021).
  • Page 64 64 Installation and Setup 5. Fold a non-abrasive, lint-free wipe and place it below the front of the Nozzle Face to catch any excess ink. Preparing to Prime the Printhead Printhead Nonabrasive Lint-Free Wipe Purge Tube (uncapped) Waste Ink Receptable Ink Line 6.
  • Page 65 Installation and Setup 65 Capping the Purge Tube Purge Tube (capped) 8. Fold a non-abrasive, lint-free wipe and hold it against the lower part of the Nozzle Face. 9. Press the Priming Bulb repeatedly until bubble-free ink comes out of all the Printhead Nozzles.

  • Page 66: Commissioning A Bag Ink System

    66 Installation and Setup Commissioning a Bag Ink System After the Ink Bag is attached, the ink system must be commissioned (primed) to get the ink flowing into the Printhead. Items Needed to Commission the Printhead: Nonabrasive lint-free wipes (Part Number 2007021) •...
  • Page 67 Installation and Setup 67 Pressing the Ink Bag 5. While continuing to press gently but firmly on the Ink Bag, replace the Cap on the Purge Tube. This seal must be tight for the printer to function. Capping the Purge Tube Purge Tube (capped) 6.
  • Page 68 68 Installation and Setup 2005995 Rev O – 210712...

  • Page 69: Software Interface

    Software Interface 69 Software Interface Interface Button Overview IMPORTANT: GUI response time may be negatively impacted when printing at high speeds. If this occurs, stop printing before attempting to modify any other settings. Button Function Start or Stop Select Start to start printing. Select Stop to stop printing. Printing Zoom Screen Select the Zoom Screen to view the message at an enlarged or reduced size.
  • Page 70 70 Software Interface Button Function Settings Screen Select the Settings Screen to configure Printer settings. Return to the Home Screen. Return to previous screen. Switch between the Settings Page One Screen and the Settings Page Two Screen. Information. Set line speed. Set distance from Printhead to trigger (Photocell).
  • Page 71 Software Interface 71 Button Function Repeat and Squid Connect trigger settings. Select Photocell as trigger Select screen as trigger SquidConnect Dongle Active Open the Counters Screen. Spit settings. Selects Printhead 1. Selects Printhead 2. Barcode validation. Connect to USB: only enabled if a USB Drive is present. A USB Drive is connected.
  • Page 72 72 Software Interface Button Function Printhead temperature. Open the Wireless Connect Screen. Access or dismiss the on-screen keyboard. Disconnect from WiFi. Open the Bluetooth Connect Screen. Access or dismiss the on-screen keyboard. Recalibrate the Touchscreen. Access a remote database server. Search the remote database.
  • Page 73 Software Interface 73 Button Function Select the Language Screen. Use a static IP address. Sleep Select the Sleep button to place the Printer into Sleep Mode. This is a soft shutdown. Sleep is useful for long periods of idle time. Touch the Controller Touchscreen to restart.

  • Page 74: Home Screen

    74 Software Interface 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.

  • Page 75: Zoom Screen

    Software Interface 75 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 on the right side of the screen.

  • Page 76: Message Screen

    76 Software Interface 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.

  • Page 77: Message Screen Remote Server

    Software Interface 77 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.

  • Page 78: Settings Screen

    78 Software Interface Settings Screen The Settings Screen contains two pages of Printer configuration settings. Select to switch between Settings Page One Screen and Settings Page Two Screen. Settings Screen – Page 1 Settings Screen – Page 2 Following describes the settings accessible through the Settings Screen and what their functions are.

  • Page 79: Line Speed

    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. Maximum line speeds are: Maximum Line Speed for Each CoPilot 500 Controller Model CP500...
  • Page 80 80 Software Interface Line Speed Using an Encoder To use an Encoder to control line speed, select ON. Select APPLY to save changes. Select BACK to return to the previous screen. 2005995 Rev O – 210712...

  • Page 81: Distance To Trigger

    Distance to Trigger is the amount of distance between the trigger (usually a Photocell) and the Jets on a Printhead. Squid Ink recommends mounting the Photocell approximately 6" (15 cm) upstream from the Printhead, and setting the “Distance to Trigger” to that distance.

  • Page 82: Print Direction

    82 Software Interface Print Direction Print Direction is the direction of the Conveyor flow relative to the position of the Printer when viewed from behind the Printhead. To Set the Print Direction for the Selected Printhead: 1. Select the button that corresponds to the direction of the Conveyor flow. 2.

  • Page 83: Encoder

    Software Interface 83 Encoder The Encoder Divider Screen sets the divider value if an optional Encoder is installed. The encoder divider value sets the horizontal scale of the printed message based on the number of pulses from the Encoder during a given time period. Use the Plus (+) or Minus (-) buttons or the slider to increase or decrease the Encoder Divider value.

  • Page 84: Repeat And Squid Connect Trigger Settings

    84 Software Interface Repeat and Squid Connect Trigger Settings The Repeat Trigger is for printing a repeating message on each single product. It controls whether SquidConnect printing is active or inactive using SquidConnect Pin 6. Refer to the SquidConnect User Guide for more information. If the SquidConnect Dongle is not installed, this option is not available.
  • Page 85 Software Interface 85 SquidConnect provides non-barcode electronic information regarding the operational status of a CoPilot printer. The outputs can be used to enable or disable the Printhead, or notify the user or PLC when the printer is ready or actively printing, when the ink supply is low or almost empty.

  • Page 86: Counters

    86 Software Interface Counters Counters can be used to track many items, such as the number of boxes or pallets printed on. Use the Counters Screen to set the current value of each printer counter in the current message. Counters Screen To change the counter value, use the Plus (+) or Minus (-) buttons or the slider to increase or decrease the counter.

  • Page 87: Spit Settings

    Ink Nozzles. Use the Spit Settings Screen to configure settings for Spit Mode. The Spit Mode is not used with oil-based inks on the CoPilot 500. Spit Settings Screen...
  • Page 88 The Printhead will continue to spit throughout the idle period to reduce the likelihood of ink drying and clogging the system. Spit Settings Screen If using solvent-based inks, contact your Squid Ink distributor for guidance on the appropriate Spit Mode settings to use. 2005995 Rev O – 210712...

  • Page 89: Barcode Validation

    Software Interface 89 Barcode Validation An optional SquidCheck™ Print Validation System (Part Number 2003850) can be used to validate bar codes and ensure that they are present, scannable, and accurate. For details on connecting the SquidCheck Print Validation System, please refer to the SquidCheck manual.

  • Page 90: Usb Load

    90 Software Interface USB Load This button is not available if no USB Drive is connected. The USB Load Screen provides functions for data management and system updates. The USB Load Screen opens automatically when a USB device is connected. NOTE: The USB format must be FAT32 or NTFS.
  • Page 91 Software Interface 91 Copies messages and fonts from a connected USB Drive to the Controller. All messages and fonts in the printer specific folder, or the generic printer folder if the specific folder does not exist will be copied. Ejects a connected USB Drive before physically disconnecting the USB Drive. 2005995 Rev O –...

  • Page 92: Reset

    92 Software Interface Reset The Reset Screen resets the production counter to zero and/or resets the ink level to full. A supervisor might wish to reset the production counter to zero at the beginning of a new shift, for example, to track the number of products labelled each shift. Reset Screen 1.

  • Page 93: Printhead Temperature

    Software Interface 93 Printhead Temperature The Printhead Temperature button is used to display the current temperature for the Printhead in Fahrenheit or Celsius. Printhead Temperature - Fahrenheit Printhead Temperature - Celsius The appropriate environmental temperature range for the Printhead during operation is 34 - 104 °F (1 - 40 °C).

  • Page 94: Calibrating The Touchscreen

    94 Software Interface Calibrating the Touchscreen If the buttons on the Touchscreen no longer activate the corresponding functions or are unresponsive, recalibration may be necessary. Select this button to calibrate the Touchscreen. To Recalibrate the Touchscreen: 1. On the Settings Screen, select the Calibrate Screen button. 2.

  • Page 95: Remote Database Server

    Software Interface 95 Remote Database Server The Remote Database function allows the Controller to connect to a remote database. Refer to the Orion Software User Guide for more information on creating database messages. Select the Database button to open the Remote Database Screen. Remote Database Server Screen Start/Stop Tab The Start/Stop tab contains the Remote Mode ON and OFF buttons.
  • Page 96 96 Software Interface Multicast Tab The Multicast Address IP setting and UDP Port will match the communication settings for the DB server created using Orion. Normally, the settings will be automatically populated with the default value and should not have to be changed. If the address is changed in Orion, it will also have to be changed at the Controller.

  • Page 97: Set Date

    Software Interface 97 Set Date Use the Set Date function to set the date in the Printer. This can be the date that printing is taking place, an expiration date, or any other date desired in the message. 1. Use the Plus (+) or Minus (-) buttons to select the date format at the bottom of the screen.

  • Page 98: Set Time

    98 Software Interface Set Time Use the Set Time function to set the current time in the Printer. This is typically set to the current time to track time of packaging. The time is displayed in hours, minutes, and seconds. To change the time value, select the Plus (+) or Minus (-) buttons for the hours, minutes, and seconds to increase or decrease the time.

  • Page 99: Peak Encoder Speed

    Software Interface 99 Peak Encoder Speed Select the Peak Encoder button to display the top line speed recorded by the Encoder in feet per minute (fpm). Peak Encoder speed is used to determine what speed the Printer requires to be able to print accurately.

  • Page 100: Custom Keyboard

    Keyboard Screen can be used to select that keyboard. Custom Keyboard Screen Standard Keyboard Selected When available, the Controller uses the standard CoPilot 500 keyboard. Custom Keyboard Unselected When the Standard Keyboard button is available, the Custom Keyboard button is not available.
  • Page 101 Software Interface 101 Custom Keyboard Example 2005995 Rev O – 210712...

  • Page 102: Language

    102 Software Interface Language The CoPilot 500 printing systems support eight languages: U.S English German Mandarin Chinese Spanish Korean Japanese Russian Polish To Select a Language: 1. On Settings Screen Two, select the Language icon. 2. In the Language window, select the desired language.
  • Page 103 Software Interface 103 4. To open Language Screen Two, select the More button. The Controller displays the selected language. Language Screen 2 5. Restart the Controller for the language change to take effect. 2005995 Rev O – 210712...

  • Page 104: Static Ip Address

    104 Software Interface Static IP Address A static IP address can be assigned to the Controller. NOTE: When assigning a new IP address, work with the local IT Administrator to ensure that the new address does not conflict with existing devices. To Provide a Static IP Address (rather than a dynamic IP address): 1.

  • Page 105: User Data

    Software Interface 105 User Data User data is data that is provided by the user. If user data is contained in the current message, the User Data button is available. The User Data function allows messages that contain user data to be edited directly from the Touchscreen, USB Keyboard, or USB Barcode Scanner.

  • Page 106: Wireless Interface

    300 ft. range The software that comes with these devices does not need to be installed. These drives are already built into the CoPilot 500 printing system. Wireless Routers and Wireless USB Adapters may be purchased directly from Squid Ink.
  • Page 107 Software Interface 107 4. On Settings Screen Two, select the Wireless button 5. On the WIFI Screen, select the Scan button . The Printer detects the available wireless networks. 6. In the SSID box, select a network from the list of available wireless networks. 7.
  • Page 108 When successfully connected to the wireless network, the Connected button is available and the IP address for the CoPilot 500 Controller is displayed. The password is not displayed after the Controller successfully connects. To end the wireless connection, select the Disconnect button before removing the Wireless USB Adapter from the USB Port on the Controller.
  • Page 109 Software Interface 109 NOTE: Restart the Controller when changing from wireless to Ethernet or from Ethernet to wireless. 2005995 Rev O – 210712...

  • Page 110: Temperature Warning Screens

    The system checks the Printhead temperature every few minutes to detect if it is overheating. For CoPilot 500 Oil systems, if a temperature over 130 °F (54.4 °C) is detected for the interface, a full-screen warning is displayed. For CoPilot 500 Solvent systems, if a temperature over 115 °F (46.1 °C) is detected for the interface, a full-screen warning is...
  • Page 111 When the temperature drops below 130 F (54.4 °C) on a CoPilot 500 Oil system or below 115 °F (46.1 °C) on a CoPilot 500 Solvent system, the original screen is displayed. Printing can resume. 2005995 Rev O – 210712...

  • Page 112: Gui Refresh

    112 Software Interface GUI Refresh GUI Refresh provides updates to the messages, such as counter, shift, time, or date, as they occur over time. Press the GUI Refresh button to turn off/on “GUI Refresh” GUI Refresh is on GUI Refresh is off 2005995 Rev O –...

  • Page 113: Software Setup

    Software Setup Before printing a message, the proper settings for the physical conditions need to be entered into Orion. This is typically done during installation by a qualified Squid Ink distributor. VIDEO: Software Setup To see a video of this procedure, click this link: https://youtu.be/zSjTfhCmU8M?t=1113...
  • Page 114 114 Software Setup 2005995 Rev O – 210712...

  • Page 115: Operation

    Operation 115 Operation Powering On When all the components have been properly mounted and connected, the system is ready to be powered up to begin printing. Checklist Before Powering On: • Ensure that the Nozzle Face is positioned to be 0.125” (3.2 mm) from the items to be printed as they pass by on the Conveyor.

  • Page 116: Creating A Print Message

    116 Operation Creating a Print Message To Create a Print Message: 1. Print messages are created on a PC using Orion software. For more information on creating a print message in Orion, see the Orion User Guide. Transferring a Print Message Once a print message has been created in Orion, it can be transferred to the Controller by USB or Ethernet.

  • Page 117: Loading A Print Message

    Operation 117 Loading a Print Message A print message can be loaded directly from the Controller or, if connected to a network, from a remote PC or network. To Load a Print Message: From the Home Screen, go to the Message Screen by selecting the Message button. 2.

  • Page 118: Printing A Message

    118 Operation Printing a Message To Print a Message: 1. From the Controller, load the desired message. The message name should be visible to the right of “Message” on the Home Screen. Message Name 2. To start printing, select the Start button in the upper left. 3.

  • Page 119: Maintenance

    Maintenance 119 Maintenance The CoPilot 500 printing system requires very little maintenance during normal operation. ATTENTION: There are no field-replaceable parts in the Printhead or Controller. Do not attempt to open the Printhead the Controller. Doing so can damage the equipment and will void the warranty.

  • Page 120: Flushing The Printhead

    Ink System or Bag Ink System is being used. Flushing takes approximately five minutes for each Printhead. The tools required are included in the CoPilot 500 Startup Kit. ATTENTION: Use only Squid Ink approved fluids for cleaning or flushing the Nozzle Face.
  • Page 121 Maintenance 121 Pushing Ink Out the Purge Tube Printhead Ink Line IN Purge Tube (uncapped) Non-abrasive Lint-Free Wipe(s) Waste Ink Tube from Receptacle Appropriate Flush Kit Syringe 9. Refill the syringe and repeat until the fluid coming out of the Purge Tube is clear and free of ink.
  • Page 122 122 Maintenance Items Needed to Flush the Printhead (Bag Ink System): Non-Abrasive, Lint-Free Wipes • • Bag of Internal Flush Fluid Appropriate for the Ink Used (see “Inks and Fluids” on page 133) Waste Ink Receptacle • To Flush the Printhead (Bag Ink System): 1.

  • Page 123: Purging The Printhead Of Air Bubbles

    Nozzle Face. Use only the appropriate cleaning or flushing fluid for the specific ink being used (see “Inks and Fluids” on page 133). Preparing a CoPilot 500 for Shipping or Storage Items Needed to Prepare a CoPilot 500 Printhead for Shipping or Storage: • Non-Abrasive, Lint-Free Wipes Syringe and Tube from Flush Kit (P/N 2001022 for oil-based, P/N 2001083 for solvent- •...
  • Page 124 (P/N 2006023) on Ink Line IN Nozzle and Purge Line Nozzle Items Needed to Prepare a CoPilot 500 Ink Reservoir for Shipping or Storage: • Non-Abrasive, Lint-Free Wipes 2 Quarts of Internal Flush Fluid (see “Inks and Fluids” on page 133).
  • Page 125 Maintenance 125 Capping Off the Ink Line and Pouring Flush into the Ink Reservoir Reservoir Vent Tube Internal Flush Fluid Ink Reservoir Ink Line 5. Pour half a quart of internal flush fluid into the Ink Reservoir, slosh it around in the Ink Reservoir, and pour it out into the waste ink receptacle.
  • Page 126 126 Maintenance Items Needed to Prepare a CoPilot 500 Ink Tray for Shipping or Storage: Non-Abrasive, Lint-Free Wipes • • Bag of Internal Flush Fluid Appropriate for the Ink Used (see “Inks and Fluids” on page 133). Waste Ink Receptacle •...

  • Page 127: Troubleshooting

    Troubleshooting 127 Troubleshooting Problem Possible Cause Solution Print quality distorts occasionally Line noise, brownouts, or Install a good-quality AC power or system locks up. blackouts may be affecting the Line Conditioner or quality of the AC power supply Uninterruptible Power Supply to the system.
  • Page 128 128 Troubleshooting 2005995 Rev O – 210712...

  • Page 129: Parts List

    Turbo* 2005964 2005900-HS 2005095-HS 2005965 * The CoPilot 500 Controller has been replaced by the CoPilot 500 Turbo Controller. ** The CoPilot 500 HiSpeed Controller has been replaced by the CoPilot 500 HiSpeed Turbo Controller. 2005995 Rev O – 210712...

  • Page 130: Other Replaceable Parts

    2004918 Printhead Rotation/Tilt Mounting Kit 2004920 Mounting Bracket Assembly CoPilot 500 Controller 2005990 (works with CoPilot 500 Oil or Solvent Printhead) CoPilot 500 Turbo Controller 2005095 (works with CoPilot 500 Oil or Solvent Printhead) CoPilot 500 Turbo Controller 2005095-HS (works with CoPilot 500 HiSpeed Printhead only)

  • Page 131: Floor Stand Assemblies

    CoPilot 500 Printheads, and Ink System Mounting Brackets 2 Arms, 2 Stitch Plate Bracket sets for four Printheads, four Ink Reservoir and 2004951 two Controllers (for two CoPilot 500 Controllers with 4 Printheads total) 1 short Arm (14"), Controller Mounting L-Bracket, black Mounting Plate for 2004956 CoPilot 500 Printhead, and Ink System Mounting Bracket 1 long Arm (30"), Controller Mounting L-Bracket, black Mounting Plate for...

  • Page 132: Conveyor Mount Assemblies

    * Must order Printhead Mounting Post (2004918) to accommodate down, horizontal, or twist applications 2004928 Tubing kit with Slider Brackets for two CoPilot 500 Printheads and Ink Systems Tubing kit (single head) with black Printhead Plate for low profile Printhead 2004943...

  • Page 133: Inks And Fluids

    Parts List 133 Inks and Fluids ATTENTION: Use only Squid Ink approved fluids for cleaning or flushing the Nozzle Face. Use only the appropriate cleaning or flushing fluid for the specific ink being used (see “Inks and Fluids” on page 133).

  • Page 134: Exploded Views

    134 Parts List Exploded Views Cartridge Ink System Cartridge Ink System Assembly (Part Number 2001065 – Oil) | (Part Number 20001066 – Solvent) Item Part Number Description System Number GENERIC INK SYSTEM ASSY 2002057 CHECK VALVE ASSEMBLY - PO 2002058 CHECK VALVE ASSEMBLY - PO Solvent 2006088...
  • Page 135 Parts List 135 Cartridge Ink System Assembly (Part Number 2001065 – Oil) (Part Number 20001066 – Solvent) 2005995 Rev O – 210712...
  • Page 136 136 Parts List Item Part Number Description System Number 2001065 Cartridge Ink System Assembly 2001066 Cartridge Ink System Assembly Solvent 1603588 FTG-ELBOW, 1/8 BARB, #10-32 1705038 SCREW, M3 X 8, FH, BLK 2003069 PZP END PLATE 2003072 PZP INK SYS COVER 2003073 PZP INK SYSTEM BASE 2003074...

  • Page 137: Bag Ink System

    Parts List 137 Bag Ink System Bag Ink System Assembly – Oil (Part Number 2001159) Item Part Number Description Number 2003014 PAN INK SYSTEM 2003015 COVER INK SYSTEM 2003017 TRAY INK SYSTEM 2006007 NUT HEX 8-32 KEPS SS 2006020 WASHER-FLAT #8 SST 2006022 FITTING-FEM LUER TO 1/8”...
  • Page 138 138 Parts List Bag Ink System Assembly – Solvent (Part Number 2001160) Item Part Number Description Number 2003013 PAN INK SYSTEM 2003015 COVER INK SYSTEM 2003017 TRAY INK SYSTEM 2006007 NUT HEX 8-32 KEPS SS 2006020 WASHER-FLAT #8 SST 2006021 FITTING OCONN FEM W/E 2006022 FITTING-FEM LUER TO 1/8”...

  • Page 139: Printhead

    Solvent 2005905 FAB, PRINTHEAD COVER 2003271 SCREW, #6-32X1/4, FH UNDERCUT, SS 2005908 FAB INSIDE GUARD, COPILOT 500 1440010 PCB ASSY – PRINTHEAD, COPILOT 500 PRINT ENGINE, OIL-BASED, COPILOT 2005999 PRINT ENGINE, SOLVENT-BASED, 2005998 Solvent COPILOT 500 GASKET, PRINTHEAD SEAL, COPILOT...

  • Page 140: Copilot 500 Controller*/Copilot 500 Hispeed Controller

    CoPilot 500 Controller*/CoPilot 500 HiSpeed Controller** * The CoPilot 500 Controller has been replaced by the CoPilot 500 Turbo Controller. ** The CoPilot 500 HiSpeed Controller has been replaced by the CoPilot 500 HiSpeed Turbo Controller. 2005995 Rev O – 210712...

  • Page 141: Copilot 500 Turbo/Copilot 500 Hispeed Turbo Controller

    Parts List 141 CoPilot 500 Turbo/CoPilot 500 HiSpeed Turbo Controller 2005995 Rev O – 210712...
  • Page 142 142 Parts List Item Part Number Description Model Number 2005095 Controller Standard 2005095-HS Controller HiSpeed 2005095 Controller Turbo 2005095-HS Controller HiSpeed Turbo 098898-001 LABEL-PROT EARTH GRND, IEC 5019 102448-001 NUT-KEP, M3, ZINC Standard 1603530 ASSY-MAIN PCB* HiSpeed Turbo 1440019 ASSY-MAIN PCB, COPILOT TURBO HiSpeed Turbo 1603526 GASKET –...
  • Page 143 EVA FOAM (HARD) SPACER* HiSpeed * The CoPilot 500 Controller has been replaced by the CoPilot 500 Turbo Controller. ** The CoPilot 500 HiSpeed Controller has been replaced by the CoPilot 500 HiSpeed Turbo Controller. 2005995 Rev O – 210712...
  • Page 144 144 Parts List 2005995 Rev O – 210712...

  • Page 145: System Updates

    System Updates 145 System Updates Occasionally software and firmware updates will become available from Squid Ink Manufacturing. Software and Printer System Firmware can be updated from a desktop computer using Orion™. Periodically check to see if updates are available at https://www.squidink.com/products/coding-marking-software/orion-software/.
  • Page 146 In the unlikely event that there is a problem, remove the USB device containing the update, power the printer off and on, and then retry installing the update. If the problem persists, call Squid Ink Manufacturing Technical Support. 2005995 Rev O – 210712...

  • Page 147: Product Warranty

    Product Warranty Warranty Statement Squid Ink Manufacturing, Inc. warrants that all of the piezo printing systems it ships will be in good working order and free from defects in material and workmanship and will conform to the published specifications for that product.

  • Page 148: Warranty Procedures

    Squid Ink, or which do not meet Squid Ink’s manufacturing specifications and have written approval of Squid Ink void the warranty on printheads. Use of a printhead wipe material not approved by Squid Ink voids the warranty on printheads. Printheads are specifically not warranted against clogged jets, crooked jets, or scratched orifice plates.

  • Page 149: Disclaimer Of Damages

    LIABLE FOR ANY SPECIAL, CONSEQUENTIAL, INDIRECT OR SIMILAR DAMAGES, INCLUDING LOST PROFIT OR LOST OPPORTUNITIES OF ANY TYPE ARISING OUT OF THE USE OR INABILITY TO USE THESE PRODUCTS EVEN IF SQUID INK MANUFACTURING, INC. HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
  • Page 150 2005995 Rev O – 210712...

  • Page 151: Technical Support

    Squid Ink reseller or Squid Ink Technical Support. Toll-Free Phone: 800-253-2627 Phone: (55) 5426-4137 Email: info@alfamaq.mx Web: www.alfamaq.mx Thank you for your purchase of Squid Ink products. We are pleased to be a part of your marking and coding needs. 2005995 Rev O – 210712...
  • Page 152 Technical Support 2005995 Rev O – 210712...

This manual is also suitable for:

Copilot 500 turboCopilot 500 hs turbo

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