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Summary of Contents for Hitachi PB
- Page 1 Service Manual HITACHI Printer Model PB Revision Jul.2011 Version B...
- Page 2 Safety Precautions ●Before using the printer, thoroughly read the following safety precautions for optimum printer use. ●You should observe the precautions set forth below in order to use the product properly and avoid endangering or causing damage to you or other persons. For the purpose of clarifying the severity of injury or damage and likelihood of occurrence, the precautions are classified into two categories, WARNING and CAUTION, which both describe the hazardous situations that may arise if you ignore the precautions and perform an incorrect handling or operating procedure.
- Page 3 Safety Precautions (Continued) WARNING ●Ensure that there is no flame- or arc-generating device within 5 m of the printer. The ink and makeup ink are both flammable and may cause fire. Fire can be generated by matches, lighters, cigarettes, heaters, stoves, gas burners, welders, grinders and static electricity.
- Page 4 ●Only use Hitachi-approved consumables and periodic replacement parts. Using products that are not designated by Hitachi may lead to malfunction or failure. Such malfunction or failure will not be covered by the warranty. ...
- Page 5 Safety Precautions (Continued) WARNING ●When charging a refill of ink or makeup ink, exchanging ink, or otherwise handling ink or makeup ink, take enough care not to spill ink or makeup ink. If you spill any ink or makeup ink by mistake, wipe it off neatly and promptly with wiping paper or something similar.
- Page 6 Caution ●Only persons who have completed an operator training course for Hitachi IJP can operate and service the printer. If the printer is operated or serviced incorrectly, it may malfunction or break down. ●Do not attempt to make repairs for any purpose other than operation or maintenance.
- Page 7 Safety Precautions (Continued) Caution ●Ensure that all electrical wiring, connections and grounding comply with applicable codes. Properly connect the printer to its dedicated ground. Complete the above procedure to avoid electrical shock hazards. ●Ink and makeup ink must be stored as flammable liquids. Storage must comply with local regulatory requirements.
- Page 8 Contents 1. Introduction ······························································································1-1 1.1 Safety precautions ················································································1-1 1.2 Structure of each part in the main body ··················································1-2 1.2.1 External views ···············································································1-2 1.2.2 Main body internal ·········································································1-3 1.2.3 Print head ·····················································································1-4 1.3 Installation ·························································································1-5 1.3.1 Wiring of power supply ····································································1-5 1.3.2 Installation procedure ·····································································1-7 2.
- Page 9 3.3 Engine part ··························································································3-8 3.3.1 EZJ93 board (MPU board)·································································3-8 3.3.2 EZJ94 board / EZJ106 board (NH board) ·············································3-10 3.3.3 EZJ103 board (I/O board) ··································································3-12 3.3.4 Circuit diagram of EZJ102/103 ··························································3-13 3.3.5 Multiple Power Supply ··································································3-14 3.3.6 High voltage power supply ·······························································3-14 3.3.7 Fan Replacement Procedure ·····························································3-15 4.
- Page 10 6. Troubleshooting ·························································································6-1 6.1 Troubleshooting List ··············································································6-1 6.2 Faults invoke ink stoppage ·····································································6-3 6.3 Faults that do not invoke ink stoppage ·····················································6-22 6.4 Warning (printing continuously performed) ···············································6-30 6.5 Faults that invoke no on-screen indications···············································6-38 6.6 Miscellaneous ·······················································································6-46 6.6.1Problems due to inappropriate ink beam position in charged electrode····6-46 6.6.2 Problems due to inappropriate ink beam position to gutter···················6-47 7.
- Page 11 1. Introduction 1.1 Safety precautions Before starting the maintenance and inspection work of this printer, thoroughly read and understand the “safety precautions”. When explaining the product to customers at the time of the installation, fully explain the “safety precautions”. ...
- Page 12 1.2 Structure of each part in the main body １.２.１ External views ...
- Page 13 １.２.２ Main body internal...
- Page 14 1.2.3 Print head...
- Page 15 1.3 Installation １.３.１ Wiring for power supply ！ caution Be sure to use an appropriate plug and connect a protective ground. Install AC outlet near the unit so that it can be easily accessed and removed. Use a power cable with an outside diameter within a designated range. Securely tighten the nut that holds the service entrance.
- Page 16 (3) Pull in the power cable from the service entrance, and connect the ground wire to terminal as shown in the figure below. (4) Connect wires (L) and (N) to the terminal block (M4) as shown in the figure. (5) Use a nylon clamp to secure the cable as shown in the figure. (See *1) (6) Securely tighten the clamp nut (M16) at the service entrance using proper tool.
- Page 17 １.３.２ Installation procedure Perform an installation work of the unit according to the following procedure at the unpacking. Step Work Related page Selection of ink used 2.2 System environment (touch panel operation) setup Instruction manual Makeup ink replenishment 6.4 Makeup ink replenishment Beam alignment Instruction manual...
- Page 18 ２. Maintenance work A screen for use in the maintenance work by a service personnel is described. 2.1 Setting of maintenance mode by service personnel For the maintenance work by a service personnel, restrictions on use of the following functions are removed.
- Page 19 Status：ＸＸＸＸＸ Password protection After you have entered a correct password, you are permitted to change the password protection settings below. Password [＊＊＊＊ ] Edit message/Select message [０] （0:access 1:protect） Save message [０] （0:access 1:protect） Decre- ...
- Page 20 Note: When the ink type is set, an initial value is automatically set. With respect to the initial value, refer to the next page. The standard nozzle orifice of PB machine is stainless. If using a ruby nozzle orifice in emergency, be sure to choose ruby using this menu.
- Page 21 Conditions set by the ink type*1 Operating Operating Excitation temperature temperature Nozzle Excitation Ink type frequency upper limit lower limit size curve (kHz) (℃) (℃) JP-K67 68.9 JP-K69 68.9 JP-K26 68.9 JP-K27 68.9 JP-R27 68.9 JP-G27 68.9 JP-B27 68.9 JP-K28 68.9...
- Page 22 2.3 Adjustment/operational checkout 2.3.1 Excitation adjustment ●Adjust the drive conditions of nozzles. ●This adjustment is performed in a state other than the IJ printer “ready” state. ●Be sure to perform this adjustment in the case of replacing the board (EZJ93, 94/106, 102), the nozzle (including the print head) or changing the ink type.
- Page 23 ２ Press Excitation adjustment. When the screen is switched, press Automatic adjustment. The excitation voltage is automatically adjusted inside the IJ printer. During the automatic adjustment, the processing state is displayed to be “In progress”. (At the adjustment, when the excitation voltage is gradually increased up to 360±20 V , the adjustment is completed.) ...
- Page 24 2.3.2 Charging voltage confirmation ●This confirmation is performed in a state the IJ printer “stop” state. ● Attach the nozzle head cover for check. ●Before this confirmation, set “the speed follow-up” on the “user environment ...
- Page 25 2.3.3 Phase margin test ●Perform the phase margin test of a nozzle. ●This test is performed for checking that ① whether or not the nozzle is in a printable state (whether or not clogging is present) and ②...
- Page 26 Phase margin test Status：ＸＸＸＸＸ Print timing [１] (1:Button input 2:Sensor) Print data [１] (1:For test 2:Data to be displayed) Abort Print phase １ (0-f phase) Start printing Printing starts at the press of [Start printing]. ・When the “Sensor” is selected, the printing phase is sequentially printed from 0 phase to 15(f) phase every time the sensor is input.
- Page 27 2.3.4 Auto phase gain adjustment ●The gain of the auto phase detection voltage is automatically adjusted. ●Perform this adjustment after confirmation that the periphery of a gutter part within the nozzle head is not made dirty with ink or the like and the printing head cover is correctly fixed.
- Page 28 Auto-phase gain adjustment Status：ＸＸＸＸＸ Auto-phase gain value [４０]（２〜６２） ← → Proc. status: Acquisition. Decre- ment Incre- １ ２ ３ ４ ５ ６ ７ ８ ９ ０ ment The gain of the auto phase detection voltage is automatically adjusted within the IJ printer. During the automatic adjustment, a processing state is displayed to be “Acquisition”.
- Page 29 2.3.5 Level sensor confirmation ●The operation confirmation of level sensor in the main ink vessel is performed. ①Level over ②Initial level The operation confirmation of level sensor in the ink vessel is performed. ● ①Insufficient ink The operation confirmation of level sensor in the makeup ink vessel is performed.
- Page 30 2.3.6 Heating unit confirmation ●The operation confirmation of heating unit is performed. ①Heating unit power ON/OFF. A display of an ambient temperature and a heating unit temperature is performed. ● Perform this operation confirmation in a state other than "ready" state. ●...
- Page 31 2.4 Test of solenoid valve/pump ●The operation confirmation of solenoid valve and pump is performed. ①Supply valve （ＭＶ１） ②Replenishment valve （ＭＶ２） Recovery valve （ＭＶ３） ③ Agitation valve （ＭＶ４） ④ Circulation valve （ＭＶ５） ⑤ Pressure relief valve （ＭＶ６） ⑥ Makeup ink valve （ＭＶ７）...
- Page 32 2.5 Download ● Use this function when upgrading programs. ● Perform this function in the service personnel maintenance mode. ● Use the memory card to download programs on EZJ93 and EZJ102 boards. ● Be sure to perform downloading when replacing the EZJ93 and EZJ102 boards. ●If the customer uses the password to engage password protection for maintenance work, release the protection once, and after completing the maintenance work, reset...
- Page 33 ３ Turn power on. A version of the controller part and the engine part is displayed. When the version of the engine part is older than that of the controller part, be sure to perform the download. ...
- Page 34 ６ Press Execute . “Wait for a minute” is displayed. After the completion of the download, the screen returns to the print description screen. Download Wait for a minute. ７ After copying is finished, turn power off and press the ejector (button) to remove the memory card from the slot.
- Page 35 2.6 Calibration of viscometer 2.6.1 Calibrating viscometer ● The calibration of viscometer is to determine the “coefficient” inherent in the equipment. ● Calibrate the viscometer when installing equipment. Normally, calibrating it once is enough. However, calibrate the viscometer again when changing the type of ink, and also calibrate a new viscometer after replacement.
- Page 36 ４ After completion of the measurement, a coefficient (calculated value) is displayed. When updating (calibrating) this coefficient, press Execute. The calibration is completed. Note: It is recommended that you always record the coefficient value or back it up. The coefficient will be stored in the memory of EZJ102 board.
- Page 37 2.6.2 Operation test of viscometer This function allows you to check the viscometer operation and measure the ● current ink viscosity. Note that this operation test is not to determine the coefficient. It is not necessary to use new ink for operation test. ●...
- Page 38 2.7 System reset ●Set the set values on the “Printing data,” “User pattern” and “Maintenance” screens to the values of initial condition. ●Perform this function when the EZJ102 board or the EZJ93 board is replaced in a state allowing no backup. ●If this function is performed, perform setup and/or adjustment according to the contents described in “3.2.1 EZJ102 board”...
- Page 39 2.8 Data copy ●Perform this function in the service personnel maintenance mode. ●Copy the print data, user patterns and the data unique to machine, to memory card. ●Backup data can be copied on a IJ printer. ●Backup on a Memory card Data to be copied Mode...
- Page 40 ２ Insert the memory card (CF card) into the slot. Inside of operation panel viewed from Cover CF card Slot EZJ102 board Operation ３ Turn power on. Caution for electric shock It is necessary to supply power with the operation panel open for this work. ...
- Page 41 Data copy Status：ＸＸＸＸＸ Copy direction Data type User data ＩＪＰ → User pattern Unit-specific data Memory card User pattern Memory card → Cancel Print data ＩＪＰ Folder to be copied ［ＰＢ９９９９９］ ↑ ↓ Serial number ＰＢ９９９９９９９９ Start Copy ...
- Page 42 2.9 Unit information ● Indicate the unit Type-Form, Ink type, Ink viscosity coefficient. ● Ink viscosity coefficient can be set in this screen without “Calibration of viscometer”. １ Turn on the power. ...
- Page 43 2.10 Handling Warning for “Product speed matching error” ●This function switches “Product speed matching error” between enable and disable. Enable: Indicated warning in case of the speed for encorder signal period was exceeded. Disable: Not indicated Warning.
- Page 44 2.11 Language Change ●Use this function to change the language used for screen display. ●Copy the display language from the memory card to IJ printer. ●If customer is using password to restrict the functions for maintenance work, release the restriction on functions and, after setting this function is finished, reset the restriction on function.
- Page 45 ４ Use Password protection to set the printer to the service personnel maintenance mode. Maintenance menu Shut Status：ＸＸＸＸＸ Manual down Solenoid valve/ System Adjustment/ Next environment setup operational checkout pump test menu Download Unit information Language change System reset Back ５ Press Language Change on the second page of service maintenance screen.
- Page 46 2.12 Faults/Warning Log ●This function displayed code number in Fault/Warning Log screen. Fault/Warning Log Code Table Code （Fault）Message name Code No. （Warning）Message name Code No. Message name Ink Low Excitation Setting Review Replenishment Time-out ００１...
- Page 47 3. Maintenance of controlling part 3.1 Construction of controlling part The controlling part is mainly composed of a controller part of performing the display and the data management, and an engine part of performing the printing control and the circulation system control. ...
- Page 48 [Controller part ( back of operation panel )] Touch panel （back of steel） (operation side) EZJ102 board CF card EZJ97 Battery SW１ LCD back light connector board power supply When the parts replaced, remove the harness from the clamp (3 locations) as shown below in case put the operator panel in floor ③...
- Page 49 3.2 Controller part T his section shows the functional overview of electric parts/control board in the ● controller block, switch settings, a list of check points/LEDs, and cautions on replacement. 3.2.1 EZJ102 board (controller board) 【Function】 ●Creates print data and manages it. ...
- Page 50 【Notes when replacing board】 ●Be sure to turn power off before replacing the board. ●After replacing the board, set the contrast of LCD to “5”, and then use the LCD contrast adjustment VR to adjust the contrast. ●After replacing the board, reset the date and time. ●Before replacing the board, use the procedure below to save the data to Memory card.
- Page 51 Connector for Setscrews Setscrews LCD contrast Setscrews touch panel (5 locations) (5 locations) adjustment VR (5 locations) Connector for LCD harness CF card connector Connector for EZJ97 board ...
- Page 52 3.2.2 Battery 【Function】 ● Battery to back up RTC on EZJ102 board 【Note at the replacement】 ●When replacing batteries, be sure to cut off the power supply. ●Be sure to insert it into CN2. ●After replacing batteries, set the date and time. With respect to the ...
- Page 53 3.2.3 Control panel 【Function】 ●LCD, converter, touch panel and EZJ97 board (LED board) are included in the control panel. With respect to the 【Note at the replacement】 setting the touch panel coordinates, refer to the ●At the replacement, be sure to cut off the power supply. instruction manual “5.4 ●Incorporate the EZJ102 board and the battery as shown in the following correcting the touch...
- Page 54 3.3 Engine part ●With regard to the electric parts/control board of the engine part, the functional outline, the setting of the switch, the list of the check point/LED and the note at the replacement are described. 3.3.1 EZJ93 board (MPU board) 【Function】 ...
- Page 55 In the case where the EZJ93 board is replaced in a state allowing no backup, ● perform setup and/or adjustment according to the following table. Item Reference manual No. 1 System reset "2.7 System reset" 2 Download "2.5 Download" System environment setup “2.2 System environment setup” ...
- Page 56 3.3.2 EZJ94 board / EZJ106 board (NH board) 3.3.2.1 EZJ94 board 【Function】 ●Control of nozzle (charging voltage control, excitation voltage, APH detection, PTC control and the like) is performed. 【Setting of switch/check point/LED display and the like】 ●Setting of switch ...
- Page 57 3.3.2.2 EZJ106 board 【Function】 ●Control of nozzle (charging voltage control, excitation voltage, APH detection, PTC control and the like) is performed. ●EZJ106 board can be used as the replacement of EZJ94 board. 【Setting of switch/check point/LED display and the like】 ●Setting of switch ...
- Page 58 3.3.3 EZJ103 board (I/O board) 【Function】 With respect to the ●The I/F signals with conveyer are connected. wiring, refer to Instruction manual “1.5 Output signals : Ready, Fault, Warning Connection of signals”. Input signals : Print target sensor, encoder (for product speed matching) ...
- Page 59 3.3.4 Circuit diagram of EZJ102/103 ...
- Page 60 3.3.5 Multiple Power Supply DC output 【Function】 (connect to ●AC input：ＡＣ１００〜２４０Ｖ EZJ93 CN9) （５０／６０Ｈｚ） DC output：＋５Ｖ ＋１２Ｖ ＋２４Ｖ 【Note at the replacement】 ●Be sure to turn power off before the EZJ93 board. *) If the power switch is turned off, AC power will still be supplied to terminal board.
- Page 61 3.3.7 Fan Replacement Procedure １ Turn off the power supply. ２ Remove the operation panel, and then hang it on the unit. Operation panel Caution: Be careful that the wire harness does not get caught on anything. Do not hang the panel with the maintenance cover open for a long time (less than 10 minutes allowed): Leaving it hanging more than 10 minutes could...
- Page 62 Rear cover Water-proof cover ５ Remove the four screws holding the fan, and then remove the fan. Rear cover Connector ...
- Page 63 4. Maintenance of Circulation System 4.1 General Structure of Circulation System 4.1.1 The general structure of the circulation system is shown in the following figure. Using an open/close type door (unit door) as a partition, the system is roughly divided into an ink circulating area (the front side of the equipment) and a driving part area (the rear side of the equipment).
- Page 64 4.1.2 Approach to the parts on the front side of the equipment １ Move the ink tank and the makeup ink tank to a safe place after removing the connection tube block. Connection tube block Ink reservoir Connection tube block Makeup ink reservoir ２...
- Page 65 4.1.3 Approach to the parts on the rear side of the equipment １ Perform the operations of 1 to 3 in “4.1.2 Approach to the parts on the front side of the equipment”. ２ Remove the fixing screws (2 pieces) of the unit door and open the unit door.
- Page 66 4.2 Main Ink Tank Replacement Procedure １ Drain the ink in the main ink tank. (Execute “Ink Drainage” or drain ink from the drain tube.) ２ Turn off the power supply. ３ Perform “4.1.2 Approach to the parts on the front side of the equipment”. ４...
- Page 67 4.3 Pressure Relief Valve Replacement Procedure １ Perform “Pressure relief”. ２ Perform “4.1.2 Approach to the parts on the front side of the equipment”. ３ Remove the mounting screws (2 positions) of the pressure relief valve. The pressure relief valve can be removed. "Caution"...
- Page 68 4.4 Joint Structure and Handling 4.4.1 “ICU joint” structure and handling When removing the tube during the maintenance work, loosen the tube lock beforehand. The ICU joint should be removed only at occurrence of damage. ICU joint Tube lock Procedure for installing the tube １...
- Page 69 4.4.2 “Filter joint” structure and handling Usually, for disconnecting the tube, loosen the filter joint nut and remove the whole without disassembling the filter. Disassembling should be performed only at occurrence of damage. Disassembling the filter joint １ Loosen the filter joint nut and remove the whole from the mounting part. ２...
- Page 70 4.5 Pump Unit Replacement Procedure １ Perform “Ink drainage” to “Pressure relief”. ２ Turn off the power supply. ３ Perform “4.1.3 Approach to the parts on the rear side of the equipment”. ４ Remove the wires from the clamps (5 positions) that fix them. ５...
- Page 71 ７ Remove the fixing screws (8 positions) at the upper and lower connecting parts of the circulation unit. The pump unit can be removed. "Caution 1" : When removing the screws with a screwdriver, hold the lower side of the unit door so that the unit door and hinge may not be deformed.
- Page 72 4.6 Solenoid Valves Replacement Procedure Caution : The MV8(cleaning valve) is not compatibility with other than solenoid valve. It recognizes as shown below. MV8 (Cleaning valve） Other than solenoid valve Orange TYPE-FORM White TYPE-FORM (serial No.) (serial No.) １ Perform the following pre-replacement operation for each solenoid valve that you are to replace.
- Page 73 ５ Remove the fixing screws (2 positions) of the solenoid valve. "Caution" Put wiping paper under the solenoid valve to provide for an ink drip. Fixing screw ６ Clean the portion stained with ink and then install a solenoid valve by reversing the above procedure.
- Page 74 4.7 Pressure Gauge Replacement Procedure １ Turn off the power supply. ２ Perform “4.1.2 Approach to the parts on the front side of the equipment”. and “4.1.3 Approach to the parts on the rear side of the equipment”, and pull out the unit door. (The reason is that the connector is provided on the rear side of the equipment.) ３...
- Page 75 4.8 Circulation Unit Replacement Procedure １ Perform “Ink drainage” and then “Pressure relief”. ２ Turn off the power supply. ３ Perform “4.1.3 Approach to the parts on the rear side of the equipment”. ４ Remove the wire connecting part screws (3 positions) of the liquid level sensor in the main ink tank and the exhaust tube.
- Page 76 ６ Remove the clamps (5 positions) that fix the wires. １０ ６ ９ ７ ８ ７ Remove the connectors of the electric parts (motor, solenoid valves, pressure sensor, and viscometer) ８ Remove the fixing screws at 4 positions that fix the circulation unit. The circulation unit can be removed Fixing screw Fixing screw...
- Page 77 4.9 Viscometer Replacement Procedure 4.9.1 In the case where an abnormality arises to the viscometer, the following action is necessary. Note: In the case where the viscometer is abnormal, it operates by a dot count method. ①Viscometer variation abnormality : Foreign substance mixing Cause Treatment : (a) To replace the viscometer filter.
- Page 78 ⑤Unscrew two setscrews of the viscometer. "Caution" The O-ring and squeezing pin may remain in the circulation unit. Remove them as well. ⑥Attach a new viscometer, and assemble the lead wire and the tube to their original positions. "Caution" Insert and then mount the O-ring and squeezing pin on the viscometer OUT side as shown below.
- Page 79 ④Unscrew two setscrews of the viscometer. ⑤Draw the bottom part of the viscometer, unscrew the setscrews of the proximity sensor cover and take out the proximity sensor. ⑥Put a new proximity sensor into the viscometer. “Caution” Dispose the proximity sensor so that the type display surface is on the bottom.
- Page 80 ⑥Place the cylinder, the plunger, the viscometer cover, the viscometer IN joint, the viscometer case and each O-ring into a beaker or the like filled with the makeup ink and wash them using an ultrasonic washing machine. “Caution” Do not dip the coil, the thermistor and the proximity sensor in the makeup ink.
- Page 81 4.10 Print Head Replacement Procedure １ Turn off the power supply. Operation panel ２ Remove the operation panel, and then hang it on the unit. Caution: Be careful that the wire harness does not get caught on anything. Do not hang the panel with the maintenance cover open for a long time (less than 10 minutes allowed): Leaving it hanging more than 10 minutes could...
- Page 82 ５ Remove the removed tube from the fixing clamp. ６ Perform “4.1.3 Approach to the parts on the rear side of the equipment” and open the unit door. ７ Remove the wires removed in 3 from the fixing clamps. ８ Pull out the tube removed in 4 from the rear side of the equipment. ９...
- Page 83 4.11 Troubleshooting Procedure for the Circulation System Perform “① Fault locating and repairing method” for each trouble symptom. For the items marked * in “Probable Cause”, perform “② Locating method for the control system/circulation system” to make sure that the control system is normal, and then perform the repair work.
- Page 84 symptom Probable cause Repairing method Check method The makeup ink in the pipe N is sucked even The pressure during operation resistance of (except at supply). Replace the solenoid MV7 is (Make a check valve (MV7). faulty. after removing the tube connection block of the makeup ink tank.)
- Page 85 symptom Probable cause Repairing method Check method The circulation pump The same as “Ink does not jet". malfunctions. When “Release” is Replace or repair the executed on the solenoid valve (MV3). The solenoid Solenoid Refer to “4.12 ※MV4 valve Valve/Pump Test Repairing method malfunctions.
- Page 86 ②Fault locating method for the control system/circulation system (a) When the pump motor and all the solenoid valves are not operated, the multi- power supply (24 V system) is abnormal. (b) If the electric parts (pump motor and solenoid valve) are not operated in any case other than the above, make the following checks first.
- Page 87 4.12 Repairing Method When the Circulation Route Is Dry or Sticks 4.12.1 Cleaning method for the solenoid valve １ Remove the sticking solenoid valve. (Refer to “4.6 Solenoid Valves Replacement Procedure) ２ Connect the connector of the target solenoid valve. ３...
- Page 88 4.12.3 Repairing method for the makeup ink pump １ Remove the tube connecting block of the makeup ink reservoir and connect the cleaning bottle. (You can apply pressure more easily by putting a tube between the pipe and the cleaning bottle.) Cleaning bottle Pipe...
- Page 89 Print head-related maintenance 5.1 Outline structure of print head and how to remove each cover (1) Outline structure of print head The outline structure of the print head is shown in the following figure. Two kinds of ① bases (head base and gutter base) are joined to the head cable by screws. The sealing valve, the heating unit and the deflecting base are disposed on the head base.
- Page 90 5.2 Nozzles Replacement Procedure (appendix: nozzle drive conditions) (1) Depressurize the printer. (2) Unscrew the video signal wire setscrews and the charged electrode setscrews, and remove the charged electrode. (3) Remove the nozzle setscrew (2 locations), the nozzle IN joint presser foot (sealing valve side) and the excitation connector.
- Page 91 Attach a new nozzle and fix the nozzle setscrew, (2 locations), the nozzle IN joint presser foot (sealing valve side), the nozzle OUT joint and the excitation connector. “Caution” Confirm that a filter is present in the terminal area (inside the sealing valve) of ①...
- Page 92 Appendix: nozzle drive conditions This table shows the nozzle drive conditions for each ink of the PX type IJP together. When performing the reset or the like of the kinds of ink, be careful because the excitation frequency and the standard pressure vary depending on the ink. 65 mm nozzle (1) Standard pressure...
- Page 93 5.3 Deflecting base Replacement Procedure When the LED protection glass is damaged or when the deflection base is extremely dirty and cannot be rid of the abnormality even after cleaning, it is necessary to replace the deflection base. Perform it by using the following procedure. Depressurize the printer.
- Page 94 Perform the assembly in inverse procedure. Caution ①When mounting the rear cover and the deflection base, pay attention to pinching of the lead and gasket. There are two kinds of length of the M2 screw. It may cause a failure ②...
- Page 95 b) Fill it up with the silicone sufficiently as shown below. The metallic portion of the high- voltage line terminal portion Silicone Filling Portion should be completely hidden. (Hatching Portion) Rib of the base plate Fill it up to approximately the same D section height as the rib of the base plate so that the screw head will not be out.
- Page 96 Knack of infusing the silicone When infusing the silicone into the dispenser, perform it as shown below (to purge air). Cylinder Put the silicone in Metallic needle Place the needle on the upside Cylinder Wait until the silicone comes down to the piston Downside is NG Piston...
- Page 97 5.5 Sealing valve (MV9) Replacement Procedure Depressurize the printer. Remove the head cover and the heater cover. Remove the head base rear cover and disassemble the connector of the sealing valve. Unloosen the nozzle IN joint presser foot and the sealing valve presser foot. A filter is put in the terminal area (inside the sealing valve) of the nozzle IN joint.
- Page 98 Prepare a new sealing valve and put O-rings into the respective holes of the joint part. Put the O-ring P2.2 (hole diameter: about 2.1) into the hole on the heating unit side ① and put the O-ring P1.7 (hole diameter: about 1.6) into the hole on the intensifier IN side.
- Page 99 5.6 Heating unit Replacement Procedure When “ink heating abnormality”, “heating unit abnormality detection” and “heating unit abnormality” occur, the heating unit must be replaced. Perform depressure. Remove all of the covers. Heating unit connector Remove the connector (4P, white) of the heating unit. Remove the sealing valve.
- Page 100 Connect the ink-furnishing tube(E) and fasten it by the heating unit joint presser foot. “Caution” Engage the slit of the heating unit joint presser foot as shown in the following ① figure. After dipping the O-ring in an intensifier, connect the ink-furnishing tube. ②...
- Page 101 5.7 Gutter base group Replacement Procedure When damaging the gutter and the gutter base, the gutter base group must be replaced. Perform it by the following procedure. Unloosed the gutter base setscrews and remove the gutter base group from the head base.
- Page 102 5.8 Head base Replacement Procedure When damaging the head base, the head base must be replaced. Perform it by the following procedure. Remove all of the covers described in the item 5.1. Remove the nozzle described in the item 5.2. Remove the deflecting base described in the item 5.3.
- Page 103 (12) Attach the heater, the heater spacer, the deflecting base, the heater spacer packing, the heater packing and the deflecting base packing. Deflecting base Heater Heater spacer Heater Heater packing Deflecting base packing Heater spacer packing (13) Dispose the APH tube part group on the head base and connect it to the recovery tube.
- Page 104 Screw the video signal wire and the high voltage wire. After screwing the high voltage wire, coat it with silicon. With respect to the coating method, refer to the item 5.3. (17) Assemble each connector and close the base rear cover. (18) Attach the gutter base, the sealing valve and the nozzle.
- Page 105 6.Troubleshooting 6.1Troubleshooting List [Fault invoke ink stoppage] Subsectio Name Remarks 6.2.1 Ink Low Refer to 6.2.1. 6.2.2 Ink Over Fill Refer to 6.2.3. 6.2.3 Makeup Ink Low 6.2.4 Replenishment Time-out 6.2.5 Ink Drop Charge Too Low 6.2.6 No Ink Drop Charge 6.2.7 Noise Fault M/S/C 6.2.8...
- Page 106 [Faults that invoke no on-screen indications] Subsectio Name Remarks 6.5.1 Chipped print (lower dots) 6.5.2 Chipped print (upper dots) 6.5.3 Varying character height 6.5.4 Increased character distortion 6.5.5 Disordered characters 6.5.6 Ink leakage/blowout Printing initiation failure in ready state 6.5.7 6.5.8 No ink ejection from nozzle [Miscellaneous]...
- Page 107 6.2 Fault invoke ink stoppage 6.2.1 Ink Low Ink Low Open the maintenance cover. Uncap the ink reservoir and add ink. Is there ink in the ink reservoir? Is the fault cleared by pressing the Reset key? ・Turn OFF the power. ・Unscrew and pull out the sensor section.
- Page 108 6.2.2 Ink Over Fill Ink Over Fill Is the initial-level sensor Open the maintenance cover. Check the initial- Has the excessive ink Is the ink main tank full level sensor level fault frequently of ink? connection again and occurred?
- Page 109 6.2.3 Makeup Ink Low Makeup Ink Open the maintenance cover. Is the makeup ink reservoir charged with the makeup ink? Uncap the makeup ink reservoir and add the makeup ink. Turn OFF the power. Can the fault be cleared by pressing the Reset key? Is the sensor connector disconnected?
- Page 110 6.2.4 Replenishment Time-out Replenishment timeout Is the ink refilling function being executed? Press the Reset key to clear the fault and execute the ink Press the Reset key to clear the fault refilling function again. and restart the printer. Does the “replenishment Timeout”...
- Page 111 6.2.5 Ink Drop Charge Too Low Ink Drop Charge Too Low １ Is the nozzle clogged or the beam bent? Pour a cleaning solution over the orifice plate surface to clean it, then allow it to thoroughly dry. If the problem is Does the charge not fixed:...
- Page 112 6.2.6 No Ink Drop Charge No Ink Drop Charge Is the beam being See under “No ink ejected from the ejection from nozzle.” nozzle? See under “Insufficient Is the nozzle clogged or electrical charge.” the beam bent? See under “Insufficient Is the gutter section electrical charge.”...
- Page 113 6.2.7 Noise Fault M/S/C Noise error M/S Is the IJ printer connected to its dedicated ground? Properly establish the ground connection. Are the nozzle head and IJ printer main body insulated from the other equipment? Ensure that the print head and printer main body are not in contact with the other equipment.
- Page 114 6.2.8 Deflection Voltage Leakage Deflection Voltage Leakage Does the ink beam enter the center of the Is the ink or makeup ink gutter? deposited on the deflection electrodes and their surrounding sections? Adjust the beam position. ...
- Page 115 １ Does the IJ printer become ready when you start it by pressing the Run key with the high-voltage power supply unit output connector Replace the high-voltage disconnected? power supply unit. ...
- Page 116 6.2.9 Charge Voltage Fault Charge Voltage Fault Is the EZJ94 board / EZJ106 board CN6 connector or high-voltage power supply CN1 connector disconnected? Disconnect the connector and then Connect the connector. reconnect it. Does the printer become ready for printing? Replace the high-voltage power supply unit.
- Page 117 6.2.10 DC Power Supply Fan Fault DC Power Supply Fan Fault Is the EZJ93 CN9 connector or Is the multiple power supply fan multiple power supply CN4 running? connector disconnected? Connect the connector. Replace the multiple power supply. Is the problem fixed? Replace the EZJ93 board.
- Page 118 6.2.11 Charge Voltage Fault Charge Voltage Fault Remove the print head cover. Pour the makeup ink over the charge electrode area to clean it. ・Allow the print head surface to adequately dry. ・Clear the fault. ・Restart the IJ printer. Does the printer become ready? Replace the EZJ94 board / EZJ106 board.
- Page 119 6.2.12 Internal Communication Error S Internal Communication Error S Does the fault recur upon power-on reset? Replace the EZJ93 board. Resume the operation. 6.2.13 F Memory Fault M/S/C F Memory F Memory Fault C Fault M/S Does the fault recur Does the fault recur upon power-on reset?
- Page 120 6.2.14 Hardware Error C Hardware Error C Does the fault recur upon power-on reset? Replace the EZJ102 board. Resume the operation. 6-16...
- Page 121 6.2.15 Ink Heating Fault Ink Heating Fault ・Clear the fault. ・Restart the IJ printer. See Section “6.5.8, No ink ejection Does the ink jet out? from nozzle.” Disconnect EZJ94 board / EZJ106 board CN7 connector and reconnect it. ・Clear the fault. ・From the maintenance screen, place the heating unit in the operating mode.
- Page 122 6.2.16 Heating Unit Sensor Fault Heating Unit Sensor Fault Disconnect EZJ94 board / EZJ106 board CN7 connector and reconnect it. Does the fault recur? Replace the heating unit. ・Clear the fault. ・ F rom the maintenance screen, place the heating unit in the operating mode.
- Page 123 6.2.17 Heating Unit Fault Heating Unit Fault Is the PTC resistance measured (between the EZJ94 board / EZJ 106 board TP3 and TP15) lower than 23 Ω? Replace the heating unit. ...
- Page 124 6.2.18 Ambient Temperature Sensor Fault Ambient Temperature Sensor Fault Disconnect the EZJ94 board / EZJ106 board CN7 connector and reconnect it. Does the fault recur? Replace the print head. ...
- Page 125 6.2.20 Pump Motor Fault Pump Motor Fault Pull out and insert the connector CN2 of the EZJ93 board and the pump motor connector. Does the fault recur? Replace the pump motor. ...
- Page 126 6.3 Faults that do not invoke ink stoppage 6.3.1 Print Overlap Error Print Overlap Error Is the next printing sequence timed before completion of the current one? Is the time interval between the end of a printing operation and the beginning of the next printing operation less than 10 Set the time interval between the...
- Page 127 6.3.2 Cover Open Cover Open Is the print head cover removed? Properly install the print head cover. Is the print head cover completely closed? Completely close the ...
- Page 128 6.3.3 Improper Sensor Position Improper sensor position Is the continuous printing function required? Is there an excessive clearance between the print head and print target detector? Is the “Continuous printing count” is set to “0000”from the Decrease the print specifications clearance between...
- Page 129 6.3.4 Target Frequency Too High Target Frequency Too High Are there more than four workpieces (print targets) between the sensor and print head? Decrease the clearance between the sensor and print head and reduce the number of workpieces between the sensor and print head to four or less.
- Page 130 6.3.6 No Print Contents No Print Contents Does any print item consisting of invalid characters alone exist? Adjust the print contents so that print items consisting of ...
- Page 131 6.3.7 Ink Drop Charge Too High Ink Drop Charge Too High Clean the gutter section and its surrounding area Is the gutter with a cleaning solution. section soiled? Does the IJ printer become ready for printing when you initiate ink ejection and start it? Resume the operation.
- Page 132 １ Is any vibration or shock applied to the IJ printer, print head, or print head cable during operation or startup? Eliminate the cause of vibration or shock. Does the IJ printer become ready for printing when you eject ink and start the IJ printer with the high- voltage power supply unit high-voltage output...
- Page 133 6.3.8 Internal Communication Error C/M Internal Communication Error C/M Is the EZJ93 board CN3 connector disconnected or in poor contact? Is the EZJ102 board CN3 connector disconnected or in poor contact? Normality is restored when the connector is disconnected and then reconnected.
- Page 134 6.4 Warning (printing continuously performed) 6.4.1 Ink Shelf Life Exceeded Ink Shelf Life Exceeded Has the “Warning time” preselected from the operation management screen elapsed since last ink replacement? Was the “Operating time” set to 0 from the operation management screen when the ink was replaced last? Enter the cumulative ink ejection time elapsed since last ink...
- Page 135 6.4.2 Operating Temperature To High/To Low Operating Temperature To High/To Low Properly set the operating Is the operating temperature upper-/lower-limit value temperature upper-/lower-limit erroneously set? value. Use an air-conditioner or the like Does the IJ printer to ensure that the IJ printer temperature indication agree...
- Page 136 6.4.3 Ink Heating Failure Ink Heating Failure Disconnect the EZJ94 board / EZJ106 board CN7 connector and reconnect it. Is the Warning issued again? Replace the heating unit. Is the Warning issued again? Replace the EZJ94 board / EZJ106 board. Is the Warning issued again? Resume the...
- Page 137 6.4.4 Battery Low Battery Low Is the EZJ102 board CN2 connector disconnected or in poor contact? Normality is restored when the connector is disconnected Replace the battery. and then reconnected. Resume the operation. 6.4.5 Product Speed Matching Error Product Speed Matching Error The frequency of the speed- follow-up signal (encoder...
- Page 138 6.4.6 Viscosity Reading Instability Viscometer uneven fault during installation Viscosity Reading (calibration) Instability * Appears in processing status approx. 12 minutes after calibration starts Perform the viscometer operation test on the Re-execute viscometer Circulation system control calibration (2-3 times). screen. Does calibration finish normally? Is it normally measured?
- Page 139 6.4.7 Viscosity Readings Out of Range Viscosity Readings Out of Range Perform the viscometer operation test on the Circulation system control screen.。 Is it normally measured? Replace the ink. Is it normally measured? Replace the proximity sensor. Is it normally measured? Disassemble and clean the viscometer.
- Page 140 6.4.8 High Ink Concentration High Ink Concentration Check the printing quality. Is the printing quality normal? Replace the ink. Operate the printer for an hour or so, and check the ink viscosity. Has the viscosity increased? Replace the ink in the ink tank. Resume the operation.
- Page 141 6.4.10 Excitation Setting Review Excitation Setting Review Readjust the excitation setup. Resume the operation. 6-37...
- Page 142 6.5 Faults that invoke no on-screen indications 6.5.1 Chipped print (lower dots) Chipped print Direction of deflection Is the ink beam positioned at the center of the gutter? Adjust the ink beam Missing dots position so that the ink Is the ink pressure beam is centered with higher that the...
- Page 143 6.5.2 Chipped print (upper dots) Missing dots Chipped print Direction of deflection Is the ink beam positioned at the center of the gutter? Adjust the ink beam position so that the ink Is the ink pressure beam is centered with lower than the respect to the gutter.
- Page 144 6.5.3 Varying character height Varying character height Is optimum clearance provided between the nozzle head end and print target? Optimize the clearance between the nozzle head end and print target. Was the character height setting changed? Adjust the character height setting. Is the ink pressure within the specified range?
- Page 145 6.5.4 Increased character distortion Increased character distortion Is optimum clearance provided between the nozzle head end and print target? Optimize the clearance between the nozzle head Is the ink pressure end and print target. within the specified range? Has the cumulative Can the ink pressure ink use time exceeded be adjusted?
- Page 146 6.5.5 Disordered characters Disordered characters Are the upper or lower print dots lost? See under “Chipped print”. Is the upper end of the print blotted? Is the operating temperature with the specified limits? Ensure that the operating temperature is within the specified limits.
- Page 147 6.5.6 Ink leakage/blowout Ink leakage/blowout Is the ink beam bent, dislocated from the gutter, or brought into contact with the gutter edge? Clean the orifice plate and the inside and outside of the nozzle head cover with the makeup ink, and then allow Clean the orifice place them to thoroughly dry.
- Page 148 6.5.7 Printing initiation failure in ready-for-printing state (no prints) No prints Does the obtained Is the printer in Is the print start print consist of the “Ready” signal entered? spaces only? state? Is the “Product Check the print Enter characters speed matching”...
- Page 149 6.5.8 No ink ejection from nozzle No ink ejection from nozzle Does the pressure gauge show the specified value? Execute the nozzle Is the supply backwash function. pump running? Is the EZJ93 board Is the problem CN2 connector, fixed? junction connector, Replace the ink filter...
- Page 150 6.6 Miscellaneous 6.6.1 Problems due to inappropriate ink beam position in charged electrode If the ink beam does not pass through the charged electrode, the following ● problems may occur: ① The height of printed characters will be larger than standard ②...
- Page 151 6.6.2 Problems due to inappropriate ink beam position to gutter If the ink beam does not enter the center of gutter, the following problems may ● occur: ① The beam hits the inner wall of gutter inlet and “splash” occurs. This will dirty the gutter, causing either excessive electrical charge or no electrical charge.
- Page 152 7.1 Circulation system diagram...
- Page 153 7.2 Electrical Connection Diagram (1/1) ...