Index

I. Definition of LED status on U2…………...………………………………………….. 1

II. Flow chart for not printing…..........…………………………………………………. 2

III. Flow chart for missing lines when printing.......…………………………………. 3

IV. PIN Definition of U2 system ……..………........……………………………………. 4

V. How to upgrade the U2 …...................………………………………………………. 4

VI. Editing Logos.........…………………………………….…..…………………………. 5

VII. How to connect U2 printers with an external Encoder & Photocell….……. 5–6

VIII. U2 FAQ……………………………....………………………………………………… 7

IX. U2 Performance…..…………………………………………………………………… 8

X. U2 installation………………………………………………………...………………… 8–9
Page 1
II. Flow chart for not printing

U2 Non-printing

Check the LED

of U2

The "RUN" LED is Connect U2 and

off power supply

Disable the Encoder and

no set the correct conveyor
speed
The "PRINT" LED If you have installed
is flashing the Encoder
yes Enable the Encoder and
set the correct
parameters

no Switch photocell to
internal
The "PRINT" LED
If you have installed
is on
the external photocell
yes
Switch photocell to
external

The "PRINT" LED Press "print on" to turn

is off on the print
Insert a new valid
cartridge

NO CARTRIDGE
Make sure the Smart
Chip contact well with
the ISD module
Press
The "ALARM" Function→4→1→1 Change a new valid
LED is on to diagnose the INVALID CARTRIDGE-1 cartridge
system

Make sure the Smart

INVALID CARTRIDGE-2 Chip contact well with
the ISD module

INVALID CARTRIDGE-3 Change a new valid

cartridge

Change a new valid

INVALID CARTRIDGE-4
cartridge

Change a new valid

INVALID CARTRIDGE-5
cartridge

INVALID CARTRIDGE-6 Upgrading software

INVALID CARTRIDGE-7 Upgrading software

INK EMPTY Change a new cartridge

PHOTOCELL IS ALWAYS Eliminate obstacle in

ON front of photocell

SD CARD INVALID Insert a valid SD Card

If the problem is still

present, please contact the
distributor

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III. Flow chart for missing lines when printing

Missing jetting

The nozzle is
There is air bubble blocked Make sure the
inside the cartridge cartridge contact well
with PEN Drive
Board
If the ink type is
porous

Take the cartridge out of

no yes
the printhead and use the
syringe to draw the air
bubble out

Use dry cloth to clean Use wet cloth to clean the nozzle
the nozzle or put the cartridge nozzle in
warm water for 1minute

The issue is still

present

Change another
cartridge

If the problem is still present,

please contact the distributor

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IV. PIN Definition of U2 system
Photocell: DB9 ~ DB15 Encoder: DB9 ~ DB15
Pin8 ~ Pin6 Pin3 ~ Pin7
Pin1 (DC 12V) ~ Pin1 (DC 12V) Pin1 (DC 12V) ~ Pin1 (DC 12V)
Pin5 (GND) ~ Pin9 (GND) Pin5 (GND) ~ Pin9 (GND)

Alarm Kit: DB15 ~ DB15

Pin8 (DC 5V) ~ Pin8 (DC 5V)
Pin11 (Red) ~ Pin11 (Red)
Pin12 (Orange) ~ Pin12 (Orange)
Pin13 (Green) ~ Pin13 (Green)
Pin14 (Beeper) ~ Pin14 (Beeper)

For Alarm Kit connected with U2, please see below diagram for reference:

Photocell
U2
P/C

E/N DB15
U2 Alarm Kit cable
Encoder Alarm Kit

V. How to upgrade the U2

V-1: Program version upgrading

a. SD Card Synchronization
1. Install Message Pro (U2 MessagePRO_x.x.xxx.xxxx.exe) on PC.
2. Run the Message Pro software and insert the SD Card Reader with an SD Card into the USB Port of the PC.
3. The system will synchronize the corresponding files into the SD Card.

b. Upgrading Procedure
4. It is important that you remove the ink cartridge from the printer before upgrading your printer.
5. Ensure that the power is off to the U2 printer and then insert the SD card.
●Printers that are version 1.98 or higher can skip to step 9.
●If your printer has a version of software lower than 1.98 you will need to complete the following steps.
6. Power on the U2 while holding the "Remote On/Off" button down for 3-5 seconds.
7. The Boot Loader screen will appear, choose "1”... SWUpgrade
8. On the next menu choose "3”... APP Program" and then select the “Robo” file to upgrade.
Once this process completes, unplug the U2 printer to power the unit off.
9. Power back on the U2 printer and follow the prompts to complete the upgrade.

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VI. Editing Logos
When you import a Logo, please be aware of the Logo height restriction due to different Line Modes.
One Line: The height of the logo ≤ 75 pixels
Two Lines: The height of the logo ≤ 37 pixels
Three Lines: The height of the logo ≤ 25 pixels
Four Lines: The height of the logo ≤ 18 pixels

Under 300 DPI condition, Logos can be printed with original size.
If you do not use Encoder, please go to "Function > Printing Setup > PringHead >Resolution" and choose 300 DPI;
If the resolution is not 300 DPI, first you may calculate a value like “x=Current DPI / 300”, then use Windows Paint
software to open the Logo, choose "Image > Stretch/Skew…" and input the value of ‘x’ to “Horizontal” column.

Please see below example for reference:

If you want to print a balck square with 400 DPI, please set up the Logo parameters as follows:

VII. How to connect U2 printers with an external Encoder & Photocell

VII-1. Single U2 printer with Encoder

U2

U2 Encoder / Photocell
signal cable
If you want to apply one Encoder signal for a single U2 printer,
you'll need:
Encoder a. 1 pc U2 Encoder / Photocell signal cable (P/N: 7004002059)

VII-2. Single U2 printer with external Photocell

U2

U2 Encoder / Photocell
signal cable
If you want to apply an external Photocell signal for a single U2
printer, you'll need:
Photocell a. 1 pc U2 Encoder / Photocell signal cable (P/N: 7004002059)

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VII-3. Single U2 printer with external Photocell and Encoder

U2

U2 Encoder / Photocell
signal cable
If you want to apply one Encoder & external Photocell
signal for single U2 printer, you'll need:
Encoder Photocell a. 1 pc U2 Encoder / Photocell signal cable (P/N: 7004002059)
b. 1 pc Y cable (P/N:TEN-023)

VII-4. Multiple U2 printers with single Encoder or single Photocell

U2 U2 U2

U2 Encoder / Photocell
signal cable
Y cable

Encoder or
Photocell
Encoder/Photocell
Extension Cable
If you want to apply one Encoder signal for “N” pcs U2 printers, you'll need:
a. N pcs U2 Encoder / Photocell signal cables (P/N: 7004002059)
b. N-1 pcs Y cables (P/N:TEN-023)
c. N-1 pcs Encoder/Photocell Extension Cable (TEN-053)

VII-5. Multiple U2 printers with external Photocell and Encoder

U2 U2 U2

U2 Encoder / Photocell
signal cable
Y cable

Photocell Encoder

Photocell extended cable

If you want to apply an external Photocell and Encoder for “N” pcs U2 printers, you'll need:
a. N pcs U2 Encoder / Photocell signal cables (P/N: 7004002059)
b. N pcs Y cables (P/N:TEN-023)
c. N-1 pcs Encoder/Photocell Extension Cable (TEN-053)

Page 6
VIII. U2 FAQ

The first step for perfect printing is to make sure that the substrate is always in the
same position relative to the printer. The best way to guarantee proper position is to
set a guide bar on the conveyor.

The following examples are possible printing problems due to improper settings.

1. Incorrect conveyor speed setting

The conveyor speed must be stable in order to produce a perfect print. Otherwise, an
encoder may need to be installed.

a. Conveyor Speed setting is too fast

b. Conveyor Speed setting is too slow

Solution: Press ”FUNCTION → 5 → 4 " to set the correct speed.

2. Incorrect Encoder DPI setting

If the DPI setting is different than the actual DPI, there will be offset printing even if
an encoder has been installed.

Solution: Press ”FUNCTION → 5 → 4" to set up correct “Pulse/Cycle” and “Diameter” based
on the Encoder.

3. Incorrect printing direction

You'll get below printing image in case you've set incorrect printing direction:

Solution: Press ”FUNCTION → 5 → 1“ to choose correct printing direction (→ ABC, ABC ←, etc.).

4. Build up on the nozzle

Solution: a) Use lint-free soft cloth to clean the cartridge nozzle

b) Change to a new cartridge
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IX. U2 Performance
IX-1. Relationship between DPI & Speed, and DPI & wheel diameter

Relation between resolution and conveyor speed For U2

WHEEL DIAMETER (PULSE/CYCLE:2500) CONVEYOR SPEED
NUMBER RESOLUTION
MM Inch Meters/Minute Feet/Minute
1 600 DPI 33.69 1.33 1-38.1 m/Min 3.3-125.0 Feet/Min
2 550 DPI 36.75 1.45 1-41.6 m/Min 3.3-136.5 Feet/Min
3 500 DPI 40.43 1.59 1-45.7 m/Min 3.3-149.9 Feet/Min
4 450 DPI 44.92 1.77 1-50.8 m/Min 3.3-166.7 Feet/Min
5 400 DPI 50.53 1.99 1-57.1 m/Min 3.3-187.3 Feet/Min
6 350 DPI 57.75 2.27 1-65.3 m/Min 3.3-214.2 Feet/Min
7 300 DPI 67.38 2.65 1-76.2 m/Min 3.3-250.0 Feet/Min
8 250 DPI 80.85 3.18 1-91.4 m/Min 3.3-299.9 Feet/Min
9 200 DPI 101.06 3.98 1-114.3 m/Min 3.3-375.0 Feet/Min
10 150 DPI 134.75 5.31 1-152.4 m/Min 3.3-500.0 Feet/Min
11 100 DPI 202.13 7.96 1-228.6 m/Min 3.3-750.0 Feet/Min
12 50 DPI 404.25 15.92 1-457.2 m/Min 3.3-1500.0 Feet/Min

IX-2. Printing length of U2

Horizontal: 30,000 dots
Vertical: 150 dots

For example: With 300 DPI, the Maximum length of the printed message (L):

L=30000 dots / (300 dots / inch)

=30000 / 300 * 25.4 / 1000 m
=2.54 m

No matter which DPI users choose the ink consumption is the same, and only the printed
length is different. See below example for your reference:

For 300 DPI: Printed length: A mm

Ink consumption: B Dots

For 600 DPI: Printed length: A/2 mm

Ink consumption: B Dots

From your view, 600 DPI will show you darker printed image!

X. U2 Installation
X-1. U2 Controller
Proposal:

a). It's not recommended to have a U2 Controller share a power supply with other
industrial equipment in order to avoid power noise. (*An online UPS system is highly
suggested.)

b). The U2 Controller needs to be grounded properly in order to avoid static electricity.

X-2. U2 Bracket
Proposal:

a). It's highly recommended that U2 brackets are separate from the conveyor in order to
avoid vibration, which may lead to ink or print quality problems. A printer stand is highly
recommended.

b). It's also essential to have a guide bar to ensure the distance between the nozzle and
printing
surface is less than 3 mm.

c). The shorter the distance between bracket holders, the more firm the installation.

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X-3. U2 Encoder (Optional)
Proposal:

a). Preferably install the Encoder directly under the U2 Print head

b). Wheel surface must be vertical with the Conveyor belt

c). Encoder tension direction should be positive

If the conveyor belt is not flat enough to install an Encoder directly, there are two options:

1). If the substrate is long and heavy enough, the Encoder can be positioned such that the wheel
contacts the substrate as it passes.

2). In case the substrate is too small and too light, an auxiliary wheel can be fabricated to mimic the
speed of the conveyor accurately.

For any conveyor belt, there must be a main wheel and secondary wheel. Make a flat wheel whose
diameter is equal to: [diameter of the main wheel + 2 * thickness of the belt].
Then, embed an axletree into the right center of the main wheel and the fabricated wheel. This is
the proper way to ensure the speed read by the Encoder is the same as the actual speed of the
conveyor.

X-4. U2 external Photocell (Optional)

Adjusting screw

If you want to adjust the detecting distance, rotate the adjusting screw as shown in Figure above.

(If you want to lengthen detecting distance, please rotate the screw to be "max" direction as it shows
you; if you want to shorten it, please rotate the screw to "min" direction as it shown.)

The range is from 0 to 10 cm.

It's highly recommended to adjust the printing position via Photocell location instead of adjusting the
print delay.

X-5. For U2 BIS (Option)

The BIS holder can be installed anywhere as long as the ink level (vertical distance between
cartridge nozzle and BIS nozzle) is kept at 45 mm. This is important whether using Side
printing or Downside printing. The tubing that connects the PEN Cartridge and bulk ink bladder
should not to be forced by pressure or strength. Forcing the tubing may cause the bottom of
the Cartridge to not make secure contact with the Pins in the PEN Stall. Poor contact may
damage the ISD or PEN Driver Board.

It's highly recommended to connect the 370 ml Bulk Ink Bladder and PEN Cartridge after
several prints to avoid air accessing the system.

Page 9