UM 4020 - Covers.

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4020

9, rue Gaspard Monge

005082-D B.P. 110
26501 Bourg-lès-Valence Cedex
France
Tél. : +33 (0) 4 75 75 55 00
www.markem-imaje.com Fax : +33 (0) 4 75 82 98 10
Contents

General 5
■ Introduction 7
■ Conditions 7
■ Safety 8
Safety Requirements 9
Environmental Laws Governing the Electronics Industry 10
WEEE (Waste from Electrical and Electronic Equipment) 10

Product Presentation 4020 11

■ Introduction 13
Case Coding Made Easy 13
Easy to Install and Maintain 13
Easy to Operate 14
Flexible Printing 14
■ Overview 15
■ Printer Parts 16
■ Ink System 17
Ink System with See Through Container, 5 Gallon (19 L) 17
Ink System with Metal Container 18
■ Controller Overview 19
Connectors 19
Display and Function Keys 20
Keyboard 21

Operation 23
■ Main Menu 25
Select Job to Print 25
Edit or Add New Job 25
Default Print Settings 25
Global Settings 25
■ Edit or Add New Job 28
Select Job to Edit 28
New Job 39
Select Job to Delete 39
Available Memory for Jobs 40
Update Job’s Head Arrangement 40

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Contents

■ Default Print Settings 42

Head Specific Print Settings 42
Set Print Speed/Encoder Mode 44
Set Print Direction 45
Set Continuous Print 45
Set Trig Mode 45
■ Global Settings 46
Time/Date Settings 46
Select Global Counter 51
Counter Type 51
Manual Counter Reset Option 52
Edit or Add New Shift 52
Edit User Prompts 54
Edit External Variables 56
■ Control Panel 57
Edit and Add New Profile 57
Set Display Language 59
Font options 59
Set Digit Format 59
Set Keyboard Layout 60
Set Display Contrast 60
View Software Version 61
Port Settings 62
Unit Settings 66
Head Arrangement /Connections 66
Low Ink Settings 67
IO Box Settings 68

Mechanical Adjustments 69
■ Vertical Adjustments 71
Adjust the Print Head Holder Vertically 71
■ Horizontal Adjustments 72
Adjust the Print Head Holder Horizontally 72
Adjust the Print Head Horizontally 73
Distances 74
■ Character Height 76

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Contents

Maintenance 77
■ Start Test Pattern 79
■ Exterior Cleaning 80
General 80
Cleaning Keyboard 80
Cleaning Print Head except Nozzle Plate 80
■ Cleaning Print Head Nozzle Plate 81
■ Internal Print Head Cleaning (Flushing) 82
■ Storage or Low Frequent Use 84
■ Replacing Print Head 85
■ Changing Ink Container 87
Changing See Through Ink Container, 5 Gallon (19 L) 87
Changing to Flush Kit 89
Changing Metal Ink Container 4,5L, 5L and 30L 91
■ Replacing Filter 94
Replacing the Air Filter on Metal Container 4,5L, 5L and 30L 94
Replacing the Ink Filter 4,5L, 5L and 30L 95

Accessories 97
■ Extension Arm 99
■ Encoder 100
■ Status Beacon 101
■ IO Box 102
■ Flush Kit 103

Technical specifications 105

■ Specifications 107

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Contents

Troubleshooting 109
■ Alarm Messages 111
■ LED Alarm Signals and Status Beacon 112
LED/Alarm Lamp Combinations 112
Status Beacon Signals (Optional) 113
■ Troubleshooting Schedule 114
No Job Is Printed 114
Poor Print-Out Quality 116
Unreadable Message 117

Tutorials 119
■ Overview 121
■ Create Your First Job 122
■ Create Job with Current Date and Expiration Date 124
■ Insert Advanced Counter Function 127
■ Create Job with Shift Codes 130
■ Create Job with User Prompts 133

Appendix 135
■ Menu Structure Overview 137
Revisions to this manual 139

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 General

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General

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General

■ Introduction

Congratulations to your new 4020 ink jet printer.

We have done our outmost to develop an ink jet printer that you will find easy to use and easy to
maintain. It is made robust in order to provide the functionality required for demanding operations.

Please take a few minutes to read this User Manual and to get familiar with the printer, its
functionality and how it operates.
Please pay special attention to the chapter describing safety and warnings.

For detailed information regarding installation and service of the 4020 we refer to the separate
Book for Service Engineers.

■ Conditions

Markem-Imaje reserves the right to change specifications in both text and illustrations without prior
notice. The contents of the publication may not be copied, either wholly or in part, without
permission from Markem-Imaje.

Markem-Imaje is not responsible for any direct, indirect, specific, accidental or resultant injuries
caused by a fault with the printer or software, or by an error in the accompanying documentation.
In particular, Markem-Imaje cannot be held responsible for any program or data stored or used
with Markem-Imaje’s products, including the cost of recovering such programs or data.

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General

■ Safety
Before using this printer, please read and fully comply with instruction manual.

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General

Safety Requirements

Markem-Imaje disclaims all responsibility regarding the CE directive if the printer is

used, altered or installed in any way other than described in this manual.

This symbol is used to indicate circumstances that may be dangerous to the user or that
cause damage to the equipment.

This symbol is used to draw your attention to important information that will facilitate
work or operations.

Please Note the Following Warnings:

Please read all instructions before using the printer for the first time.
Never use sharp or pointed tools when cleaning or replacing the print head.
The nozzle plate on the print head is sensitive to handling. Contact with this surface
must be minimized to prevent damage to the nozzle plate. Damage to the nozzle plate
surface can cause a reduction in the performance of the print head.
Use only Markem-Imaje authorized cleaners. Never clean the nozzle plate with tools.
Never expose the unit to high humidity or liquids.
Ensure that the lighting at the installation site is in accordance with local regulations.
All chemicals, even ink, may present unknown health hazards, and should be treated
with caution.
If you use flammable ink, keep electric installations and sparks/flames at least 0.50m
away from the ink container. When changing containers, while using flammable ink, all
electrical equipment must be at least 1m away up/to the side, and 3m below the ink
container.
If you use flammable ink, keep electric installations and sparks/flames at a minimum
distance of 2m from the print head.

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General

Environmental Laws Governing the Electronics Industry

During 2005 and 2006 two new environmental laws have been introduced in the EU.
These two laws are connected and aim at reducing the waste of electrical and
electronics products and at recycling as much waste as possible. The waste that cannot
be recycled must be risk-free to handle and must minimize dangerous discharges into
the surrounding environment.

WEEE (Waste from Electrical and Electronic Equipment)

The purpose of this EU directive is to ensure that electrical and electronics products are
designed and manufactured in such a way that waste is prevented. When waste does
occur it must be collected and re-used or recycled in an environmentally friendly way.
Manufacturers and importers are obliged to pay for the future recycling of the products,
and are also responsible for carrying out collection and environmentally friendly
recycling.

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 Product
Presentation
4020

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Product Presentation 4020

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Product Presentation 4020

■ Introduction
Case Coding Made Easy

Flexible and user friendly; 4020 facilitates personalized case marking. 4020 has one of
the best cost-performance ratios on the market due to its reliability, great ease of use
and simple maintenance.

Easy to Install and Maintain

The printer is compact and fits straight into your packing line. Simplified, fast
maintenance reduces downtime. The printer has quick connectors on the print head
cabling. 4020 is a rugged printer - always ready for demanding work. The print head is
easy to exchange/replace for maximum up time. The stand has a duct to hide the
cables.
The bracket and holders are robust and easy to handle. The holders have a quick-lock
mechanism and are fastened to the stand with a hinge construction. This gives the
possibility to rotate the print heads around the stand for a flexible installation. It also
serves as protection if hit by a carton or package.

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Product Presentation 4020

Easy to Operate

The user-friendly interface has icon menus and help text in many languages.
4020 can print many different characters and it is easy to choose a job from the menu.
The backlit display gives you clear operation and works in all environments.
The WYSIWYG (What You See Is What You Get) interface helps to create jobs.

Flexible Printing

4020's impressive printing performance guarantees perfect personalization of your

products for local and export markets.
4020 has the possibility to control up to 4 heads of different types.
4020 is capable of printing from both sides and from above (option).
Various ink colors are available
with various types of ink. You
can select between a 7-nozzle
print head for 1 line printing
and a 16-nozzle print head able
to print 1 or 2 lines.

1. 7-Nozzle Print Head

2
2. 16-Nozzle Print Head

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Product Presentation 4020

■ Overview

1. Print Head
2. Controller
3. Ink System with see through container 5 Gallon (19 L)
4. Metal container (4,5 L)
5. Metal container (5 L)
6. Metal container (30 L)

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Product Presentation 4020

■ Printer Parts

1. Print Head
1 2
(7N or 16N)

2. Print Head Holder 3

3. Top Screw
4

4. Ink Outlet
5
6
5. Print Head Connector

7
6. Ink Inlet

7. Photo Cell 8

8. Cable Strips 9

10
9. Support Beam with Bracket

10. Power Supply (3A or 5A)

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Product Presentation 4020

■ Ink System
Ink System with See Through Container, 5 Gallon (19 L)

3
1. External Ink Filter
2
2. Ink Tube
1 4
3. Air regulator.
max 0,5 bar

5
4. Air Tube

5. Check Valve 6
6. Pick-up Unit

7. Filter
7

8. Ink Container
8

9. Ink Container Holder

9
10. Low Ink Sensor

10

Warning!
While the system is pressurized, always store the container in its holder and keep the
holder locked.

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Product Presentation 4020

Ink System with Metal Container

2
6
8

4 3

1. Air Pump
2. Air Regulator
3. Ink Container Holder
4. Low Ink Kit
Used on 4,5, 5 liter and 30 liter system
5. External Ink Filter
6. Pick-up Unit
7. Air Filter
8. Ink Container

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Product Presentation 4020

■ Controller Overview
Connectors

1. Print Heads

2. COM 2

3. I/O Box

4. Photocell 2
1
3
5. Status Beacon 4
5
6. Power Supply

7. COM 1
6

8. LAN
7
8
9. Encoder 9
10
10. Ink System

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Product Presentation 4020

Display and Function Keys

1 2 3 4 5 6 7

ENTER

1. LED Alarm Signals (See Troubleshooting).

2. START - Press this button to activate (GREEN) or deactivate (YELLOW) the current
print job.

3. Information Field - The upper field in the display shows varying information
depending on the menu.

4. Menu field - The lower field in the display shows icons representing available
functions.

5. ESC - Press this button to exit current level in the menu to one level above.

6. ENTER - Press this button to confirm your choice in the menu.

7. Navigation keys - These buttons move the cursor in the menu and message fields.

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Product Presentation 4020

Keyboard

1 2 3 4
The keyboard has the following special keys:

1. SHIFT - The key shifts to a different set of characters in the bottom right
corner of the keys (printed in purple).

Press and hold the SHIFT key while pressing another key to
temporarily shift between normal and special characters.

Press and release the SHIFT key to shift between default and special
characters

2. T - The key accesses a list of local (depending on installed language)

and Unicode characters.

3. T2 - The key toggles between Standard and Alternate mode.

The set of characters is defined in the Keyboard Layout menu.
In the “Arabic/Latin” Keyboard Layout, Alternate mode accesses Arabic
characters, while in Standard mode Latin characters are used.

4. abcABC - The key shifts between upper and lower case letters.

Press and hold the abcABC key while pressing another key to
temporarily shift between upper and lower case letters.

Press and release the abcABC key to shift between upper and lower
case letters.

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Product Presentation 4020

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Operation

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Operation

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Operation

■ Main Menu
The main menu is the top level of the user interface and it is described below.

Select Job to Print

In this menu you choose to start any job that is already

created.

Edit or Add New Job

In this menu you can edit, create or convert jobs.

Available memory can also be seen here.

Default Print Settings

In this menu you adjust settings that have an effect on

the output of the printer (Drop size, Conveyor speed,
Sensor mode etc).

Global Settings

In this menu you adjust settings that have effect on all

jobs that will be printed (Time, Date, Formats etc).

Control Panel
In this menu you adjust settings that are related to the
user interface (Display contrast, Language, Units etc).

Start Test Pattern

This item starts a test pattern printout that can be used
during setup or cleaning of the print head(s).

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Operation

■ Select Job to Print

Here you select a job for printout. You can select among the
created jobs from the drop-down list either by using the UP and
DOWN arrows or by typing the first character in the job name, which
works as a quick search function. Normally the drop-down list
shows the job name without any symbols.

Special cases:
If a job name starts with a ≠ sign it means that it was created for a
different head arrangement than the one currently used. However
it may be possible to print this job anyway via an adaptor. If you
select the job it will take you to an adaptor menu.

In the example below one of the 16-nozzle print heads has been
replaced with a 7-nozzle print head. You must select which of the
available 7-nozzle print heads should be used for the 7-nozzle text.
It is also necessary to select which of the 16-nozzle texts that
should be printed on the only available 16-nozzle print head. This
is done by selecting a print head, press ENTER and move it to the
desired (connected) print head position.

After going through this adaptor press ESC to save the changes.
The adapted jobs will now have a ≈ sign prior the job name and the
job can be printed. To change the adaptations of a job simply
select the job again and you can go through the steps again.

The adaptor created is valid for the job’s head arrangement and
not only the job itself. It will be valid for all jobs created with the
same head arrangement.

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Operation

Manual counter reset

If the option for this feature is enabled in the Global Settings menu,
the counters of a job may be reset manually from the main menu.
Select the job already selected once more and a dialog will appear
allowing counters to be reset.

Manual counter adjustment

If the option for this feature is enabled in the Global Settings menu,
all counters may be viewed and altered from the main menu. This
gives an easy way to “undo” a failed printout even while using
batch counting. Select the job already selected once more and a
dialog will appear showing the counters and allowing counter
change with the up/down keys. Press enter when done.

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Operation

■ Edit or Add New Job

Select Job to Edit

To edit a job - choose a job from the drop-down list either by

using the UP and DOWN arrows or by typing the first character in
the job name. This works as a quick search function.

The display with message fields looks like this:

1 2

3 4
1 Select print head
2 Select job
3 Menu field
4 Message field

Use navigation keys to move between Menu Field and Message

Field (see Controller Overview).
ENTER

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Operation

Select Print Head

Each job contains the messages of all available print

heads depending on your head arrangement (up to 4
print heads of different types).

If your current head arrangement contains more than

one print head this menu will appear. Select the print
head for which to create a text message from the list.

Example:

Select Font Size

For a 16-nozzle print head you can select font size.

Large font. The print head will use all nozzles for the
text.

MARKEM-IMAJE

Small font. The print head is divided into two lines of

text.

MARKEM-IMAJE
MARKEM-IMAJE

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Operation

Select Item to Insert

In this menu you can insert many different items, for

example time, date, counters, shift and prompt.

Select Time/Date

Use this menu to insert time, date and expiration

date1&2.

Insert Time

Use the list to insert a time in the message. Time

formats are configured in the Global settings.
Example:

07
07:29
07:29:47

To see result of the insert time: select the preview

icon. With the ENTER key you can toggle between
symbol mode and preview mode.

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Operation

Insert Date
Use the list to insert a date in the message. Date
formats are configured from the Global settings.
Example:

21 MARCH 06
06 MARCH 21
2006 03 21

Select the preview icon to see the inserted date. Use

the ENTER key to toggle between symbol and preview
mode.

Select Expiration Date 1

Two separate expiration dates can be inserted in
each job. The date shown is calculated from the
current date plus an offset in days, weeks, months or
years. The offsets are job specific and can be set
independently of each other. The formats of the two
expiration dates are however global settings and will
affect all jobs (see Edit Expiration Date 1 Format).

When inserting an expiration date you can select the

unit of the offset (days, weeks, months or years).
After selecting the unit, type in the value of the offset.

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Operation

Define offset in days.

Define offset in weeks.

Define offset in months.

Define offset in years.

Insert expiration date.

Select the preview icon to see the result. Use the

ENTER key to toggle between symbol and preview
mode.

Select Expiration Date 2

See Select Expiration Date 1 above:

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Operation

Select Counter
Here you can choose to insert or modify one of the
two counters that are part of the job. You can also
insert the one and only global counter. For details
about how to edit a counter see Select Global
Counter.

Select Counter 1
Job Specific counter

Select Counter 2
Job Specific counter

Insert Global Counter

Global counter (affects all jobs)

Select the preview icon to see the result. Use the

ENTER key to toggle between symbol and preview
mode.

Insert Shift
A shift code is a text that will change to different
values depending on the shift definitions and the
current time. The shift code is global and affects all
jobs. Each text value also has a time stamp defining
the start time for the shift. The settings are global.

Select the preview icon to see the result. Use the

ENTER key to toggle between symbol and preview
mode.

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Operation

Select User Prompt

A user prompt is information that the operator must
enter in addition to selecting a job for printout. The
settings are global.

A User Prompt cannot be previewed but moving the

cursor over the user prompt symbol will cause its
prompt text to be shown.

Select External Variable

An external variable can be inserted into a text
message. The information will then be sent from an
external system, either through a serial RS232 port
(COM1 or COM2) or through the Ethernet port. The
data must be sent by special commands to be
recognized as an external variable. For further
information about the special commands etc contact
your local Markem-Imaje office. The settings for an
external variable are global and the corresponding
port must also be configured correctly.

An external variable cannot be previewed.

Select Bitmap File

A monochrome bitmap, 7 or 16 dots high, can be
inserted into the message. It could be a logo or just
a pattern. The bitmap must have been sent to the
controller’s file system earlier to show up in the list.
Downloading bitmaps can be done using FTP
through Ethernet (see port settings). Make sure the
bitmap is monochrome and that the size suits the
currently selected print head (7 or 16 dots high).

Bitmaps cannot be previewed from the display.

Moving the cursor over the bitmap symbol will
cause its name to be shown.

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Operation

Select Character to Insert

With this function it is possible to insert special
characters that are not available from the keypad.

You can select Local character, Unicode character,

Roman-Hiragana translation, Roman Katakana
translation, Roman-Kanji translation, Roman-
Hangul translation or Chinese characters input:

Select Local Character: Appears only if there are any

local characters defined in the language file. You can
select any of the defined local characters by browsing
with the LEFT or RIGHT keys. Press ENTER to insert.

Select Unicode Character: Always available and

makes it possible to select any Unicode character
defined in the font.

First select the Unicode area of

interest.
Then you will be able to browse all
characters in that area by using the
UP and DOWN keys. Press ENTER to
insert.

You can also enter a character

code manually to insert a
Unicode character.

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Operation

Roman-Hiragana translation,
Roman-Katakana translation,
Roman-Hangul translation:

Enter your Roman characters in the text field, and the

corresponding Hiragana, Katakana or Hangul is shown.
When ready with a word or sentence press enter to
insert it in your text.

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Operation

Roman-Kanji translation:
This menu works similar to the Chinese Pinyin input
method but produces Japanese Kanji characters. Enter
your Roman characters in the input window. As
characters are entered the number of Kanji’s is narrowed
down accordingly. When your desired Kanji is found
press the corresponding digit to insert the Kanji character
into the text.

Insert Simplified Chinese or Traditional Chinese: For

the use of standard pinyin editing. (Phonetic transcription
system).

Note: Some characters cannot be represented in 7 dots.

For 7-nozzle print head special characters are limited to:
Local character, Unicode character, Roman-Hiragana
translation and Roman-Katakana translation.

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Operation

Preview Text and Symbol

Use this function to toggle between
Symbol/Preview modes.
For date, time and counters it might be
interesting to see their actual value. It is not
possible to preview bitmaps, user prompts or
external variables.

Job Print Settings

The following two Print Settings: Set print
margin and Set drop size can be set to either
follow the global print setting or make an
override valid for this job only.

Set Print Margin

The print margin is the distance in mm/inch
from the photocell to the print out. It can be set
to follow the Global setting or to override it with
values from 0-9999 (mm).

Set Drop Size

Drop size (1-5) where 1 represents smaller
dots and 5 larger dots. It can be set to follow
the Global setting or to override it with values
from 1 – 5.

Copy from Another Print Head

This function gives the possibility of copying all
information written for one print head to another
(16-nozzle to 16-nozzle or/and 7- nozzle to 7-
nozzle).

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Operation

Link to Another Print Head

Here you can link all information written for one
print head to another (16- nozzle to 16-nozzle
or/and 7- nozzle to 7-nozzle). When linked to
another print head it will print exactly the same
text as the linked head. When the message
from the linked head is changed this message
will also change.

Remove Link
Delete an earlier made link. The earlier entered
information (if any) will be recovered.

Save
Save the job edited.

Save as
Save the job edited under a different name.

New Job

Type in the name of a new job. Press ENTER to

create and edit the job. If the name you type in
already exists – the existing job will be opened.
Select Job to Delete

Choose a job from the drop-down list. Pressing

ENTERcauses the job to be deleted.

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Operation

Available Memory for Jobs

Here you can see the amount of free memory

in (%) and in (K) (kilo bytes) and also how
many jobs there are stored in the memory.

Update Job’s Head Arrangement

If job’s head arrangement does not match the

current, a conversion can be made.

Choose a job from the menu (Example ≠ job 7).

For more information above the ≠ symbol see

Select Job to Print.

View Job’s Head Arrangement

Here you can see the head arrangement the
job was created for.

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Operation

New Head Arrangement

Here you can see the current heads
arrangement:

List of Job Using this Head Arrangement

This function shows a list of jobs using this

head arrangement that does not match the
current.

Convert Job to Current Head Arrangement

Use this function to convert your job (Example

≠ job 7) to current head arrangement.

Convert All Jobs with Same Arrangement

Use this function to convert all jobs using this

head arrangement to the current head
arrangement.

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Operation

■ Default Print Settings

Head Specific Print Settings

Use this menu to adjust head specific print settings.

These print settings are global and affect all jobs

that will be printed.

Select print head in the print heads menu:

It is now possible to adjust settings that have an

effect on the selected head only.

Set Print Margin

Use this function to set print margin [mm]. The print
margin is the distance in mm/inch from the photocell
to the print out. The value can be set from 0 – 9999
(mm). Input can also be made in Inch using the unit
selection in the Control Panel

Set Resolution
Use this function to set resolution (tilt step). The
resolution can be set from 0 – 4. The print head has
markings for step 0,1 and 2. The head needs to be
mechanically adjusted (see 6.1 Mechanical
Adjustment).

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Operation

Set Print Upside Down

Here you can turn the print text 180º. The text will
simply be printed upside down.

Set Drop Size

Here you can set Drop size (1-5) where 1
represents smaller dots and 5 larger dots.

Set Opposite Side Printing

Use this function to define the position of the head
in relation to the conveyor. Normal/opposite side.
Normal = same side as the controller.
Opposite = opposite side as the controller.

Set Compression
Use this function to define text compression. It can
be set from 0 – max %. Compress rate 10 %
means printing at 90% of normal width. The
compression rate may affect the proper angle of the
head. (See chapter 4. Mechanical Adjustments).

Set Character Spacing

Here you can set distance between characters in
dots. Character space (0-9 dots) is normally set to
Font Default.

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Operation

Set Print Speed/Encoder Mode

Use this function to set mode. In order to get a good

printout result, the speed set in the controller must
be the same as the actual conveyor speed. If the
conveyor speed varies during printout an encoder is
recommended.

Menu examples below are for fix speed mode.

Set Print Speed

Use this function to manually set print speed.

Detect and Set Print Speed

Select a head to print the test pattern. Press ENTER.
Run an object on the conveyor. When triggered a
test pattern will be printed on the object. Press ESC.
Measure distance between two bars on the printed
pattern.

Enter measured bar distance (mm/inch). The speed

will be set accordingly. Unit setting is made via
Control Panel.

Toggle Fix Speed/Encoder Mode

Select between constant conveyor speed or
encoder mode.

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Operation

Menu examples below are for encoder mode.

Set Encoder Pulse Rate

Use this function to manually enter the encoder
pulse rate. (Pulses/m).

Detect and Set Encoder Pulse

Rate See Detect and Set Print Speed for information.

Toggle Fix Speed/Encoder Mode

Select between constant conveyor speed or
encoder mode.

Set Print Direction

Set conveyor direction; left to right or right to left.

(seen from the controller)

Set Continuous Print

Here you can enable/disable continuous printing

(printout is repeated as long as the photocell is
active).

Set Trig Mode

Set the detection edge of the photocell. Either

positive or negative edge.

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Operation

■ Global Settings

Time/Date Settings

Use this menu to set time/date and configure time

and date formats for all jobs.

Edit Time Format

Select Time Format to Edit

Use this function to select an existing time format
Select the time format from the drop-down list:

Use the Preview Text/Symbol icon to toggle

between symbol and preview mode.

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Operation

New Time Format

Use this function to create new time format.

You can mix time components with any character.

Here an hour component has been inserted.

Use this menu to insert Hour (24 Hour Clock):

Use this menu to insert Minute:

Use this menu to insert Second:

Use the Preview Text/Symbol icon to toggle

between symbol and preview mode.

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Operation

Select Time Format to Delete

Use this function to delete any time format.

Edit Date Format

Select Date Format to Edit

Use this function to select an existing date format.
Select the date format from the drop-down list.

You can insert date components from the icons.

Use the Preview Text/Symbol icon to toggle between

symbol and preview mode.

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Operation

New Date Format

Use this function to create new date format.

You can mix date components with any characters.

Use the Preview Text/Symbol icon to toggle between

symbol and preview mode.

Example:

Select Day

Insert Day (1 – 31)

Select Month

Insert Month

Select Year

Insert Year (4 Digits)

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Operation

Select Date Format to Delete

Use this function to delete any existing date format.

Edit Expiration Date 1 Format

Use this function to edit expiration date 1 format for
all jobs that will be printed.

For further information see New Date Format.

Edit Expiration Date 2 Format

Use this function to edit expiration date 2 formats for
all jobs that will be printed.

For further information see New Date Format.

Set Time
Here the current time of the controller is set.

Set Date
Here the current date of the controller is set.

Set Date Change Time

It is possible to set the date change time. (Normally
the date changes at 00:00)

Edit Month Names

Use this menu to edit month names. Default is:
JAN, FEB, MAR etc.

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Operation

Edit Weekday Names

Use this menu to edit weekday names. Default is
MON, TUE, WED etc.

Select Global Counter

Here the global counter value is set up. The counter

is affected by all jobs printed.

Counter Type

Set the counters number-base. Chose User Defined

or one of the predefined options.
Default is: 0-9 base 10.

Edit Value
Set the current value of the counter.

Set Start Value

Set the start value of the counter (minimum counter
value).

Set Rollover Value

Set the value at which the counter rolls over and
starts from the start value (maximum counter value).

Set Number of Digits

This value represents the number of digits printed
(auto or 1-9 digits).

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Operation

Set Batch Update

Set the number of printouts in a batch. The counter
will increment when In-batch reaches the batch-
update value.
Set the value within the batch. If the batch is set to
In Batch for example 10 and the in-batch to 8, the in-batch
will increase from 8:10 up to 10:10 before updating
the counter.

Set Update Value

This value is an incremental value and is added to
the counter after each update. This value can be set
from
–999 999 999 to 999 999 999 (example update=1:
1, 2, 3… example update=2: 2, 4, 6…).

Manual Counter Reset Option

This menu allows you to switch on/off the manual

counter reset option and the counter quick-view &
adjust option. Yes activates, No disables the option.

Edit or Add New Shift

Shifts affect all jobs. The shift feature allows the day
to be divided into shifts defined by a start time. Each
shift can have a user definable text that can be
printed. It is possible to create 24 shifts.

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Operation

Select Shift to Edit

Select a shift from the drop-down menu:

Edit Shift Text

Each shift has a text that can contain any Unicode
character. The text is printed when the item is
inserted in a job.

Set Shift Start Time

This setting only specifies when the shift is starting
(hh:mm). That is, you specify when the shift will stop
by creating a new shift and specify its start time. For
example the day shift works 06.50 -14.53 and the
night shift 14.54 – 06.49.

New Shift
This creates a new shift item that will be available
for all jobs.

Edit Shift Text

Each shift has a text that can contain any Unicode
character. The text is printed when the item is
inserted in a job.

Set Shift Start Time

This setting only specifies when the shift is starting
(hh:mm). That is, you specify when the shift will stop
by creating a new shift and specify its start time. For
example the day shift works 06.50 -14.53 and the
night shift 14.54 – 06.49.

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Operation

Delete Shift
Use this function to delete any shift code.

Edit User Prompts

A user prompt is a prompt for additional information

that the operator must enter before a job can be
started.

Select User Prompt to Edit

Select an existing user prompt for editing.

Question
This parameter sets the user prompt message that
the operator will see in the display when activating a
job referring to this user prompt

Contents
Here optional default contents can be entered.

Resident
Can be false or true. If a user prompt is resident the
prompt appears only once. When its value has been
set no further prompting is needed. Can be used for
entering production line number etc.

Reset
Can be false or true. When set to false the user
prompt will appear upon job selection but earlier
entered contents are visible. If set to true (reset)
the display is always cleared forcing a new value to
be entered.

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Operation

Min Length
Set the minimum number of characters.

Max Length
Set the maximum number of characters.

Character Type
Specify character type of user input: alphanumeric
or digits.

New User Prompt

This creates a new user prompt.

Select User Prompt to Delete

Use this function to delete any existing user prompt.

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Operation

Edit External Variables

An external variable is additional information coming

from an external device, for example weight data
from a scale.

Select External Variables to Edit

Select an existing external variable for editing.

Description
The text entered here has no technical significance.
Its purpose is to be purely descriptive.

Reset
Can be false or true. If true the external variable can
be printed only once. After used in a printout it will
clear itself.

Data Input Device

Can be false or true. If true the variable will get
eventual data from Data Input Device if variable set
mode is selected.

New External Variables

Select External Variables to Delete

Use this function to delete any external variable.

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Operation

■ Control Panel

Edit and Add New Profile

Use this function to prevent unwanted mistakes and

ease operation of the printer for different user
groups. The profile has a specific set of
characteristics in which functions can be locked or
unlocked. Each profile has a name and a password.
The first time the printer is used the profile feature
is deactivated. This feature is optional and can be
activated or deactivated at any time.
You activate it by entering this function when it’s
deactivated.

Select Profile to Edit

One profile is predefined when activating the profile
feature:

DEFAULT – this profile has a minimum of

operational access.

Edit Profile
This function makes it possible to lock or unlock
items in the menus. If a menu is locked, all its
submenus are locked. To change an item in a
submenu the upper menu has to be open.

Toggle with ENTER between locked and unlocked

items.
To save settings in the profile press ESC and then
confirm saved changes.

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Operation

Rename Profile
Rename the profile.

Change Password
Change the profile password.

New Profile
Create new profile.

New Default Profile

Create a new default profile (DEFAULT is the
predefined default profile).

Profile Login
Log in with any profile. The operator is prompted for
profile name and password.
It is also possible to log in from the menu system.
The system will prompt the operator to log in when
a menu is locked in the current profile.

Delete Profile
Delete a profile.
The behavior when deleting the last profile is
equivalent with. Delete all and stop using profiles.

Delete all and stop using profiles

Delete all profiles. This is equivalent with stop using
profiles.
The operator will be logged out and leave this
menu.

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Operation

Set Display Language

Set the desired display language, which is used, in

the entire user interface.

Font options

Here optional font preference settings can be made.

Select style of zero character

Can be set to normal or stroked.

Select style of Arabic characters

Can be set to Arabic or Farsi style.

Set Digit Format

Select which character set to be used when printing

a counter, date or time;
ASCII (standard & default)
Arabic
Farsi
Chinese
ASCII Full width
(Only applicable for digits.)

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Operation

Counters
Select which character set to be used when printing
a counter. Note that counters must be type 0-9
base 10 default in order for this setting to have
effect

Date Items
Select which character set to be used when printing
a date item.
You will also be prompted to choose to have
leading zeroes or not.

Time Items
Select which character set to be used when printing
a time item.
You will also be prompted to choose to have
leading zeroes or not.

Set Keyboard Layout

Set the desired keyboard layout:

The set of characters is defined in the Keyboard

Layout menu.
Example: In the “Arabic/Latin” Keyboard Layout,
“Alternate mode” accesses Arabic Characters, while
in “Standard mode” Latin characters are used.
Use T2 Key to Toggle between Standard and
Alternate Mode.

Set Display Contrast

Increase and decrease display contrast (1-16).

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Operation

View Software Version

View all different software and hardware versions.

See below:

Application Version

Print core Version

Boot Version

FPGA Version

Hardware Version

CPU Board S/N

I/O Board S/N

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Operation

Box S/N

Port Settings

View and adjust settings for serial communication

ports.

LAN Settings
View and adjust LAN settings.

IP Address
Set IP address.

IP Mask
Set IP mask.

Default Gateway
Set default gateway.

Keep Alive
Set telnet keep alive time in seconds. (0-7200)
Default: 0.

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Operation

Host
Set host name. Used as a user defined
identification.
Default: Printer1.

Port
Port number for connection when using XCL
commands. (1024-65535)
Default: 9100.

DHCP
Activate DHCP for automatic setting of IP address,
mask and default gateway.
IP address, mask and default gateway are read
only when DHCP is used.
Default: yes.

MAC Address
Unique Ethernet hardware identification string.
Cannot be changed, only viewed.

COM Settings
View and adjust COM settings.

COM Port
Select COM port (1-3). COM3 is only available if an
I/O box is used (option).
Selected port will be the current port and port
number is shown above the menu row.
All other sub menus will affect the current port
properties.

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Operation

Data Rate/Baud Rate

Select baud rate. (300-115200 in steps)
Default: 9600.

Parity
Select parity.
None, one, even, odd and zero.
Default: none.

Data Bits
Select number of data bits. (7-8)
Default: 8.

Stop Bits
Select number of stop bits. (1-2)
Default: 1.

Flow Control
Select flow control.
Both, disabled, none, xon/xoff, rts/cts.
Default: both.

Buffer Size
Set buffer size. (500-10000)
Default: 2000.

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Operation

Com Port Mode

Use print mode for normal operation when a PC or
other system that controls the printer is connected
to the COM port.
Use terminal server mode when a device like a
scanner or scale is connected and you want to
access it through Ethernet.
Use data input device mode to directly interface
the printer to a scale or scanner and adapt to the
device’s protocol.

Data Input Device

When Com Port Mode is set to Data Input Device,
this menu appears to let you configure the input
filter

Device Mode
Specifies the operating mode of the Data Input
Device. You can choose Job Selection Mode or
Variable Set Mode

Packet Start Marker

Specify the string/character that marks the start of a
data package.

Packet Stop Marker

Specify the string/character that marks the end of a
data package.

Sequence Start Marker

Specify the string/character that marks the start of a
data sequence within the package.

Sequence Stop Marker

Specify the string/character that marks the end of a
data sequence within the package.

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Operation

Data Offset
Optionally if no sequence markers are used, specify
offset into the data package.

Data Length
Optionally if no sequence markers are used, specify
length of the data of interest from the offset.

Filter Test
A test window is provided catching the input data
and displaying it. Use it to test the filter settings
made.

Unit Settings

Choose between metric or inch/feet units.

Head Arrangement /Connections

Use this function to detect, view and edit head

arrangement.

Re-detect Head Arrangement

After you changed the print heads you can compare
the present printer head arrangement with the
previous arrangement.

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Operation

View Head Arrangement

Here you can view the present print head
arrangement.

Specify Connections Manually

Use this function to manually specify the head
connections. You can do this when you want to
redirect a message, which is edited for a certain
head/port, to another head/port. You can only
redirect a message to a head of same type.

Low Ink Settings

Select low ink kit.

There are some predefined selections with different
volumes and sensors.
Selections are:
Metal container 4,5 or 5L (active high)
No low ink kit (input disabled)
Metal container 30L (active low)
See through container 5 gallon (19L) (active low)

This setting is used for detecting low ink and no ink

and will activate the status beacon as well as the
LED lights.

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Operation

IO Box Settings

Set up inputs, outputs and enable/disable the IO

box. For further information about the IO box,
please see the 4020 software and integration
manual.
Use the test pattern to verify the function of the print
heads. You will have to select print head and press
ENTER to activate the test print.
Print nozzles will be activated after trig.
The test print is aborted after 30 seconds or when
pressing any key.

For further information see chapter Maintenance.

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 Mechanical
Adjustments

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Mechanical Adjustments

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Mechanical Adjustments

■ Vertical Adjustments

Tool needed: Allen Key 5mm.

Adjust the Print Head Holder Vertically

The Print Head Holder can be adjusted vertically:

1. Loosen the screw and move the

print head holder vertically to the
desired position.

2. Tighten the screw.

1 2

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Mechanical Adjustments

■ Horizontal Adjustments
Tool needed: Allen Key 5mm.

Note: There are two ways to adjust the print head in the horizontal position.

Adjust the Print Head Holder Horizontally

1. Loosen the screws and move

the print head holder 1 2
horizontally to the desired
position.

2. Tighten the screws.

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Mechanical Adjustments

Adjust the Print Head Horizontally

1. Loosen the top print head holder screw.

1

2. Move the print head

horizontally to the desired
position.

3. Tighten the top print head

holder screw.

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Mechanical Adjustments

Distances

1. Minimum standard adjustment

is 20 mm outside the conveyor
edge.

2. Maximum standard adjustment is

75 mm inside the conveyor edge.

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Mechanical Adjustments

3. Maximum adjustment with

extension arm is 450 mm. (Option)
See chapter Accessories. 3

4. The distance from

the print head to the
object should be
between 5 and
20mm.
4
5-20 mm

5
5. The distance
between the objects 100 mm
on the conveyor
should be at least
100 mm.

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Mechanical Adjustments

■ Character Height

The print head has two tilt angles for different text
heights. It also has a flush (F) angle for print head
maintenance.

Note: First change the character height by using the

head specific print setting function. (See Head
Specific Print Settings/ Set Resolution).

Then change the character height by Loosen the top

screw and turning the print head in its holder.

1. Tilt angle maintenance position.

2. Tilt angle positions. 1

2
Note: F is used for maintenance only. (See Internal
Print Head Cleaning).

7 Nozzle 16 Nozzle

Print head Tilting angle Text height Print head Tilting angle Text height
marking (mm)* marking (mm)*
0 straight 28 0 straight 64
1 45 20 1 45 44
2 63 12 2 63 27
F flush F flush
(*) The head can be tilted beyond these marked tilt steps, to get 8mm of text height with the 7
nozzle and 15mm with the 16 nozzle.

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Maintenance

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Maintenance

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Maintenance

■ Start Test Pattern

The 4020 printer has a test program to verify that the nozzles are working before
starting to print.
The program can also be used to refresh the nozzles when resuming printing after a
stop.

Warning!
While the printer is active, keep away
from the front of the printer. Never
point the nozzle end of a print head at
yourself or another person.

Place a cardboard in front of the

printer.

Select Start Test Pattern from Main

menu:

Select print head and press ENTER to activate test

pattern.

Note: The Test Pattern will be printed when the photocell is covered.

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Maintenance

■ Exterior Cleaning
General

Warning!
While the printer is active, keep away from the front of the printer.
Never use sharp or pointed tools when cleaning or replacing the print head.

Cleaning Keyboard

Important!
When cleaning the keyboard,
use a cloth dampened with
water or ethanol.

Cleaning Print Head except

Nozzle Plate

Important!
When cleaning the print head (except
nozzle plate) use the appropriate
solvent for the ink type.

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Maintenance

■ Cleaning Print Head Nozzle Plate

Warning! 1
Before starting this maintenance
procedure, make sure the printer is
deactivated.

1. Spray the nozzle plate or soak

a Markem-Imaje wipe card 2
with solvent.

3
2. Carefully wipe the nozzle
plate.

3. Make sure the nozzles are

clean.

Note: Use solvent of the same base as the ink type.

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Maintenance

■ Internal Print Head Cleaning (Flushing)

To achieve a longer operational lifetime for the print head, preventive flushing is recommended.

1. Install solvent container with an appropriate solvent for the ink type used. (See Changing
ink container). For see through container a separate flush kit is used

2
2. Loosen the top screw on the print head
holder.
F

3. Change the tilt angle to flush position. 3

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Maintenance

4. Insert the flush tube to the outlet 4

connector.

5. Flush the print head with solvent

as shown until clear solution
comes out of the flush tube.

6. Use the waste container to collect

the solvent.

7. Remove flush tube.

8. Run the test pattern program (3

times).
(See Start Test Pattern).

9. If necessary repeat the flushing procedure.

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Maintenance

■ Storage or Low Frequent Use

Markem-Imaje recommends storing the print head filled with solvent for a longer print stop.

This is especially important when using pigmented and NP-EA inks.

Regular Maintenance Period

Regularly flush the print head in PW inks (water based): Preventive

correspondent solvent. flushing recommended every third
month.

PP/PE inks (Propanol/Etanol based):

Preventive flushing recommended every
second month.

NPEA inks (Ethylacetate based):

Preventive flushing recommended every
month.

PWP (Pigmented water): Preventive

flushing recommended every week.

Storage/low frequent use For longer print stop than above,

recommended preventive period, store
print head filled with solvent. When stored
in solvent flushing is not needed.

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Maintenance

■ Replacing Print Head

Note: Make sure that you know

the position of the print head in
3
comparison to the print head
holder, before you replace the
print head. (It makes it easier to
place the new print head in the
right position).
1
1. Disconnect the print head
cable.
4

2. Disconnect the ink tube.

2
3. Loosen the top screw on the print head holder.

4. Remove the print head.

5
Note: The message on the Controller indicates that
connections to head are altered. (See Alarm Message).
Wait to press any button on the keyboard, until you have
replaced the print head.

5. Place the new print head in position.

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Maintenance

6. Attach it with the top screw on the print head holder.

7. Connect the print head cable.

6
8. Connect the ink tube.

To adjust the print head see:

Chapter 4 Mechanical Adjustment 7

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Maintenance

■ Changing Ink Container

The message on the display indicates when the ink container is empty. (See Alarm
Messages).
Check that the ink-type marking on the container matches that on the print head.

Note: Always use Markem-Imaje ink or you risk damaging the system or
invalidating the warranty.

Changing See Through Ink Container, 5 Gallon (19 L)

Warning: Be careful while opening and closing the

container holder to avoid personal injury.
1
Always keep the ink container in the closed and
correctly locked holder while being pressurized.

1. Release the air pressure on the empty ink 2

container by loosen the pick-up unit without
removing it.

2. Unlock and open the container holder.

3
Note: Keep the lid on to avoid ink spill

3. Place the empty ink container on the ground next

to the holder and place the new ink container in
the holder as shown.

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Maintenance

4. Close and lock the holder correctly.

4

Caution: Make sure the pick-up unit stays clean from dirt
during the exchange. For example do not rest it on the ground.
5

5. Remove the container lid and move the pick-up unit

from the old to the new ink container.

6. Tighten the pick-up to regain air pressure.

Note: Make sure the pick-up is correctly threaded, or the system may not be air tight.
No excess force is needed to tighten the system.

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Maintenance

Changing to Flush Kit

1 2 3
When flushing the 4020 with see
through ink system, a separate flush kit is
needed.
4
1. Ink tube
2. Pick-up unit 5
3. Air tube
4. Refillable solvent bottle 2 L
5. Solvent container 1L

1. Pour the solvent into the refillable bottle (2L).

1

2
2. Disconnect the ink system
from the check valve

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Maintenance

3. Disconnect the ink system from the

3
external ink filter.

4. Connect the flush kit ink tube with the 4 5

ink filter.

5. Connect the flush kit air tube with the

air regulator.

Note: The symbol on the check valve indicates the air flow and must be
connected in the right direction.

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Maintenance

Changing Metal Ink Container 4,5L, 5L and 30L

Warning!
When changing containers while
using flammable ink, all electrical
equipment must be at least 1 m
away from the ink container.

1. Release the air pressure by

turning the pressure switch
clockwise.
Note: Wait for 15 seconds in
order to release the air pressure
completely.

2. Place the empty ink container on

the floor.

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Maintenance
3. Place the new ink container next to the empty one.
Remove the sealing cap.

4. Move the pick-up from the empty ink container to the new
one.
Caution: Make sure the pick-up unit stays clean from
dirt during the exchange. For example do not rest it on the
ground.

5. Push the cork into the container with the pick-up rod.

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Maintenance

6. Place the new ink container in the holder.

7. Re-pressurize the system by turning the

pressure switch counter-clockwise.

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Maintenance

■ Replacing Filter
Replacing the Air Filter on Metal Container 4,5L, 5L and 30L

Note: The images are illustrating the principles

and details may differ from your installation.

The air filter should be replaced once a year

and is positioned near the air pump.

1. Release the air pressure by turning the

pressure switch clockwise.
Note: Wait for 15 seconds in order to release
the air pressure completely.

2. Disconnect the air tube from

the filter.

2
3. Remove the old filter.
2 3

4. Position the new filter.

5
5. Reconnect the air tube.
5 4

6. Re-pressurize the system by turning the pressure

switch counter-clockwise.

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Maintenance

Replacing the Ink Filter 4,5L, 5L and 30L

Note: The images are illustrating the principles

and details may differ from your installation.

The ink filter should be replaced once a year and

is positioned under the low ink kit.

1. Release the air pressure by turning the

pressure switch clockwise.
Note: Wait for 15 seconds in order to release
the air pressure completely.

2. Disconnect the ink tubes.

3. Remove the old filter.

2

4. Position the new filter. 2 3

Note: Please note the arrow on the ink
filter indicating the ink direction

5. Reconnect the ink tubes. 5

5 4

6. Re-pressurize the system by turning the

pressure switch counter-clockwise.

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Accessories

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Accessories

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Accessories

■ Extension Arm

By using the extension arm, 4020 can

print from above the conveyor.
(See Distances)

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Accessories

■ Encoder
Printing is synchronized to the conveyor by the
pulse encoder.

The encoder makes 5000 pulses/turn and with a

wheel circumference of 0.2 m it makes 25000
pulses/meter.

See Set Print Speed /Encoder Mode.

Connect to controller

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Accessories

■ Status Beacon

The Status Beacon shows the same

signals as LED lamps.

Connect to controller:

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Accessories

■ IO Box
The IO box provides access to binary input signals and relay outputs. Various
functions in the 4020 controller can be executed upon simple binary inputs.
Relay outputs can be set to signals from the 4020 controller reflecting different
states of the controller. The IO box has 8 digital inputs and 5 relay outputs.

The behavior of the IO box is easily and quickly set up with straightforward
menus. No complicated programming of the IO box is necessary.

The simple yet powerful capabilities of the IO box make the use of a PLC
unnecessary in most cases.

Connect to controller

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Accessories

■ Flush Kit

The flush kit is used for internal cleaning of the 4020 with see trough container ink
system.

See Internal Print Head Cleaning (Flushing)

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Accessories

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 Technical
specifications

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Technical Specifications

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Technical Specifications

■ Specifications

Dimensions (H x W x L) 270 mm x 152 mm x 45 mm

Weight 1,55 kg without ink can

Power supply (2 pcs) 100 - 240 V AC 50 - 60 Hz, 1,9 A

Output 24 V DC, 3 A

100 – 250 V AC 47 – 63 Hz, 3 A

Output 24 V DC, 5 A

Printer technology Electro valve drop-on-demand (DOD) ink-jet

Print height 7 nozzle: 8-28 mm

16 nozzle: 15-64 mm

Printing speed up to 90 m/min (295 ft/min)

Consumables Water based ink (Black, Red, Blue, UV-visible)

Water based solvent
Propanol based solvent
Propanol based ink (Black, Blue, Red)
Ethyl Acetate based ink (Black)
Ethyl Acetate based solvent

Ink pressure at head level In 0,3 bar - max 0,5 bar (pressure drop 0.1bar/m)

Communication ports 4 x head connections (7N and/or 16N)

1 x I/O box
1 x COM port (RJ45) for RS232 communication
1 x COM port (9 pin D-sub) for RS 232 communication
1 x LAN (Ethernet)

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Technical Specifications

Output 1 x status beacon

Input 1 x Ink system (no ink/low ink)

1 x photocell
1 x pulse encoder

Counters 3 internal counters

Display Graphic LCD backlight display 240 x 64 pixels

Memory 4 MB Flash PROM

8 MB DRAM
0,5 MB SDRAM with battery backup

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Troubleshooting

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Troubleshooting

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Troubleshooting

■ Alarm Messages

Status Error Measure

1 Low ink level. Replace ink container!  Indicates that the ink is running
out.

2 Voltage dip detected.  Slow down the printing

Check your power supply! frequency (conveyor speed, tilt
step, compression, dot size).
 Decrease the dot size.
 Too many heads – check if the
right power supply is
connected (3A or 5A).

3 Internal battery low. Immediately  Contact your Service center.

backup your jobs!

4 Ink container empty! Replace ink  Appears when the ink can is
container! empty. Printing will be stopped
until a new container is
inserted.
(See Changing Ink Container).

5 Temperature fault!  Stop printing and check

environment.

6 Conveyor speed too fast!  Slow down speed.

7 Head temperature fault!  Stop printing and check

environment.

8 The head connections have been  Check print head arrangement/

altered! connections.

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Troubleshooting

■ LED Alarm Signals and Status Beacon

LED/Alarm Lamp Combinations

LED Signal Description

System is online. Ready to trigger.

Green

During the printing. System is OK.

Flashing green

System is offline: trigger disabled.

Yellow

Low ink level! Replace ink container!

Flashing yellow

Blue Out of ink! Cannot print. Replace ink

container!
Yellow

Blue New head arrangement has been detected or

there are no heads connected! Printing not
possible!

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Troubleshooting

Status Beacon Signals (Optional)

Status Description
System is online. Ready to trigger.

Green

During the printing. System is OK.

Flashing green

System is offline: trigger disabled.

Yellow

Low ink level! Replace ink container!

Flashing yellow

Out of ink! Cannot print. Replace ink container!

Blue/Yellow

Blue New head arrangement has been detected or

there are no heads connected! Printing not
possible!

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Troubleshooting

■ Troubleshooting Schedule
No Job Is Printed

Check power supply connection to mains.
Check power supply connection to control unit.
Check that the control unit starts up with proper
print head connection/head arrangement (No
alarm messages on the display).

NOT If the print head is not properly
OK connected or connections have been
altered an alarm will be displayed
(See Alarm Messages).

Check print head cable connections.
Check print head arrangement
(See Print Head
Arrangement/Connection).

OK

NOT
Run Test Pattern program (see Start Test Pattern). OK No print when running Test Pattern
program.




OK

Check that the print head nozzle

plate is clean and the print head is
recently flushed. If not, do required
maintenance. (See Cleaning Print
Head Nozzle Plate and Internal Print
Head Cleaning).


Continued on next page

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Troubleshooting


Print Quality is OK when running Test Check that ink system is activated (see Start
Pattern program but still no job is printed. Test Pattern).

Check the recommended pressure (see

Specifications).


Check air supply.

Check photocell and photocell connection.
If ink container is empty but no alarm is
displayed; check low ink connection and low
ink setting (see Low Ink Settings).


Check that you have ink flow to the print

If encoder is used - check encoder and head by disconnecting the ink tube from the
encoder connection. print head. Then press the ink tube valve
into a waste can (see Internal Print
Cleaning).
Inlet connection needs to be properly
inserted.



NOT OK OK

Check if the print job is selected (see Select Re-connect the ink Go through
Job to Print. tube to the print head ink flow for all
and flush. connections
Check that there are item and characters (See Internal Print step by step.
inserted (see Head Specific Print Settings). Cleaning).


Check that your default print settings are

matching your installation (see Default Print
Settings).

Hints: Make sure that encoder and trig

modes are properly set.

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Troubleshooting

Poor Print-Out Quality

Check recommended air pressure (see Specifications).



Check that the print head is not too far from print object.
Recommended print distance is 5-20mm (see Mechanical
Adjustment).


Check that the print head is free from air. Connect a flush tube to
waste can to prime the head.


Clean the print head nozzle plate (see Cleaning Print Head
Nozzle Plate).

Flush the print head (Internal Print Head Cleaning).



Check ink flow. Usual reasons for poor ink flow:

Ink tubes not properly connected
Ink filter clogged
Air filter clogged


Check that you have ink flow to the print head. Inlet connection
needs to be properly inserted.


NOT OK OK

Re-connect the ink tube to the Go through ink flow for all
print head and flush. (See connections step by step.
Internal Print Head Cleaning).

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Troubleshooting

Unreadable Message

Check that object speed matches print speed

setting (see Default Print Settings).


Check that encoder settings match encoder

arrangement (see Default Print Settings).


Check head specific print setting (see Head

Specific Print Settings).

Hints: The angle of the head should be

correctly set according to the resolution (see
Set Resolution).

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 1.
2.
3.
4.

Tutorials

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 1.
Tutorials 2.
3.
4.

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 1.
Tutorials 2.
3.
4.

■ Overview
This section provides you with practical examples about how to best take advantage of 4020.

Characters are available in three different ways:

Keyboard
Local characters
Unicode

Some of the examples in the tutorials are only applicable if you have a 16-nozzle printer head.

Thesaurus for tutorials:

(Text) = Normal text within brackets indicates a variable.
(Text) = Bold text within brackets indicates the explicit characters to type.

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 1.
Tutorials 2.
3.
4.

■ Create Your First Job

This section describes how to create your first job with 4020. The result is a text and a current
date, current time “stamp”.

Note: If you have a 7-nozzle printer, the job has to be printed in one row.

Edit or Add New Job.

New Job.

Type (JOB1) in the

Field.

Select Print Head (If

more than 1 print head).

Select Font (Only

applicable with 16
nozzle printer).

Select Small Font (Only

applicable with 16
nozzle printer).

Type (CURRENT
TIME:)

Select Item to Insert.

Select Time/Date.

Insert Time.

Select Time to Insert

(Example 1).

Type (CURRENT

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 1.
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4.

DATE:)

Select Item to Insert.

Select Time/Date.

Insert Date.

Select Date to Insert

(Example 1).

Press ESC until you are

in the main menu.

Save.

Select Job to Print.

Select JOB1.

Verify the result with a

printout.
CURRENT TIME: 13:30,
CURRENT DATE: 14 MARS 06

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 1.
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3.
4.

■ Create Job with Current Date and Expiration Date

Two separate expiration dates can be inserted in each job. The date shown is calculated from
the current date plus an offset in days, weeks, months or years. The offsets are job specific
and can be set independently of each other. The format of the two expiration dates is however
a global setting and will affect all jobs. This example shows how to create a job with both
production date and expiration date. The product is assumed to last for at least a month.

Note: If you have a 7-nozzle printer, the job has to be printed in one row.

Global Settings.

Time/Date Settings.

Edit Exp Date 1

Format.

Select Year.

Insert Year (4 Digits).

Select Month.

Insert Month (1-12).

Select Day.

Insert Day (1-31).

Save.

Affect all Jobs? –Yes!

ENTER

Press ESC until you are

in the main menu.

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 1.
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3.
4.

Edit or Add New Job.

New Job.

Type (JOB3) in the

Message Field.

Select Print Head (If

more than 1 print
head).

Select Font (Only

applicable with 16
nozzle printer).

Select Small Font

(Only applicable with
16 nozzle printer).

Type (PRODUCT
DATE:)

Select Item to Insert.

Select Time/Date.

Insert Date.

Select Date to Insert

(1).

Type (EXPIRATION
DATE:)

Select Item to Insert.

Select Time/Date.

Select Exp Date 1.

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 1.
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4.

Set Offset to Months

(or Days, Weeks,
Years).

(Example 3 months).

Insert Expiration Date.

Press ESC until you are

in the main menu.

Save.

Press ESC until you are

in the main menu.

Select Job to Print.

Select JOB3.

Verify the result with a

printout.
PRODUCT DATE: 2006-03-14
EXPIRATION DATE: 2006-06-14

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 1.
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2.
3.
4.

■ Insert Advanced Counter Function

Following example shows how to insert advanced counter functionality in a job. It will contain
two separate counters. The first counter starts at the value 1 and will contain two digits and
rollover from 09 to 01. The second counter will count backwards every tenth print. This
functionality represents a batch of 10.

Note: If you have a 7-nozzle printer, the job has to be printed in one row.

Edit or Add New Job.

New Job.

Type (JOB4) in the

Field.

Select Print Head (If

more than 1 print
head).

Select Font (Only

applicable with 16
nozzle printer).

Select Small Font

(Only applicable with
16 nozzle printer).

Type (COUNTER:).

Select Item to Insert.

Select Counter.

Select Counter 1.

Set Rollover Value.

Set value to (9).

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4.

Set Number of Digits.

Type (2).

Insert Counter.

ENTER.

Type (BATCH:).

Select Item to Insert.

Select Counter.

Select Counter 2.

Set Start Value.

Set value to (10).

Set Rollover Value.

Set value to (1).

Set Update Value.

Set value to
(-1).

Set Batch Update.

Set value to (10).

Insert Counter.

Press ESC until you

are in the main menu.

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 1.
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2.
3.
4.

Save.

Select Job to Print.

Select JOB4.

Verify the
result with a
COUNTER: 01 printout.
BATCH: 1

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■ Create Job with Shift Codes

Following example shows how to create and set two different values for a shift code. A shift
code is a text that will change to different values depending on the current time and the settings
for it. There is only one shift code available and the setting is global and affects all jobs. Each
text value also has a time stamp when the shift code will change to that value.

Note: If you have a 7-nozzle printer, the job has to be printed in one row.

Global Settings.

Edit or Add New Shift.

Affect all Jobs?

ENTER

New Shift.

Edit Shift Text.

Type (DAYSHIFT).

Press ESC.

Press ENTER.

Set Shift Start Time.

Set Value to (11 00).

New Shift.

Edit Shift Text.

Type (NIGHTSHIFT).

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Press ESC.

Press ENTER.

Edit Shift Start Time.

Set Value to (23 00).

Edit or Add New Job.

New Job.

Type (JOB4).

Select Print Head (If

more than 1 print
head).

Select Font (Only

applicable with 16
nozzle printer).

Select Small Font

(Only applicable with
16 nozzle printer).

Type (CURRENT
SHIFT).

ENTER.

Select Item to Insert.

Insert Shift.

Press ESC until you

are in the main menu.

Save.

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Select Job to Print.

Select JOB4.

Verify the result with a

printout.

This text is active for

shift between
CURRENT SHIFT
11.00 – 22.59.
DAYSHIFT

CURRENT SHIFT This text is active for

shift between
NIGHTSHIFT 23.00 – 10.59.

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4.

■ Create Job with User Prompts

A user prompt is additional information that the operator must enter before a job can be started.
The entered text will then be printed according to the job setting. Following example shows
how to create and insert user prompts in a job.

Note: If you have a 7-nozzle printer, the job has to be printed in one row.

Global Settings.

Edit User Prompts.

Select User Prompt to

Edit.

Choose user prompt to

edit (Example 1).

Edit User Prompt

Question (WEIGHT:)

Select Content in User

Prompt if you want a
default text to appear
when prompted (1 KG).

Edit or Add New Job.

New Job.

Type (JOB5) in the

Field.

Select Print Head (If

more than 1 print head).

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Select Font (Only

applicable with 16
nozzle printer).

Select Small Font (Only

applicable with 16
nozzle printer).

Type (SPAGHETTI).

Select Item to Insert

Select User Prompt

Choose User Prompt

(Example 1).

Press ESC until you are

in the main menu.

Save.

Select Job to Print.

Choose a job from the

menu:

Select JOB5.
WEIGHT:
1 KG

Verify the result with a

SPAGHETTI 1 KG printout.

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Appendix

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Appendix

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Appendix
■ Menu Structure Overview
This is an overview of the menu structure.
Print
Edit or Add New Job
Default Print Settings
Global Settings
Select Print Head
Font Size (Only applicable for 16 nozzle printer)
Insert Item
Character
Preview
Job Print settings
Copy from another print head
Link to another print head
Save
Save as
Set Specific Print Head
Set Print Speed/Encoder Mode
Set Print Direction
Set Continuous Print
Trig Mode
Time/Date settings
Select Global Counter
Edit or add New Shift
Edit User Prompts
Edit External Variables
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Appendix

Edit and add New Profile

Set Display Language
Font Options
Set Digit Format
Set Keyboard Layout
Set Display Contrast
Control Panel View Software Versions

Port settings

Unit settings
Head Arrangement/Connections settings
Low Ink settings

IO box

Start Test Pattern

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 12/ 2003
05/ 2005
Revision 11/
03/
2006
2007
05/ 2008

Revisions to this manual

Revision index

Date published Revision index documentation

09/2009 C
07/2012 D

Photographs and drawings are not binding in detail. This document was originally written in English. The English text of this document
shall alone be authentic and shall prevail in the event of a dispute. Markem-Imaje reserves the right to modify the specifications of its
products without prior notice. Any reproduction, even partial, of this document is prohibited. Translation of the original manual: the
original manual (in English) is available on the CD-Rom supplied with the printer.
© 2012 Markem-Imaje All Rights Reserved. English version.

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