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. 43s Ink Jet Printer Service Manual P/N 361451-01 Revision: AC, September 2003. Copyright 2003, Videojet Technologies Inc. (herein referred to as Videojet). All rights reserved.

This document is the property of Videojet Technologies Inc. And contains confidential and proprietary information owned by Videojet. Any unauthorized copying, use or disclosure of it without the prior written permission of Videojet is strictly prohibited. Compliance Information For Customers in the U.S.A. This device complies with Part 15 of the FCC Rules.

Operation is subject to the following two conditions: 1) this device may not cause harmful interference, and 2) this device must accept any interference received, including interference that may cause undesired operation. Videojet 43s Inkjet Printer Service Manual For Customers in Canada This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. The Tot al Source Commitment The Videojet Tot al Source® Service Program is an integral part of our business in providing marks, codes, and images where, when, and how often customers specify for packages, products, or printed materials. Our commitment includes:. Videojet Technologies Inc. Customer Training. For more information on Videojet Technologies Inc.

Customer Training Courses, call 1-800-843-3610 (within the United States only). Outside the U.S., customer should contact a Videojet subsidiary office or their local Videojet distributor for further information. Table of Contents Compliance Information For Customers in the U.S.A.i For Customers in Canada.

Videojet 43s Inkjet Printer Service Manual Internal Source. 2–21 External Source.

Videojet 43s Inkjet Printer Service Manual Phase Profile Adjustment.5–24 Phase Offset Calibration. Videojet 43s Inkjet Printer Service Manual Ink System Operation.6–55 Function. Videojet 43s Inkjet Printer Service Manual Removal.8–13 Installation. 43s Ink Jet Printer. Videojet 43s Inkjet Printer Service Manual Electronics Compartment.12–12 Printhead Assembly. Videojet 43s Inkjet Printer Service Manual Rev AC. This handbook uses metric units of measurement.

The equivalent English measures are included in parenthesis. Associated Publications The following publications are related to this document:. Videojet 43S Ink Jet Printer Instructions for Use, Part Number: 361450.

About this Guide Rev AC. Note: Initial availability of the Instructions for Use is indicated by an asterisk (.). Availability of the Service Manual is indicated by a plus sign (+). For more information, consult your Videojet distributor or subsidiary. About this Guide Rev AC.

Videojet 43s Inkjet Printer Service Manual Installation and Inspection The equipment described in this handbook must be installed and subsequently inspected at the recommended intervals by qualified service and maintenance personnel. Mains Power Supply Ensure that the mains electrical supply is within the range indicated by the label adjacent to the mains inlet on the printer. Videojet 43s Inkjet Printer Service Manual Hazard Information This section contains important hazard notices. You must read these notices before using the printer. The hazard information is prioritized into typographically distinct warning and caution notices as follows: Warning Warning notices denote a potential hazard to the health and safety of users. Videojet 43s Inkjet Printer Service Manual Warning Notices Warning LETHAL VOLTAGES. Lethal voltages are present within this equipment when it is connected to the mains electrical supply.

Manual Car Service Manuals

Only trained and authorized personnel may carry out maintenance work. Observe all statutory electrical safety codes and practices. Unless it is.

Videojet 43s Inkjet Printer Service Manual Warning FIRE AND HEALTH HAZARD. The ink, solvent and top-up are volatile and flammable.

They must be stored and handled in accordance with local regulations. Do not smoke or use a naked flame in the vicinity of these substances. Videojet 43s Inkjet Printer Service Manual Warning TOXIC HAZARD. The cleaning agent is poisonous if taken internally. Do not drink.

Seek medical attention immediately if ingested. Warning HANDLING CLEANING AGENT.

The cleaning agent is irritating to the eyes and respiratory system. To prevent personal injury when handling this substance: Always wear protective rubber gloves and clothing. Caution DEGRADED PERFORMANCE. Machine functions that only Videojet-trained personnel can access are set at Password Level 3 (MASTER password), these functions must not be given as customer options.

Caution ELECTROSTATIC SENSITIVE DEVICES. Videojet 43s Inkjet Printer Service Manual Caution FALSE READINGS. To avoid the risk of false readings, the pump zero offset should only be calibrated when there is no ink in the system and the pump is off.

Caution PRINT QUALITY. To ensure high print quality, ink viscosity must be checked and must be correct prior to attempting modulation calibration.

Videojet 43s Inkjet Printer Service Manual Caution EQUIPMENT DAMAGE. Never attempt to bend the gutter. It is in a fixed position. Caution EQUIPMENT DAMAGE. The I/O Board LEDS connector must not be used to drive anything other than LEDs as specified otherwise damage may occur. Videojet 43s Inkjet Printer Service Manual Caution CLEANING MATERIALS.

To avoid damage to the printer components use only soft brushes and lint free cloths for cleaning. Do not use high pressure air, cotton waste or abrasive materials. Caution EQUIPMENT DAMAGE. Ensure that the cleaning agent is compatible with the ink used before carrying out printhead cleaning otherwise the printhead may be damaged.

Videojet 43s Inkjet Printer Service Manual Caution RISK OF DATA LOSS. The Clear Message option, when selected, does not ask for confirmation to clear the message.

Caution RISK OF DATA LOSS. The Delete user field option does not ask for confirmation to delete a User Field.

Installation Introduction The printer is tested prior to dispatch to the customer. The “Commissioning” section in this chapter contains the necessary instructions for setup and additional testing at the customer site. Each installation must be approached on an individual basis due to variations in production line build specifications. Videojet 43s Inkjet Printer Service Manual Caution EQUIPMENT DAMAGE. Only Videojet-trained personnel may carry out installation and maintenance work. Any such work undertaken by unauthorized personnel may damage the printer and will invalidate the warranty.

Required Items You will need the following items to complete this procedure:. Videojet 43s Inkjet Printer Service Manual Preparation for Use (1) Mains power button (2) Mains power cord (3) FMS tray (4) Retainer screw (5) Breather tube Figure 2-1. Beginning the commissioning process Fitting the breather tube Open the ink compartment door as shown in Figure 2-1. Videojet 43s Inkjet Printer Service Manual Start up calibration and testing Disconnect the electrical connectors from V1 (top-up add valve). If the customer has ordered the positive air pump option, the pump should be installed now (before the power is switched on).

See “Positive Air Pump (optional)”. Videojet 43s Inkjet Printer Service Manual Select Set Time/Date from the Configure menu. Enter the correct details and then press the Enter key. Filling the ink system Remove the filler plug (Item 2 in Figure 2-2).

Prime the mixer bowl (3) with approximately 250 ml of the correct ink using a syringe and a length of 40 mm x 6 mm tube. Videojet 43s Inkjet Printer Service Manual Warning HANDLING INK, SOLVENT AND TOP-UP.

The ink, solvent and top-up are irritating to the eyes and respiratory system. To prevent personal injury when handling these substances: Always wear protective clothing and rubber gloves. Videojet 43s Inkjet Printer Service Manual Removing trapped air Remove the front and rear printhead covers and the nozzle seal (retain the seal for refitting if the machine has to be transported). Slacken the jet valve (V11) screws. Place tissue paper around the printhead and jet valve to absorb solvent when the priming procedure commences. Videojet 43s Inkjet Printer Service Manual Allow the machine to run for approximately 30 seconds before pressing F1 (Abort Flush.). Tighten the jet valve (V11) screws and dry the printhead.

Note: The majority of air should now have been removed. However, if a significant amount of air remains trapped in the flush system, you can remove it by manually priming the flush pump. Videojet 43s Inkjet Printer Service Manual Connecting the nozzle Extend the nozzle PTFE tubes forwards across the head heater as shown below. Cut the tubes off at the length required to reach the rear end of the head heater. It is best if the tubes are cut exactly at the edge of the manifold. Videojet 43s Inkjet Printer Service Manual Press the information key again and verify that “visc set” and visc actual” are now identical.

Replace the connectors removed from valve V1. Final configuration and testing Set the throw distance for the clean start/stop, modulation and charge tests to 14mm. Videojet 43s Inkjet Printer Service Manual Test print Input a message. The message must contain a six-digit incrementing counter. Place an earthed print collector dish under the printhead. Select the created message for printing. Select Continuous Print mode: a.

From the Print menu, select Continuous Print. Videojet 43s Inkjet Printer Service Manual Machine Parameter Typical Value (see Note above) Dependency Ink Pressure Ink type, Pressure set value. Cabinet Temperature Ambient temperature.

Viscosity Set Point Ink type, Ambient temperature. Phase Angle Any value (must be stable) Correct Jet Break-up. Videojet 43s Inkjet Printer Service Manual Clean Start/Stop Standards The following illustrations show the minimum acceptable standards for clean start and clean stop. Compare these to samples obtained by placing a sheet of blank paper directly under the printhead. (samples are shown.

Videojet 43s Inkjet Printer Service Manual Jet Start and Stop Diagnostics Use the flow charts in this section to diagnose problems with dirty jet starts and stops. Quick Start Diagnostics Figure 2-2. Quick start diagnostics flowchart 2-14 Jet Start and Stop Diagnostics. Videojet 43s Inkjet Printer Service Manual Clean Start Diagnostics Figure 2-3. Clean start diagnostic flowchart, sheet 1 (Continued on next page) Jet Start and Stop Diagnostics 2-15 Rev AC. Videojet 43s Inkjet Printer Service Manual Figure 2-4.

Clean start diagnostics flowchart, sheet 2 2-16 Jet Start and Stop Diagnostics Rev AC. Videojet 43s Inkjet Printer Service Manual Clean Stop Diagnostics Figure 2-5. Clean stop diagnostics Jet Start and Stop Diagnostics 2-17 Rev AC. Set the Passwords for Levels 1 and 2.

Caution DEGRADED PEFORMANCE. Machine functions that only Videojet- trained personnel can access are set at Password Level 3 (MASTER password), these functions must not be given as customer options. Videojet 43s Inkjet Printer Service Manual Setting up Shifts Liase with the customer to confirm shift requirements (if any). The example below show how to set a shift system where the day is split into three shifts with each shift numbered from 1 and shift 1 starting at 0700.

Videojet 43s Inkjet Printer Service Manual Production Line Setup Typical Installation A typical installation is shown in Figure 2-5, where the printer (6) is mounted on a printer stand (5). The printhead (4) is configured to print vertically via a clamp (2) and bracket (3) assembly. A lamp stack (1) is fitted to the printer stand. Videojet 43s Inkjet Printer Service Manual Shaft Encoder Internal Source If no external shaft encoder is to be fitted then set the Shaft Encoder Source to Internal, via the Configure menu. However, if the line speed varies then a shaft encoder must be fitted in order to maintain constant message width. Videojet 43s Inkjet Printer Service Manual Product Sensors Figure 2-5 shows a photocell (8) connected via a cable (7) to PRINT TRIGGER 1 on the connector panel.

The printer can be configured to use two product sensors (PRINT TRIGGER 1 and PRINT TRIGGER 2). Videojet 43s Inkjet Printer Service Manual Table 2-2 lists the settings for jumper JB1.

Print trigger Device type Jumper 1 Pins Jumper 2 Pins 9-10 Table 2-2: Jumper JB1 Settings Connect the printer to the mains supply and then press the mains power button to switch the printer on. Videojet 43s Inkjet Printer Service Manual 2-24 Product Sensors Rev AC. Selecting Fluids A complete range of inks, top-up fluids and cleaning solutions for the 43s are available from Videojet.

These fluids can be ordered either as individual bottles or as kits that contain several bottles of ink, as well as the corresponding top-up fluid and cleaning solution. Videojet 43s Inkjet Printer Service Manual Warning HANDLING INK, SOLVENT AND TOP-UP. The ink, solvent and top-up are irritating to the eyes and respiratory system. To prevent personal injury when handling these substances: Always wear protective clothing and rubber gloves. Firmware Download Introduction To download new operating software to the flash memory in the printer use either:.

Microsoft Windows version 3.xx Terminal mode in conjunction with the Debug Monitor option from the System menu. Microsoft Windows version HyperTerminal mode in conjunction with LCD option from the System menu. Videojet 43s Inkjet Printer Service Manual Windows 3.xx Procedure Checking the Communications Link Before attempting to download new software check the communications link between the PC and the printer. Using a pre-configured connection cable, connect Com1 of the PC to COMM1 of the 43s Printer. Videojet 43s Inkjet Printer Service Manual From the Data Logging menu, select the Serial Port Functionality option.

Reset Status to Enable. Using Microsoft Windows 3.xx to Download Firmware Connect the serial communications cable between the serial port of the PC and printer connector COMM1. Videojet 43s Inkjet Printer Service Manual On the PC type DU1 and press. 0 (zero) is enter displayed in the Terminal Window.

On the PC press + T (Transfers menu), select Send Text File and press enter To select the new operating software file from the Send Text File Window, proceed as follows: a. Videojet 43s Inkjet Printer Service Manual Windows Procedure Checking the Communications Link Before attempting to download new software check the communications link between the PC and the printer. Using a pre-configured connection cable, connect COM1 of the PC to COMM1 of the 43s Printer. Videojet 43s Inkjet Printer Service Manual Change the Connect Using edit box to Com1.

Connect To Menu (Windows 2000) When the COM1 properties menu is displayed, ensure the settings are as follows: Baud Rate: 9600 Data Bits: Stop Bits. Videojet 43s Inkjet Printer Service Manual MON MON Press X and then on the PC to return the printer to normal enter control. From the Data Logging menu, select the Serial Port Functionality option and reset Status to Enable. Using Windows 95, 98 or 2000 to Download Firmware. Videojet 43s Inkjet Printer Service Manual On the PC press + T (Transfer menu), select Send Text File and press enter To select the new operating software file from the Send Text File Window, proceed as follows: a.

From the Look in field, select A. Videojet 43s Inkjet Printer Service Manual Boot Monitor Recovery Procedure If a data communications error occurs whilst downloading a new software Flash File or the system memory becomes corrupted, the system may “lock-up.” If this situation occurs, use the following recovery procedure: Switch off the 43s unit. Videojet 43s Inkjet Printer Service Manual Switch on the printer and download new software using the download procedure.

The printer will now be operational. 4-10 Boot Monitor Recovery Procedure Rev AC. Calibration and Testing Introduction The system calibration and test procedures described below should be performed as necessary to commission the machine after repairs have been carried out. All or part of the procedure may be required, as indicated in the failure diagnosis and repair instructions at the beginning of this section. Videojet 43s Inkjet Printer Service Manual (1) Mains lead earth wire (2) PSU cover (3) PCB mounting bracket (4) LCD cover plate (5) Electronics compartment door (6) Ink system compartment door Figure 5-1.

Earth Continuity Test Points Earth Continuity Test. Videojet 43s Inkjet Printer Service Manual Machine Power-Up Connect the printer to the mains power supply and press the mains power button. Ensure that the machine initializes correctly.

If the LCD is not visible, press, and then + L. When the ctrl LCD is readable, press any key to set the contrast. Videojet 43s Inkjet Printer Service Manual Pressure Zero Offset Calibration Caution FALSE READINGS. To avoid the risk of false readings, the pressure zero offset should only be calibrated when there is no ink in the system and the pump is off. Videojet 43s Inkjet Printer Service Manual I/O Board LED Check Check that LEDs 1, 3, 4 and 5 on the I/O board are illuminated and that LED2 is dimly illuminated. The LEDs represent the following voltage rails: LED 1 (green) +12 V customer's isolated supply for shaft encoder/photocell. Videojet 43s Inkjet Printer Service Manual Gutter Fault and Charge Error Disable From the System menu select Charge Error Shutdown Disable.

Press enter Select Charge error and toggle to Disable. Select Gutter fault and toggle to Disable. Press to disable both functions. Videojet 43s Inkjet Printer Service Manual Voltage Checks Check the voltages on the POWER connector, situated at the bottom left- hand corner of the I/O board. Use Pin 2 as the 0 V reference.

Figure 5-3 is a representation of the POWER connector with the voltages shown for each pin. Videojet 43s Inkjet Printer Service Manual Reset Run Hours If the Service icon is displayed, the time until the next service is due must be entered to remove it. Note: the contact information that is displayed on screen when this icon appears can be configured by selecting Enter Service Information in the Data Logging menu.

. Universal 37pc Service Manual P/N 361518-01 Revision: AB, March 2004. Copyright 2004, Videojet Technologies Inc. (herein referred to as Videojet).

All rights reserved. This document is the property of Videojet Technologies Inc. And contains confidential and proprietary information owned by Videojet.

Any unauthorized copying, use or disclosure of it without the prior written permission of Videojet is strictly prohibited. Compliance Information For Customers in the U.S.A. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1) this device may not cause harmful interference, and 2) this device must accept any interference received, including interference that may cause undesired operation. Universal 37pc Service Manual Rev AB. The Tot al Source Commitment The Videojet Total Source® Service Program is an integral part of our business in providing marks, codes, and images where, when, and how often customers specify for packages, products, or printed materials.

Our commitment includes:. Videojet Technologies Inc. Customer Training. For more information on Videojet Technologies Inc. Customer Training Courses, call 1-800-843-3610 (within the United States only). Outside the U.S., customer should contact a Videojet subsidiary office or their local Videojet distributor for further information. Table of Contents Compliance Information For Customers in the U.S.A.i Support and Training Contact Information.

Universal 37pc Service Manual Chapter 4 — Theory of Operation Introduction.4–1 The Ink Jet Printing Process. Universal 37pc Service Manual Chapter 8 — Troubleshooting Introduction.8–1 Fault Diagnosis. Universal 37pc Service Manual viii Rev AB. Equipment Description The Videojet Universal 37pc (postal coder) printer is a non-contact, ink jet printer that prints at high production speeds onto almost any surface in any direction. This equipment is typically used for printing postal bar codes onto mail pieces. The Universal 37pc Service Manual is intended to be a supplement (and not a replacement) to training.

Availability of the Service Manual is indicated by a plus sign (+). Availability of the Illustrated Parts Breakdown is indicated by the number sign (#).

For more information, consult your Videojet distributor or subsidiary. About the Service Manual Rev AB. Universal 37pc Service Manual About the Service Manual Rev AB.

Read this chapter thoroughly before attempting to install, operate, service, or maintain this product. Introduction The policy of Videojet Technologies Inc. Is to manufacture non-contact printing/coding systems and ink supplies that meet high standards of performance and reliability. We enforce strict quality control techniques to eliminate the potential for defects and hazards in our products. Universal 37pc Service Manual Safety Conventions Used in the Manual Specific safety information is listed throughout this manual in the form of Warning and Caution statements. Pay close attention to these statements as they contain important information on avoiding potential hazards to yourself or to the equipment. Universal 37pc Service Manual For Example: Caution Never turn the printer Off by switching the AC power switch to the OFF (O) position before pressing the STOP/START key and allowing the printer to complete the two-minute shutdown sequence.

Failure to follow this procedure properly prevents the printer from drawing the ink in the ink return line back into the reservoir. Latex gloves should only be used in operations where the only concern is exposure to ink which may stain skin. For cases involving skin contact with VIDEOJET® fluids or organic solvents, a more durable glove such as Butyl rubber gloves are recommended. If any of these circumstances apply, it may be necessary to vent the printer exhaust to outside air. Consult the appropriate regulatory agency concerning emission permitting and venting system requirements before venting printer exhaust to outside air. Note: A Vapor Exhaust Ducting Kit is available through Videojet. Equipment Safety Guidelines Rev AB.

To maintain regulatory approval, the printhead stand must be bolted to the floor, conveyor, or other stable foundation when installed. Using Printer Accessories To maintain regulatory approval for the printer, you must use only Videojet approved accessories when attaching any device to the equipment.

Placement of the Printer Rev AB. For continued protection against possible fire hazard, use only Videojet supplies with a flash point no lower than -22°C (-8°F) and boiling point no lower than 56°C (133°F). Ink, Make-up Fluid, and Cleaning Solution No Smoking Do not smoke when near the printer or printhead. Universal 37pc Service Manual Wear Safety Glasses Wear safety glasses with side shields (or equivalent eye protection) when handling any ink, make-up fluid or cleaning solution. If splashed into your eyes, flush eyes with water for 15 minutes and see a physician immediately. Additional copies of MSDSs are available upon request and can be obtained by contacting the Videojet Customer Service Department at 800–843–3610. Outside the U.S., customers should contact a subsidiary Videojet office or their local Videojet distributor.

Universal 37pc Service Manual Note: The service tray is available through Videojet. Refer to the Illustrated Parts Breakdown for further information. Grounding the Service Tray 2-10 Ink Safety Guidelines Rev AB. Rocky Mountain Poison Control Center All of Videojet inks, make-up fluids, and cleaning solutions are also registered with the Rocky Mountain Poison Control Center, located in the United States.

If the bottle or MSDS cannot be located, the physician can contact the Rocky Mountain Poison Control Center to obtain the information required. Universal 37pc Service Manual 2-12 Medical Emergencies Rev AB. Caution It is strongly recommended that a Videojet Technologies service engineer install the printer. This will ensure that the printer has been installed properly, and that the system parameters have been set to match your line application.

appropriate electrical source – refer to Appendix A for electrical requirements Items denoted by an asterisk (.) are Videojet supplies or accessories which are available from Videojet Technologies Items can be ordered by referring to the Accessories and Spare Parts chapter (Chapter 3) of the Illustrated Parts Breakdown manual. Mount Printer to Stand Caution If the printer is to be located on the floor, use of the Videojet stand (P/N 378415) is required. Failure to attach this stand to printers placed on the floor will void the Underwriter’s Laboratories Inc. Universal 37pc Service Manual Connect Printer to Power Source The printer contains a universal power supply that operates from 90 to 264 VAC without adjustment. The printer comes equipped with a Power cord with a 120 V plug (North America). An air dryer may also be needed. An air input filter kit can be purchased separately through Videojet Technologies.

If a non-Videojet filter/regulator package is used, a reducer fitting (P/N 208644) is available from Videojet Technologies. This 5/16-inch to 1/4- inch reducer union is used to adapt the 1/4 inch outer diameter (O.D.).

Universal 37pc Service Manual Procedure Complete the following steps to connect compressed air to the printer. Retrieve the coil of unconnected tubing from the ink compartment.

Retrieving the air tube coil The ends of the coil are joined by a brass fitting. Disconnect one end of the coil from this fitting.

Universal 37pc Service Manual Feed the free end of the coil through the air tube hole in the back of the cabinet. Sliding the air tube into the printer Note: A small amount of alcohol applied to the outside of the tube will make it easier to slide the tube through the hole. Mount the air pressure regulator in a suitable location. Note: It is not necessary to mount the regulator on the printer itself. However, the air pressure regulator that Videojet sells for use with this printer may be mounted on the printer as shown in Figure 3-4. If using a third party air regulator, consult the instructions that came with the regulator being used.

If using an air regulator provided by Videojet, follow the steps below: a. Connect the compressed air source to the input of the air regulator assembly. Universal 37pc Service Manual Turn Printer On Press the AC power switch to the ON ( ) position to turn power to the printer On (refer to Figure 3-5). The light and the display screen on the keyboard will illuminate indicating that power is being supplied to the printer. Universal 37pc Service Manual Select POSTNET or I.D. Tag Use A Universal 37pc in parallel mode can function as either POSTNET or I.D.

However, the bar code type must be selected the first time the printer is powered on. Universal 37pc Service Manual Verify Preliminary Vacuum Setting Vacuum must be present in the system to complete the installation process. However, the final vacuum setting cannot be set until after the printer has been loaded with ink. Complete these steps to confirm there is enough vacuum to complete the installation process. Note: A Trap Bottle accessory may be installed when using water based inks due to the potential for foaming to occur in the ink reservoir. The Trap Bottle accessory is available from Videojet Technologies. Continue to Checking the Pressure Tank Full (PTFL) Switch.

Universal 37pc Service Manual Checking the Pressure Tank Full (PTFL) Switch Before loading the printer with fluid for the first time, check to make certain the pressure tank full (PTFL) switch is operating properly. Caution If the PTFL switch is faulty, the pressure tank will overfill when loading fluid into the printer. Universal 37pc Service Manual Pressure Tank Fitting Ink Output Line Fitting Figure 3-8. Checking the PTFL Switch Connection Caution Do not use a hard or abrasive object to push the float into the pressure tank as it may scratch or damage the wall causing the float to hang up or get stuck in the pressure tank. Universal 37pc Service Manual Figure 3-9. LED Panel Continue to push the float all the way up into the pressure tank until it stops and observe the PTFL LED on the LED bank at the same time. If the PTFL LED did light up, the pressure tank full (PTFL) switch is operating properly.

Universal 37pc Service Manual Continue to Ink System Service Preparation. Checking the PTFL Switch Setting Up the Printer 3-17 Rev AB. Universal 37pc Service Manual External Data Connections This section describes the external data connections for the Universal 37pc printer.

The six data connectors, numbered J1 through J6 are located on the rear of the printer cabinet (refer to Figure 3-11). Universal 37pc Service Manual J1, J2 and J3 — Product Detect / Encoder / Alert Light These three ports are provided for the connection of product detectors, shaft encoders and alert lights. The design allows all three devices to be connected to the same port or each device to be connected to a separate port. Universal 37pc Service Manual J1, J2 and J3 (DB9 Male) Pin Description Signal Name Description GREEN Green Alert Light. This output signals an attached alert light to switch the green lamp on or off.

The lamp should be on when the signal is low, off when the sig- nal is high. Universal 37pc Service Manual J4 — RS-232 Serial Interface This standard DB9 RS-232 serial interface is used to connect the printer to a host computer that will direct printing operations. See Chapter 9, “Serial Interface” for more in depth information on this interface. Universal 37pc Service Manual Setting the baud rate The Baud Rate is the speed at which data is received and transmitted.

Use the following procedure to set the Baud Rate. With the printer in the Standby mode, press the F1 key to select. Universal 37pc Service Manual J5 — Parallel Interface Connects the printer to a host computer that will direct printing operations. See Chapter 10, “Parallel Interface” for an in depth description of this connector’s functions.

Pinouts for connector J5 (external view). Universal 37pc Service Manual J6 — I/O This connector contains auxiliary inputs and outputs that are not included in the primary interfaces. All inputs can be driven using an open collector, drain, etc. The open collector should be rated for a minimum of 15V and a maximum of V (SAT) of 0.4V @ 10ma. Universal 37pc Service Manual J6 (DB25 Male) Pin Description Signal Name Description FLUIDLOW Fluid Low Warning. This active high output will indicate when the fluid in either the ink or makeup bottle is low. After 30 minutes of a fluids low warn- ing, an ink out fault will occur and printing stops.

Universal 37pc Service Manual Install Printer After the printer compressed air and AC power is connected, the printer is ready to be loaded with ink and prepared for operation. Shown below are the steps necessary to load the printer with ink and prepare it for operation. Figure 3-12. Removing the Printhead Cover Always use a metal grounded tray to collect flammable fluids.

A metal service tray is available through Videojet Technologies. Place the service tray on a flat surface such as the floor. Then, position the printhead in the holder as shown in Figure 3-13. Universal 37pc Service Manual Install the printhead chassis into the holder on the service tray as shown. Grounding the Service Tray Install Bleed Tube A bleed tube must be attached to the ink valve bleed port when performing certain ink maintenance procedure. Universal 37pc Service Manual Procedure Complete these steps to attach a bleed tube.

Locate the bleed port on the ink valve. Attach the bleed tube securely to the port and route the tube through the hole in the printhead face plate (refer to Figure 3-14).

Universal 37pc Service Manual Prime Printer with Make-up Fluid (AUTO PRIME) Priming the printer with make-up fluid flushes an empty ink system and prepares it for loading with ink. Complete these steps to prime the printer with make-up fluid. Remove the two empty bottles in the fluid pan portion of the printer. Universal 37pc Service Manual Press the Service key to enter the Service mode.

37 PC/UI PRINT HEAD SYSTEM Press the F2 key to select. INK SYSTEM CONTROL UPKEEP Press the F2 key to select. Press the Down Arrow key twice to move the cursor to the. Universal 37pc Service Manual Wait two minutes and confirm that the ink pressure regulator is set to 5 psi (refer to Figure 3-14). If it does not read 5 psi, adjust the ink pressure regulator until the gauge reads 5 psi.

Universal 37pc Service Manual Note: If the fluid drip rate is not set correctly, the printer may display an ALERT and priming will stop. If this occurs, reset the alert and restart the AUTO PRIME procedure. A “FILL TIME TOO LONG” alert indicates a too fast drip rate. Universal 37pc Service Manual Drain Make-up Fluid From Printer (AUTO DRAIN) The make-up must be completely drained from the ink system before it can be loaded with ink.

Complete these steps to drain the make-up fluid from the printer. Press the Down Arrow key three times to move the cursor to the. Universal 37pc Service Manual Close the bleed valve, but don’t remove the allen wrench from the set screw.

Continue to Prime Printer with Ink. Drain Make-up Fluid From Printer (AUTO DRAIN) 3-35 Rev AB. Universal 37pc Service Manual Prime Printer with Ink (AUTO PRIME) Complete the following steps to load (prime) the printer with ink and prepare it for operation.

Remove the previously installed bottle of make-up fluid on the right side of the fluid pan. Universal 37pc Service Manual Press the Down Arrow key twice to move the cursor to the field next to. SET PRESSURE AUTO REFRESH AUTO PRIME MORE OPTIONS Press the Yes/No key to select. The message “FOR PRIMING SYSTEM WITH NEW FLUIDS.”.

Universal 37pc Service Manual Refresh Ink System (AUTO REFRESH) The Auto Refresh procedure removes all of the ink currently in the ink system, and replaces it with fresh ink from the ink bottle. The Auto Refresh procedure takes approximately 15 minutes once it has been started. Universal 37pc Service Manual Warning When the key is pressed, ink will spray from the printhead. Ensure the printhead is aimed into the service tray. With the cursor in the field next to, press the Yes/No key to begin the Refresh procedure. The message “AUTO REFRESH RUNNING REFER TO MANUAL”. Universal 37pc Service Manual Ink Stream Calibration The ink stream calibration procedure ensures that the following conditions are met: the ink is aligned into the ink return block properly, the ink drop break-off occurs at the proper location in the charge tunnel.

Universal 37pc Service Manual Press the Service key to enter the Service mode. 37 PC/UI PRINT HEAD SYSTEM Press the F1 key to select. INK ON HIGH VOLTAGE ON TEST PRINT ON CHANGE SETTINGS Warning Ink may spray out of the printhead when completing the next step - turning the Ink On. Universal 37pc Service Manual. Turn the vertical adjustment screw to move the ink stream vertically (up and down). Horizontal Horizontal Locking Screw Adjustment Screw Vertical Adjustment Screw Figure 3-19. Adjustment Screws on Bottom of Printhead Align the ink stream so that it enters the ink return block horizontally centered and slightly above the vertical center, as shown in Figure 3- Figure 3-20.

Universal 37pc Service Manual Set Final Vacuum Adjustment The final vacuum adjustment must be made with the ink On. The preliminary vacuum adjustment was a rough adjustment. The final vacuum adjustment is needed to fine tune the amount of vacuum in the system, after ink is introduced into the printer. Universal 37pc Service Manual Vacuum Gauge Figure 3-22. Viewing the Vacuum Gauge Continue to Center the Ink Drop Break Off. 3-44 Ink Stream Calibration Rev AB. Universal 37pc Service Manual Center the Ink Drop Break-off Complete these steps to center the ink drop break-off in the charge tunnel: With the ink stream On (ink stream spraying from the nozzle into the ink return block), press the Down Arrow key on the keyboard three times to move the cursor to the.

Universal 37pc Service Manual Figure 3-23. Positioning Magnifier over the Charge Tunnel Note: A magnifier holder used to hold the magnifier lens to the printhead is available. Refer to chapter 3, “Accessories and Spare Parts” in the Illustrated Parts Breakdown for further information. Universal 37pc Service Manual. Press the Left Arrow key to decrease value by 25. Breakoff centered in charge tunnel Charge Tunnel Nozzle Figure 3-24.

Centering Ink Drop Break-off in Charge tunnel Press the Save key to establish the new nozzle drive setting. Universal 37pc Service Manual Set the Ink Pressure Complete the following steps to set the ink pressure in the system: Note: Make certain the printhead is clean and dry before performing this procedure. If it is not, the printer will not allow you to set the ink pressure.

Universal 37pc Service Manual Press the F2 key to select. INK SYSTEM CONTROL UPKEEP Press the F2 key to select. SET PRESSURE AUTO REFRESH AUTO PRIME MORE OPTIONS With the cursor in the field, press the Yes/No key to select. Universal 37pc Service Manual centered inside the charge tunnel simultaneously before pressing the Save key. Press the Save key to set the ink pressure.

The following screen will appear. WAIT FOR THE SET POINT TO BE ESTABLISHED (APPROX 5 MINUTES) Note: If the Save key is not pressed after the SET was achieved, the printer will not establish a new set point. Universal 37pc Service Manual Setting the Nozzle Drive In this procedure, you will set the nozzle drive to obtain the correct drop breakoff pattern for printing.

This adjustment will provide good print quality in typical environments under most circumstances. If a more precise setting is required, the nozzle drive setting may be further optimized by following the procedure “Find the Optimal Nozzle. Universal 37pc Service Manual Press the F1 key to select.

TEST PRINT ON NOZZLE DRIVE Use the Arrow keys to decrease the nozzle drive value to 0. Note: No Signal and /or Phasing faults may occur during the ink stream calibration causing the ALERT light to flash. Universal 37pc Service Manual Use the Arrow keys to increase the nozzle drive setting until the ink drop break-off pattern looks similar to the one shown in Figure 3-27. Pressing the Arrow keys will increase or decrease the current nozzle drive setting by the following increments.

Universal 37pc Service Manual Conduct a Test Print The test print feature is used to confirm good print quality and to ensure correct ink stream alignment into the ink return block. Test Print Guidelines These guidelines apply to the test print procedure:. Universal 37pc Service Manual Press the F1 key to select. INK ON HIGH VOLTAGE ON TEST PRINT ON CHANGE SETTINGS Ensure that the field is set to. If it is not set to, press the Yes/No key to set this field to. Universal 37pc Service Manual You have completed the Calibrate the Ink Stream procedure.

Continue to Set the Fluids Low Adjustment. 3-56 Ink Stream Calibration Rev AB.

Universal 37pc Service Manual Set the Fluids Low Adjustment Air passes through the fluids low needle valve to supply the fluids low switch and replenishment bottles. This air is used to monitor the fluid level within the bottles.

Use a screwdriver to adjust the fluids low needle valve (see Figure 3-28). Universal 37pc Service Manual Adjust the needle valve for approximately one to two bubble(s) per second. This procedure adjusts the fluids alert for both replenishment bottles. Setting the Fluids Low Adjustment Note: Do not hold the Dip Tube more than 1/2 inch below the liquid surface, or you will not see any bubbles. Adjust the positive air setting at the positive air needle valve (refer to Figure 3-28). Use a screwdriver and a flow meter (Videojet P/N 365230) for this adjustment.

The air flow is measured at the printhead with the ink On. Universal 37pc Service Manual Adjusting the High Voltage Plate Gap Introduction The physical distance between the high voltage deflection plate and opposing ground plate must correct. This procedure confirms the correct gap exists.

Warning Ink and High Voltage must be Off during this procedure. Universal 37pc Service Manual Adjust the High Voltage Gap The physical distance between the high voltage deflection plate and opposing ground plate must be correct. This procedure confirms the correct gap exists. Loosen the four screws holding the high voltage arm. Universal 37pc Service Manual Adjusting the Bar Code Height The physical height of the bar code can be adjusted.

Print height is measured in percent; the default is 50%. The print height can be set between 1 and 100%.

Adjusting the Bar Height. Theory of Operation In this chapter you will find:.

a description of the ink jet printing process, including the ultrasonic, electrostatic, and pressure effects on the ink stream. an explanation of the two factors that control the ink stream: ink pressure and nozzle drive. Universal 37pc Service Manual The Ink Jet Printing Process The ink jet printing process is based on the physical behavior of a fluid ink stream under the influence of pressure, ultrasonic vibration, and electrostatic forces. Read the following sections in this order to better understand the ink jet printing process:. Universal 37pc Service Manual Electrostatic Effects on the Ink Stream The charge tunnel is an in-line electrode that charges the drops for printing. Just before each drop forms, a positive electrical pulse is applied to the charge tunnel at the same ultrasonic rate as the signal to the nozzle (refer to Figure 4-2). Universal 37pc Service Manual The High Voltage Plate After passing through the charge tunnel, the ink stream enters the electric field of the high voltage deflection plate, where each charged drop is deflected from its path.

This deflection changes the drop’s trajectory and places the drop at a precise location on the print surface (see Figure 4-3). Universal 37pc Service Manual Pressure Effects on the Ink Stream The only true variable in the printing process that is beyond the operator’s control is the pulsed voltage amplitude at the charge tunnel. Recall that this voltage is predetermined by the controller PCB. Changes in internal printer ink pressure, however, can also affect character formation. Universal 37pc Service Manual Controlling the Ink Stream Two different printer adjustments control the ink stream: ink pressure and nozzle drive. These adjustments are typically made during initial installation, after changing ink types, and after servicing certain printer components.

Adjusting the Ink Pressure As discussed on page 4-5, the ink pressure controls the ink stream velocity and, as a result, print quality. Universal 37pc Service Manual A) Minimum Drive B) Low Drive Slow Satellites C) Correct Drive Fast Satellites Note: For proper break-off Acceptable pattern, refer to the Breakoff specifications sheet supplied with your Videojet ink. Effect of Nozzle Drive Adjustment. Universal 37pc Service Manual Functional Analysis Understanding how the printer operates will aid in troubleshooting the system.

The following sections contain a complete breakdown and analysis of both the hydraulic/pneumatic functions of the printer and the sequence of events that happen during various modes of operation. All sequences are controlled by the microprocessors on the controller printed circuit board (PCB). Universal 37pc Service Manual carburetor, the passage of air through the throat develops a low pressure at the side port, drawing fuel into the venturi.

In the printer, the rush of air through the venturi, or throat, of the vacuum generator causes a comparable low pressure at the side port. Universal 37pc Service Manual The software compares the flow time to the set point time to measure the ink viscosity. As a result, various actions may be taken depending upon the printer mode of operation. LED Panel on the Printer Circuit Board (PCB). Universal 37pc Service Manual forms at the right time in relation to the charging signal will receive the best total charge. This APC signal is sensed in the ink return block and monitored by a sensing circuit on the controller PCB to determine which of the four phases provides a signal where the amplitude is greater than a fixed threshold.

Universal 37pc Service Manual 2. When the transfer solenoid valve is closed (de-energized), vacuum is applied to the transfer pump. Vacuum helps pull the diaphragm backward, causing fluid to be drawn into the pump from the reservoir.

As fluid is transferred from the res- ervoir to the pump, the fluid level and the float in the reser- voir begin to drop. Universal 37pc Service Manual 5. As the fluid level in the pressure tank drops, the pressure tank float drops as well. Once the magnet in the pressure tank float reaches the pressure tank low (PTLW) switch again, the transfer solenoid switches (TVAL) to allow air pressure (instead of vacuum) to the transfer pump.

Universal 37pc Service Manual Air Control Solenoid Nozzle Solenoid (NVAL) (AVAL) Pressure System Tank Operating Air Pressure Make-up Add Solenoid (MVAL) Vacuum Vacuum Generator Vacuum Filter Fresh Ink Add Solenoid (IVAL) PTFL OFIL PTLW RFUL RLOW Transfer Solenoid Reservoir (TVAL). Universal 37pc Service Manual Pressure System Tank Operating Air Pressure Make-up Add Solenoid Vacuum Make-up Add Line Fresh Ink Add Solenoid Make-up Add Valve Fresh Ink Add Line PTFL Fresh Ink Adder Valve Reservoir Overfill PTLW Switch (OFIL) Reservoir Full. Universal 37pc Service Manual Pressure System Tank Operating Air Pressure Make-up Add Solenoid Vacuum Fresh Ink Add Solenoid Make-up Add Valve PTFL Fresh Ink Adder Valve (OFIL) PTLW (RFUL) Reservoir Low Switch (RLOW) Transfer Solenoid Magnet Reservoir (TVAL) Reservoir Float. Universal 37pc Service Manual Ink Pressure Regulator Nozzle Solenoid Pressure System Tank Operating Air Pressure Float Limit Pin Vacuum Primary Ink Filter Pressure Tank Full Switch Check (PTFL) Valve Pressure Pressure Tank Low (OFIL) Tank Float Switch (PTLW) (RFUL) Ink Valve.