9450 Bfse A49725 Svc Man.pdf

Book for service engineers Internal use only

Content

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Content

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Content

CONTENT ........................................................................................................................................... 3

SAFETY ............................................................................................................................................ 11 ■ REMINDER........................................................................................................................................ 13 ■ COMPLIANCE TO STANDARDS ............................................................................................................ 13 ■ SAFETY ............................................................................................................................................ 13 ■ RULES OF CONDUCT FOR TECHNICIANS WHEN VISITING CUSTOMERS .................................................... 14 PRINTER DESCRIPTION .................................................................................................................. 15 ■ OVERVIEW ....................................................................................................................................... 17 ■ PRINCIPLE OF OPERATION ................................................................................................................. 18 ■ AVAILABLE CONFIGURATION ............................................................................................................. 19 ■ PRINT HEAD DESCRIPTION ................................................................................................................ 19 ■ MAIN FEATURES ............................................................................................................................... 20 ■ ADVANCED CONSUMABLES MANAGEMENT ........................................................................................ 21 OVERVIEW .......................................................................................................................................... 21 ■ UMBILICAL CONFIGURATIONS (G/M HEADS) ....................................................................................... 22 ■ G/M HEAD DIMENSIONS .................................................................................................................... 22 ■ M PRINT HEAD VS G PRINT HEAD ....................................................................................................... 22 ■ CABINET DIMENSIONS ....................................................................................................................... 24 ■ OPERATOR INTERFACE ..................................................................................................................... 25 PROFILE SELECTION ............................................................................................................................ 25 OPERATOR LANGUAGES ....................................................................................................................... 25 PRINTER INTERFACE ............................................................................................................................ 26 ■ ELECTRONIC COMPARTMENT ............................................................................................................. 27 ■ HYDRAULIC COMPARTMENT .............................................................................................................. 28 ■ INK FEATURES .................................................................................................................................. 29 CARTRIDGE IDENTIFICATION ................................................................................................................. 30 ■ GENERAL SPECIFICATION OF THE PRINTER ......................................................................................... 31 MAIN PRODUCT FEATURES ........................................................................................................... 33 CHARACTER HEIGHT ............................................................................................................................ 35 FONTS AND ALGORITHMS ..................................................................................................................... 35 MESSAGE / JOB CONTENT .................................................................................................................... 37 PROFILE MANAGEMENT........................................................................................................................ 38 MARK AND READ SOLUTION .................................................................................................................. 40 PROMOTION CODING ............................................................................................................................ 41 QR CODE ............................................................................................................................................ 42 DATA MATRIX....................................................................................................................................... 44 9450 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Content BARCODES .......................................................................................................................................... 44 COUNTERS .......................................................................................................................................... 45 MESSAGE/JOB STORAGE ...................................................................................................................... 45 SIMPLIFIED PROTOCOL ........................................................................................................................ 46 TOOLS ................................................................................................................................................ 47 CUSTOM FONT ..................................................................................................................................... 47 FILES FORMAT..................................................................................................................................... 48 COMPATIBILITY .................................................................................................................................... 49 PRINTER INSTALLATION ........................................................................................................................ 50 PRINT HEAD INSTALLATION ................................................................................................................... 51 STANDARDIZED PRODUCT SENSOR ....................................................................................................... 52 POSITIVE AIR PUMP KIT......................................................................................................................... 53 EXTERNAL COMMUNICATION ................................................................................................................. 54 ■ HISTORY RECORDING ........................................................................................................................ 55 ■ PLANET PORTAL ............................................................................................................................... 56 PRE-INSTALLATION INSTALLATION TRAINING ........................................................................... 57 ■ PRE-INSTALLATION POLICY............................................................................................................... 59 PRE-INSTALLATION FORM ..................................................................................................................... 59 OPERATOR TRAINING ........................................................................................................................... 60 SIMPLIFIED INSTALLATION PROCESS ...................................................................................................... 60 ■ INSTALLATION GUIDE ........................................................................................................................ 61 PROCESS DESCRIPTION ....................................................................................................................... 61 STEP 1: CUSTOMER PROJECT VALIDATION ............................................................................................ 62 STEP 2: INSTALLATION PREPARATION ................................................................................................... 64 STEP 3: INSTALLATION ........................................................................................................................ 65 STEP 4: SHORT BASIC INSTRUCTION .................................................................................................... 66 STEP 5: INSTALLATION VALIDATION ...................................................................................................... 66 STEP 6: REPORT THE INSTALLATION TO MI ........................................................................................... 66 9450 INITIAL START-UP INSTRUCTION (APPROXIMATELY 30 MINUTES) ...................................................... 75 INSTALLATION VALIDATION CHECKLIST .................................................................................................. 76 9232 INSTALLATION CERTIFICATE ......................................................................................................... 77 OUT OF BOX CHECKING LIST ............................................................................................................... 78 ■ CUSTOMER TRAINING ....................................................................................................................... 79 ■ PRINTER IN DEMO MODE ................................................................................................................... 81 PRINTER START-UP .............................................................................................................................. 81 SAFELY TRANSPORTING THE PRINTER ................................................................................................... 82 AFTER-SALES .................................................................................................................................. 83 ■ AFTER SALES POLICY....................................................................................................................... 85 GENERAL POLICY ................................................................................................................................. 85 SPARE PARTS POLICIES ........................................................................................................................ 86 ENR POLICY ....................................................................................................................................... 87 MAINTENANCE POLICY ......................................................................................................................... 88 SIMULATOR ......................................................................................................................................... 89 9450 Book for Service Engineers 6/298

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Content PRINTER INFORMATION ........................................................................................................................ 89 PROBLEM DESCRIPTION IN SAP NOTIFICATION ...................................................................................... 90 ■ ON SITE INTERVENTION ..................................................................................................................... 92 ■ HISTORIES AND RUNNING STATUS ...................................................................................................... 92 PRINTING HISTORY............................................................................................................................... 92 MAINTENANCE HISTORY ....................................................................................................................... 93 (PRINTER) AVAILABILITY (HISTORY)...................................................................................................... 94 (ADDITIVE) CONSUMPTION (HISTORY) ................................................................................................... 96 WARNINGS / FAULTS (HISTORY) ........................................................................................................... 97 CONSUMABLE HISTORY ........................................................................................................................ 98 RUNNING STATUS (HISTORY) FILE ......................................................................................................... 99 START/STOP LOG FILE ....................................................................................................................... 101 REPAIR ON CUSTOMER’S SITE ............................................................................................................. 102 TECHNICAL BULLETIN ......................................................................................................................... 102 SOFTWARE RELEASE ......................................................................................................................... 102 ■ ESCALATION PROCESS ................................................................................................................... 103 REPORTING A TECHNICAL ISSUE ......................................................................................................... 103 ESCALATION PROCESS ....................................................................................................................... 103 MAINTENANCE .............................................................................................................................. 105 ■ GENERAL ....................................................................................................................................... 107 REGULAR MAINTENANCE .................................................................................................................... 107 PRESSURE PUMP REPLACEMENT PERIODICITY ..................................................................................... 108 INK FILTER REPLACEMENT PERIODICITY ............................................................................................... 108 ■ MAINTENANCE ALARMS .................................................................................................................. 109 FILTER KIT ........................................................................................................................................ 109 FLUSHING & MAINTENANCE KIT........................................................................................................... 109 ■ MAINTENANCE RECORD & FAULT CLEARING ..................................................................................... 110 PREVENTIVE MAINTENANCE ................................................................................................................ 110 CURATIVE OPERATIONS ...................................................................................................................... 111 ■ NEXT MAINTENANCE ALARM RESET.................................................................................................. 112 ■ MAINTENANCE HISTORY .................................................................................................................. 112 ■ PREVENTIVE MAINTENANCE CHECK LIST (PM) ................................................................................. 113 FLUSHING & PARTS REPLACEMENT ..................................................................................................... 114 ■ DRAINING AND RINSING RECOMMENDATION ...................................................................................... 115 SHUT-DOWN > 3 WEEKS ..................................................................................................................... 115 STORAGE TIME > 2 MONTHS ............................................................................................................... 115 TROUBLESHOOTING..................................................................................................................... 123 ■ INTRODUCTION ............................................................................................................................... 125 ■ PROFILES....................................................................................................................................... 125 ■ STATUS ......................................................................................................................................... 126 GENERAL STATUS .............................................................................................................................. 126 ■ MAINTENANCE MENU ...................................................................................................................... 128 INK CIRCUIT MAINTENANCE MENU ....................................................................................................... 128 9450 Book for Service Engineers 7/298

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Content INK CIRCUIT OVERVIEW ...................................................................................................................... 129 PRINT HEAD MAINTENANCE MENU ....................................................................................................... 130 ACM INFORMATION (TAG) ................................................................................................................. 133 SAFETY REMINDER............................................................................................................................. 135 ■ ERROR CODE & TROUBLESHOOTING CHART ..................................................................................... 139 TROUBLESHOOTING TABLES ............................................................................................................... 140 ■ LIST OF SPECIAL SPARE PARTS FOR M-I TECHNICIANS ..................................................................... 174 ■ LIST OF SPARE PARTS FROM CATALOGUE (A48599) ........................................................................ 178 MODULATION ASSEMBLY RECOGNITION ............................................................................................... 181 EHT PLATE RECOGNITION .................................................................................................................. 181 CONNECTING THE MI TECHNICIAN TOOL .............................................................................................. 182 DRAINING AND FLUSHING PROCEDURE ................................................................................................ 183 STORAGE TIME > 2 MONTHS ............................................................................................................... 183 ■ ACCESSIBILITY TO THE IC PARTS ..................................................................................................... 184 OBJECTIVE ........................................................................................................................................ 184 PROCEDURE...................................................................................................................................... 184 ■ SPARE PARTS SHEETS .................................................................................................................... 186 ■ SPARE PARTS SHEETS .................................................................................................................... 188 ■ ADJUSTMENT SHEETS ..................................................................................................................... 211 CHARGE ELECTRODE ......................................................................................................................... 211 MOTOR SPEED................................................................................................................................... 212 BREAK-OFF POINT ADJUSTMENT ......................................................................................................... 214 ELECTRONICS ............................................................................................................................... 217 ■ DIAGRAM BLOC .............................................................................................................................. 219 ■ POWER SUPPLY .............................................................................................................................. 220 ■ NEP BOARD ................................................................................................................................... 220 BLOCK DIAGRAM NEP BOARD ............................................................................................................. 221 ■ TECHNOLOGY INTERFACE BOARD .................................................................................................... 222 COMPONENT LAY-OUT TECHNOLOGY INTERFACE BOARD ...................................................................... 223 BLOCK DIAGRAM TECHNOLOGY INTERFACE BOARD .............................................................................. 224 ■ INK CIRCUIT BOARD (A48181) ......................................................................................................... 225 ■ PRINT HEAD BOARD ........................................................................................................................ 226 COMPONENT LAY-OUT PRINT HEAD BOARD .......................................................................................... 226 BLOCK DIAGRAM PRINT HEAD BOARD .................................................................................................. 227 ■ INDUSTRIAL INTERFACE BOARD ....................................................................................................... 228 COMPONENT LAY-OUT INDUSTRIAL INTERFACE BOARD ......................................................................... 228 ■ INPUT /OUTPUT SPECIFICATION ....................................................................................................... 229 TRIGGER & ENCODER ........................................................................................................................ 230 ALARM & FAULT (READY) ................................................................................................................... 232 SERIAL LINK ...................................................................................................................................... 235 MISCELLANEOUS INPUTS .................................................................................................................... 236 MESSAGE NUMBER ............................................................................................................................ 237 MISCELLANEOUS OUTPUTS ................................................................................................................. 238 NETWORK ......................................................................................................................................... 239  DHCP MODE (DYNAMIC HOST CONFIGURATION PROTOCOL) ........................................................................ 239  FIXED IP ADDRESS MODE .................................................................................................................... 239 9450 Book for Service Engineers 8/298

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Content ■ INPUT / OUTPUT SIGNALS DESCRIPTION ............................................................................................ 240 PRINTING SETTINGS .......................................................................................................................... 240 JOB SETTING ..................................................................................................................................... 242 ONE CELL SPEED MEASUREMENT .............................................................................................. 243 TWO CELL SPEED MEASUREMENT ............................................................................................. 245 ENCODER.......................................................................................................................................... 246 ALARM & FAULT ................................................................................................................................. 247 PRINTER READY ............................................................................................................................ 247 INVERSE MESS .............................................................................................................................. 247 INHIBIT TRIG................................................................................................................................... 248 JOB (MESSAGE) SELECTION INPUTS .................................................................................................... 249 ON / OFF ......................................................................................................................................... 250 COUNTR INCRM X & Y .................................................................................................................... 250 COUNTR RESET X & Y .................................................................................................................... 251 COUNTR END ................................................................................................................................. 251 HYDRAULICS ................................................................................................................................. 255 ■ DIAGRAMS OF THE HYDRAULIC CIRCUIT............................................................................................ 257 ■ PART IDENTIFICATION ..................................................................................................................... 258 FILTER .............................................................................................................................................. 258 INK CIRCUIT START –UP ..................................................................................................................... 261 PRINT HEAD START-UP ....................................................................................................................... 263 VISCOSITY MEASUREMENT ................................................................................................................. 264 INK LEVEL MEASUREMENT .................................................................................................................. 265 INK TRANSFER PHASE ........................................................................................................................ 267 ■ JET START-UP AND SHUT-DOWN ...................................................................................................... 269 ■ JET PRINCIPLES .............................................................................................................................. 270 BREAK OFF POINT (BOP) ................................................................................................................... 270 PHASE DETERMINATION (CHARGE SYNCHRONIZATION) ......................................................................... 272 JET SPEED CALCULATION ................................................................................................................... 272 PIEZO FREQUENCY ............................................................................................................................ 272 JET POSITION .................................................................................................................................... 272 ■ JET IN THE GUTTER PRINCIPLE ......................................................................................................... 273 SOFTWARE .................................................................................................................................... 275 ■ GENERAL ....................................................................................................................................... 276 OPERATING SYSTEM .......................................................................................................................... 276 9450 APPLICATION SOFTWARE............................................................................................................ 276 ■ SOFTWARE INSTALLATION / UPDATE PROCEDURE ............................................................................. 277 GENERAL .......................................................................................................................................... 277 SOFTWARE PACKAGE ......................................................................................................................... 277 PREPARATION ................................................................................................................................... 278 FIRMWARE INSTALLATION (STANDARD) ............................................................................................... 279 INSTALLATION REPORT ...................................................................................................................... 281 ■ FACTORY CONFIGURATION SETUP.................................................................................................... 282 9450 Book for Service Engineers 9/298

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Content PRINTER CONFIGURATION .................................................................................................................. 282 PREVENTIVE MAINTENANCE DATA ....................................................................................................... 284 HISTORIES ERASURES ........................................................................................................................ 285 ■ INTERFACE FOR MI SERVICE ENGINEER ........................................................................................... 285 MI ENGINEER PROFILE ....................................................................................................................... 288 ■ COPY SCREEN ................................................................................................................................ 294 PREPARATION ................................................................................................................................... 294 USE .................................................................................................................................................. 294 ■ SIMULATOR .................................................................................................................................... 295 INSTALLATION & LAUNCHING .............................................................................................................. 295 USE .................................................................................................................................................. 295 ■ ALGORITHMS.................................................................................................................................. 296 CODIFICATION ................................................................................................................................... 296

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Safety

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Safety Notes:

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Safety ■ Reminder Please read all the safety instructions that appear in the manuals provided to customers.

■ Compliance to standards All our products are imposed to meet certain standards depending on local legislations.

Any (local) modification and or alteration to our equipment other than communicated by MARKEM-IMAJE DS department, either by a MI employee or a customer is therefore strictly forbidden.

The uses of non MARKEM-IMAJE parts or drilling a hole in the cabinet are examples which affect the compliance to standards. Keep this in mind at any time and make sure the customer does the same.

■ Safety Although we are able to meet a large variety of applications with our product range, there is one application which we cannot meet: Hazardous environments A hazardous environment is defined as a place where concentrations of flammable gases, vapours, or dusts occur.

It is strictly forbidden to use any product of MARKEM-IMAJE in an environment which is determined as hazardous environment

The safety precautions mentioned in the operators, service and installation instructions should be understood, communicated to the customer and followed up at any time without any exceptions.

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Safety ■ Rules of conduct for technicians when visiting customers Technicians must comply with the safety rules in effect at the customer's site: Prevention plan: Technicians must request and examine the customer's prevention plan (where applicable) in advance or upon arriving at the customer's site. -

Traffic areas,

-

Authorization to use spark-producing tools,

-

Authorizations to perform work,

-

Necessary accreditation (chemical, electrical, etc….)

If the business being visited does not provide specific equipment, technicians must wear MarkemImaje personal protective clothing at least.

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Printer description

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Printer description Notes:

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Printer description ■ Overview

Full Tightness Stainless Steel Print Head: G Print head: Font height up to 32 dots (Resolution = 2.8 dots/ mm) IP56/IP66 Stainless Steel cabinet

Intuitive touch screen user Interface Based on icon design

M Print head: Font height up to 24 dots (Resolution = 4.5 dots/ mm)

Mark and Read solution

Advanced Consumable Management Consumable Identification & Management

Compatible with M-I accessories

Ink circuit based on 9232 printer with additional features: Auto diagnostic sequences embedded Improvement of start/stop sequences Securing Ink tank level

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Printer description ■ Principle of operation The principle of operation is divided in two (2) priorities: Priority1: Constant Jet speed. Feedback loop reaction time less than 2 seconds

Pressure adjustment

Jet Speed Reference

Modulation assembly Jet speed Measurement

Priority2: Constant Concentration. Feedback loop reactivity less than 30 mn

INK Temperature measurement

Viscosity measurement Viscosity reference

Viscosity vs temperature

T (°C)

Additive addition

Constant Ink Level management

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Printer description ■ Available configuration Type

Head type G

9450 M

Jet

Font height (dots)

Resolution (dots/mm)

P/N

IP56

1.1G

32

2.8

A48310

IP66

1.1G

32

2.8

A48316

3 or 6 meters

IP56

1.1M

24

4.5

A48311

(118 or 236 inch)

IP66

1.1M

24

4.5

A48317

IP

Umbilical length

■ Print head Description The design of the print head matches upside-down print head applications. The design of the print head is based on 9200 series. New stainless steel sleeve for easy & secure print head cleaning Front cover allows easy

The mechanical interface ensures tightness and a flexible link between Umbilical <>print head

access to the print head parts

New Head filter Mono layer filter

New 4 ELV Block Mechanically designed to prevent blockage issue

Print head parts reuse from 9200 series (electronic & Hydraulic)

IP 66 Seal (option)

Cover Magnet

Tightness is ensured by compressing a seal between the hydraulic plate and the print head sleeve

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Printer description ■ Main features Print features

M head

G head

Head /Jet

1 head / 1 jet

1 head / 1 jet

Number of lines

Up to 5 lines

Up to 5 lines

Number of dots

From 5 to 24 dots

From 5 to 32 dots

Character height

1,8 to 8,7mm

1,1 à 11,4 mm

Characters choice

Latin, Arabic, Cyrillic, Greek, Japanese, Chinese, Hebrew, Korean…

Print speed

Up to 4.4 m/s

Up to 6.6 m/s

Message library

Up to 1000 message

Up to 1000 message

Counters

Up to 2 per message

Up to 2 per message

Promotional coding (unique code)

Yes

Yes

Barcodes

EAN8/EAN13/EAN128/UPCA/UPCE barcodes, code 39, code 128, interleaved 2 of 5, Data matrix, QR codes

Shift code

Yes

Yes

External variables

Yes

Yes

Postdates

Yes

Yes

Configuration Cabinet

Full stainless steel

User interface

WYSIWYG 7-inch wide touch screen

IP rating

IP56/IP66(optional)

Umbilical length (conduit)

3m/6m(optional)

Connectivity

USB – SD port /Ethernet - Alarm - Encoder - RS-232 - Detection

Print head pressurization kit Autonomous pressurization kit (no plant air required)

Yes (Optional)

Print head

Modulation assembly GS/GL type

Consumables Ink cartridge

0.8l cartridges. Mistake proof - Equipped with radio identification (Tag)

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Printer description ■ Advanced Consumables Management Overview The Advanced Consumables Management is composed of an identification system, implemented in the printer, which is able to identify Markem-Imaje consumables. The customer’s benefits are:  No mistake with consumables references recognition, 

Optimum marking/printer performances,



Identification of out-of-date cartridges,



MI consumables authenticity proven.

The ACM design meats the ISO15693 standards. Each consumable is equipped with a TAG. The printer is equipped with antenna board and IC board which transmits interrogator signals and also receives authentication replies from tags situated on the consumable cartridge. The TAG contains ink or additive reference, batch number, expiry date and volume. The IC board transmits to the NEP all data from the TAG. These data are used to manage different functionalities of the printer (fluid levels, ink characteristics and validity...).

Consumable cartridges

NEP board

IC/RFID board TAG (Consumables): References Batch number Expiration date Volume

Antenna board Signal frequency= 13,56 MHz

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Printer description ■ Umbilical configurations (G/M heads) The umbilical configuration is performed by our manufacturing center: straight or angled head, according to the umbilical option selected in the SAP configurator. Four (4) configurations are available (0°, 90°, 180° and 270°) as follow:

■ G/M Head dimensions

Minimum radius of curvature (r): - Static: 100 mm (3.93”) - Dynamic: 150 mm (5.90”)

r

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Printer description ■ M Print head vs G Print head G head hydraulic plate

M head hydraulic plate

1

6 5

1

2

2

3 3 4 4bis

4 4bis

7

7

ID

Designation

Compatible (G/M heads)

Comments

1

Modulation Assembly

No

G head: ENM38980 (GS) G head: ENM40038 (GL) M head: ENM47391

2

Charge electrode

No

Including with Active plate (7)

3

Deflection Plate

No

M head: ENM46263 G head : ENM40783

4

Gutter Block

Yes

M/G head: ENM38941

4bis

Gutter Sensor

Yes

M/G head: ENM38973

5

4ELV Blocks

Yes

M/G head: ENM46408

6

Print head Board

Yes

M/G head: ENM39168

7

Active Plate

No

Not sealable for FSE. Dedicated for repair center

8

Head Cover including EHT

No

M head/G head: ENM47458

9

Ink Filter

Yes

M head/G head: ENM46708

Head sleeve

No

New reference (M head):ENM45303

Not Shown

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Printer description ■ Cabinet dimensions

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Printer description ■ Operator interface Profile selection When connecting the printer to the AC power, the printer displays the user profile selection.

Operator profiles: These profiles allow performing the basic operations (Jet maintenance, Job selection). By default, no password is required. This profile is configurable by an advanced profile. Advanced profile: This profile allows performing advanced operations (Printer/Printing configurations, Job creation, operator profiles configuration, ink circuit or print head maintenances…). By default, the password for this profile is “0000”. MI Engineer profile: This profile provides total access to all printer parameters. It is exclusively dedicated to MI Field service Engineer. (See Software section – MI Engineer profile).

Operator languages Arabic, Bulgarian, Chinese, Taiwanese, Croatian, Czech, Danish, Dutch, English, Finnish, French, German, Greek, Hebrew, Hungarian, Indonesian, Italian, Japanese, Korean, Norwegian, Persian, Polish, Portuguese (Brazil and Portugal), Romanian, Russian, Slovenian, Spanish, Swedish, Thai, Turkish, Vietnamese.

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Printer description Printer interface Current Job in production Printer/jet Status

USB connected

Alarm and fault notifications Zoom (Job)

Job management (creation, modification…)

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Printer description ■ Electronic compartment

Power Supply board

NEP board + Techno board

Industrial interface board

Cooling Fan

Rear view of the Top of the printer

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Printer description ■ Hydraulic compartment First level: Customer interface (basic operations) Possibility to transfer data from/to USB connector/SD card to/from printer

Easy access to the ink and additive cartridges (No tools required)

Adjustment of the pressure pump

Second level: Accessibility to the ink circuit components (using a 3mm Allen key)

Pressurization kit

Pressure pump

Antenna board Cartridges equipped with tag

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Printer description

Ink Pressure sensor + anti-pulse

Peltier cell

Ink Level sensor Level cells (Overflow, min level)

Ink filter

IC/RFID board

Transfer pump

Electrovalves

-

New hydraulic block: Additive pressure sensor CP3 Rinsing electrovalves EV6,EV7

Hydraulic parts (Ink/additive transfer pumps and electrovalves)

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Printer description ■ Ink features Cartridge identification The reference system has been set up to facilitate customer and Markem-Imaje team understanding on the consumables content (colour, solvent base…). The logic of this reference system is explained below:

Note: J can be found instead of A for some countries due to regulations

Certain inks require being equipped with specific accessories (pressurization kit) or require specific settings (partial transfer). These inks are the following: Ink reference Additive reference Head type Partial transfer

MC117

MB139

MB243

MB247

A188/J188 G-M -

A188/J188 G Mandatory Mandatory ENM40205

A188/J188 G-M Mandatory

Pressurization kit

A188/J188 G Mandatory ENM40205

Ink reference Additive reference Head type Partial transfer Pressurization kit

DB513

MB554

DS560

A181 A188/J188 A508 G G-M G Mandatory Mandatory ENM40205

-

ES590

FB651

MB248

A591 G-M Mandatory

A652 G Mandatory ENM40205

A188/J188 G-M Mandatory

-

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-

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Printer description ■ General specification of the printer Physical characteristics Printer body(LxPxh) .................... 360mm x 304mm x 555mm Print head (LxPxh): G head: 229mm x 45mm x 45mm M head: 231mm x 45mm x 45mm

Dimensions (mm) Umbilical length:

Weight (kg) Stainless steel

3000 mm or 118 inches 6000 mm or 236 inches Complete machine ........................... 25 kg without options and ink Cartridge ........................................... 0.8Kg 304L

Operating limits Operating temperature Humidity Altitude Protection

[5°C to + 40°C] Use of certain inks can limit the temperature range 10 to 90 % without condensation 3000m maximum IP56 (standard configuration) IP66 (Optional configuration) EN60529

Installation details Working position of the printer Maximum height offset between head and Printer cabinet

Vertical for the printer cabinet Any position for print head [- 2 m & + 2 m] for umbilical 3m [-1m & +2m] for umbilical 6m (print head vertical down or horizontal) [0m & +2m] for umbilical 6m (print head vertical up) No setting required

Head / Object distance

G head: 10 and 30 mm / M head: 7 and 14 mm

Head movement

Possible with limited ink range, refer to IRS (Maximum acceleration: 10m/s². Max linear speed: 1m/s)

Compliance with standard Safety

Electromagnetic compatibility

CE marking (self-certification) Conformity with the machine directive, the EMC directive and the low voltage directive: CEI 60950 (EN60950) + Safety standard ISO 13849 Certification cULus-GS Emissions: EN 61000-6-4 Immunity: EN 61000-6-2 Vibrations : NF EN 22247 / NF EN 60068-2-29 Impacts: NF EN22248 (falls/impacts)/NFH00 -60 NFH00-41, 47, 58, 59

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Printer description Energy 100 - 120V 0.5A alternative (Automatic switching)

Power supply

200 - 240V 0.3A alternative (Automatic switching). Frequency 50 or 60 Hz Power 60 VA. Air quality

Air pressurized (head pressurization option)

Filtration Flow rate Nominal pressure

Max: 0.12 grams of water/m³ (0.15 oz. of water/cubic foot) – 1 PPM of oil and size of particle < 5μ 90% (particle > 0.1μm) 800 Nl/hour (0.47 scfm) for a IP56 version equipped with air pressurisation at 7 bar (101 PSI) 5 < P <8 bar (72.5 < P < 116 PSI)

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Main product features

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Main product features Notes:

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Main product features ■ Printer features 

Large choice of fonts and algorithms,



Industrial barcodes,



History recording for maintenance interventions,



Printer availability and additive consumption,



Faults with corresponding running data.



Character height up to 24 drops (M) or 32 drops (G),



Print speed up to 6.6 m/s (9232, 9232S)



G : resolution 2.8 dots/mm (71dpi),



M: Resolution = 4.5 dots/ mm (printing resolution: 115 dpi)



Head/object distance: from 5 to 30 mm,

Character height The print head has one jet with the possibility to print characters and customized logos up to 32 dots in height. Refer to the printing capabilities sheet available on MI web site for details.

Fonts and Algorithms

Fonts: a

Standard fonts (a) are: Latin, Arabic, Hebrew, Greek, Chinese, Cyrillic, Chimney, and Japanese The range of font size (b) is expressed in dots from 5 up to 32 dots.

b

The file extension of the fonts used on the 9232 is (*.mif): xxx.mif

Algorithms: There are several algorithms (c) available to fulfil customer’s expectation: Quality, Speed, and Height… All algorithms are available in the printer. The Algorithms are divided in 2 packages and selected automatically depending on the print head configuration:

c

Quality (jet speed 20 m/s) or Speed (jet speed 23 m/s)

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Main product features Caution: The print head configuration in particular for speed is depending on the Ink Running Specification

9450

xx

In order to optimize the printing quality, the 9232 printer can change the algorithm according to the printing speed. In this mode (automatic mode), the printer selects automatically the most suitable algorithm according to the conveyor speed. There are two algorithm selection modes:

Automatic: If the algorithm number is «0000» in the message parameter, the printer selects the best algorithm by itself Manual: If the algorithm is different from "0000" in the message parameters, the printer will only use this algorithm for printing.

Printing capabilities are detailed in the 9400 User manual

This table gives the most suitable algorithm according to the printing speed, number of lines in the message, resolution…

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Main product features Head object distance The head/object distance (d) depends on the head type as follow: G head

M head

Standard resolution

2.8 dots/mm

4.5 dots/mm

Head – object distance

10 and 30 mm

7 and 14 mm

Message / Job content Up to 5 lines can be defined for each job; it could be up to 4 Kbytes. Each job/message is named (up to 20 ASCII char) & numbered (1 to 998). A job is composed with several blocks. Extension file for job is: *.mim (M-I Message)

Blocks

Lines

This includes printing parameters (18 bytes) and variable attributes (when it applies): Counter (49 bytes per counter), Barcode 1D (24 bytes + data per BC) Barcode 2D (14 bytes + data per BC) QR code () Shift Code (9 bytes for mode 1, 12 bytes for mode 2, 46 bytes for mode 3) Postdate (8 bytes per postdate)

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Main product features A job is composed with several blocks. Blocks can be protected for modification or given free for the standard operators. Blocks can be: Text Symbol (Glyphs, Characters, logo…) Graphics (pictures, logo…) External Variable (up to 20 per job) Date/Time/Postdate Shift code Custom date Counter (up to 15 per job) Bar Code (up to 4 different barcodes per job) Unique code

Profile Management The” Profile Management” feature consists of configuring and managing different operator profiles.

Operator profiles: This profile allows performing the basic operations (Jet maintenance, Job selection). By default, no password is required. This profile is configurable by an advanced profile. Advanced profile: This profile allows performing advanced operations (Printer/Printing configurations, Job creation, operator profiles configuration, ink circuit or print head maintenances…). The password for this profile is “0000”.

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Main product features The configuration feature is activated only for advanced / MI Engineer profiles.

Assigning a password

Configuring the operator profiles

Note: Consult User Manual A48586 for more details.

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Main product features Mark and read solution Mark & Read solution ensures what is printed by the printer is present on the product, readable and correct. This solution could be implemented using a vision system (Cognex Insight camera) plus a printer 9450 or by using CoLOs software. This solution ensures: Presence (complete data is printed) - Readability (Data readable by human eye) - Integrity (Data content is coherent). System set-up The Cognex Insight camera setup consists in: - Creating the “.job” setting files for each printer job - Teaching the camera for the fonts used in the printer Job Mark and Read with CoLOS - CoLOS ITF is linked to one camera’s job. - Fields in CoLOS ITF are linked to Symbolic Tags in the Camera. - The data exchange between CoLOS and the camera is done according the mapping table defined in the ITF. - Sending or getting data from CoLOS are made by using Telnet protocol. CoLOS (ITF)

2

3a

1

3b Cognex (.job)

4

5

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Main product features Promotional coding Promotional coding or unique code consists of sending a unique value to the printer. In that sense, each product coded has a unique printed message. One message = one product. The solution consists of embedding an amount of data on a media (USB stick) that are automatically pulled after each Dtop signal.

Installation: Set the printer in the Production Settings Factory. The selection case allows the operator to use the promotion coding in standalone mode. If not activated, the promotion coding can be used in V24 mode.

Restrictions and limitation 1.

In case the printer is switched off from the mains, data are lost from the queue. Only data remaining into the USB key are saved.

2.

In case the operator changes the message in production or modifies the existing message, data are lost from the queue. Only data remaining in the USB key are saved.

3.

The unique code must be in ASCII character from 20h to 7Fh. Note: Consult User Manual A48586 for more details.

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Main product features QR code Three (3) algorithms are especially dedicated to 21, 25 and 29 dots height printing. Head type

G head

M head

font size (dots)

Algorithm number

Hmessage (mm)

21 dots (21x21)

321

7,8

25 dots (25x25)

325

9,3

29 dots (29x29)

329

21 dots (21x21)

321

5,4

25 dots (25x25)

325

6,4

29 dots (29x29)

329

7,5

Resolution

Head – Object distance (mm)

Horizontal : 2.7 Vertical : 2.7

10 mm

Horizontal : 3.9 Vertical : 3.9

7 mm 9 mm for 29 dots

10,8

Algorithms are activated when changing the vertical resolution as follow:

When creating a new job, algorithms are now available in the list:

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Main product features Recommendations Stable product movement: no vibration, product with a flat surface and well guided. Angle of distortion: Adjust the tilt of the head in order to compensate the speed effect (inclination of the raster).The tilt should be adjusted at the main print speed in case of short acceleration and deceleration ramps and at the average speed if all the speed range is used.

Tacky encoder is mandatory: The tacky encoder is mandatory to ensure a constant length of the QR code in spite of the speed variations. In case 1, it is mandatory to change the tacky division for reading the code.

THT value: Check that the THT value indicated in the MI Engineer menu is the one indicated on the Print module. Quiet zone: The quiet zone value should be equal at least at 4. Never set the value of the quiet zone at 0. Head sense installation: We recommend sens1

Sens 1

Sens 2

QR code capacity

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Sens 3

Main product features Data matrix Three (3) algorithms are especially dedicated to 16, 18 and 24 dots height printing. Head type

G head

M head

font size (dots)

Algorithm number

16 dots

316

18 dots

318

24 dots

324

16 dots

316

18 dots

318

24 dots

324

Resolution

Head – Object distance (mm)

Horizontal : 2.6 Vertical : 2.6

10 mm

Horizontal : 3.9 Vertical : 3.9

7 mm

Recommendations Stable product movement: no vibration, product with a flat surface and well guided. Angle of distortion: Adjust the tilt of the head in order to compensate the speed effect (inclination of the raster) Tacky encoder is mandatory: The tacky encoder is mandatory to ensure a constant length of the Data matrix in spite of the speed variations. Head sense installation: The L pattern has to be printed with the less deviated dots. We recommend sens1 and 4.

Sens 1

Sens 2

Sens 3

Sens 4

Horizontal resolution: the tacky division has to be set to get a horizontal resolution of 2,6 dots /mm (G head) and 3.9 dots /mm (M head). THT value: Check that the THT value indicated in the MI Engineer menu is the one indicated on the Print module.

Barcodes 9232 barcodes capabilities: EAN 8, EAN 13, UPCA & UPCE, 2/5 interleaved, Barcode 39

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Main product features Counters Up to 15 Counters can be added to one single job. They can be incremented and reset by external signals or by internal settings. An external signal can be given to inform the end value has been reached.

Message/job storage 

The printer can “Store” up to 999 Jobs.



From the main repository up to 255 jobs could be selected to be part of the “Library” of the printer.



Any job in library could be selected using parallel interface (8bit input on Industrial Interface) or serial link protocol.



Extra input on industrial interface allows Job sense change.

Parent/Child This feature could be used when sending a job in production (with parameters) to several printers connected together. In this case, it should be necessary to identify a printer as a “parent” and others as “Children”. Parent

Children

By default, the configuration of a printer is “Children”. The configuration of the parent/child feature is done in the printer configuration menu:

Enter IP address and S/N of printers connected as a children

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Main product features Simplified Protocol The Simplified Protocol is now embedded on the printer. It can be used through the serial ports and through the Ethernet. It includes the following features: 1/ "Job name selection": Job selection from the store (By Name) (9232E mode 1 only). 2/ "Job library selection": Job selection from Library (By position) (9232E mode 1 only). 3/ "Simplified - external variable": Update external variable in active Job.

Overview

The format of the frame is “STX (ASCII DATA) ETX”. There is no response from the printer. When an error is detected, the User Interface displays the "External com error" Warning (without port origin).

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Main product features Tools Conversion of files from 9020/9030/9040 to 9232 format is performed by CoLOS GRAPHICS.

GCG Files (*.GCG) S7S Files (*.S7S)

MIF files (*.MIF) Binary format

MIF Files (*.mif)

Custom font There is no font editor with 9450. It is necessary to use CoLOS GRAPHICS to create custom font. (Name=admin/Password=admin) Create a bitmap (font type) and save it (as a MIF file) and upload it on a USB key or on a SD disk.

Connect the USB key to the printer and upload the font in the printer.

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Main product features Create a new message, select font “MILogo” and add the symbol in the message.

Save the message and select it in production.

Files Format

Fonts

Idem 9232: MIF files (*.mif)

Algo

Idem 9232: MIA Files (*.mia)

Message

Idem 9232: MIM files (*.mim) The V24 protocol is identical to the 9232 printer with additional commands.

V24 Consult the Network Interface Manual A48602.

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Main product features ■ Accessories Compatibility The printer is equipped with the connections for the MARKEM-IMAJE standard accessories. (Consult the spare part catalogue A48599 for more information about accessories).

Accessories

Compatible with

1

2

1-Standard Printer bracket 2-Standard Stainless steel table 3

5

3-Standard print head support 6

4-Standard head/Printer stand 5-Print head quick fixation 6-New Beverage print head stand

4

This new stand (A48235) offers an accurate and fast positioning of the print head.

7

7-Standardized Product Sensor 8-Standard Encoder 9

8

9- Configurable encoder

Previous CIJ alarm tower(A34791) 10

11

10-New Alarm A43931 + cable A43941 (kit A34792)

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Main product features Printer installation See Instruction manual for details about printer installation.

9450 could be mounted on existing 9232 stand thanks to the dedicated bracket stand support kit including stability weights.

Bracket (Stand mounting) Maintenance tray

9450 could be mounted on existing 923 wall support thanks to the dedicated bracket wall support kit

Bracket (Wall mounting)

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Main product features Print head installation Distance between the 2 fixing screws is the same as 9030, 9040, 9232 and 9450 (E=65mm), so the use of existing head support is possible.

Head support

E E E E F G F

Plug & play with 9030 and 9232 heads (x, y and z axis):  Same head/object distance (G head),  Same position for the printing (F=58.8mm) Compatible with 9040 head thanks to existing interface bracket:  On y and z axis but gap of 12 mm on “x” axis  G = F + 12mm  Mechanical adaptation on site could ensure the compatibility: Use the bracket interface Head Support.

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Main product features Standardized product sensor The following table gives the part number of the product sensor and the required cable to connect on the printer. (Note: For each sensor, the cable is ordered separately) Product Sensor Sensor type

Name

DIFFUSE PROXIMITY

Photoelectric Sensors

Inductive Sensor

ref

Picture

Required Cables

A45652

A45638

Notes/Applications

Universal (standard applications): Cardboard, paper, plastic…

A45652

Transparent product requiring precision like bottling line, glass… Universal (Standard application): Cardboard, paper, plastic… Film with dark mark

A45646

A45652

Film with mark

FORK

A45647

A45654

Bottling line

BACKGROUND SUPPRESSION

A45643

A45652

Application with precision in term of product guiding Transparent product

INDUCTIVE M18

A45642

POLARIZED RETRO REFLEX

A45639

CONTRAST

A45645

COLOR

GLASS FIBER

A45640

A45652

No picture

No picture

A45652

Metallic can

A45652

Electronic component (small parts) Application with difficult integration (small place)

A45652

Electronic component (small parts) Application with difficult integration (small place)

Optical Sensors GLASS_FIBER THROUGH BEAM

A45641

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Main product features Positive air pump kit The positive air pump kit (A44425) is a compressor which permits pressurization of the print head in order to avoid any dust from the environment being introduced to the printer.

A44425 POSITIVE AIR PUMP KIT

The compressor requires no compressed air coming from the customer’s industrial network. It can be used in dusty environments only; the positive air pump kit does not replace the Air treatment unit, the compressor cannot be used in humid environments. The compressor can be mounted on the printer using the location normally used for the classic air treatment unit.

Note: Print head cleaning frequencies when using the compressor are:

- Once a week for print speed < 200m/min - Once every three days for print speed > 200m/min

The Autonomous Compressor is recommended for use for print speed > 200m/min to improve the printing autonomy. Positive Air Pump kit vs. Air Treatment Unit KIT

Printer configuration IP56

ENM40206 Air treatment unit without switch

x x

A40205 Air treatment unit A44425 Positive air pump kit

IP66

Environment Humid

dust

x

x

x

x

x

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Main product features External communication The printer is standard equipped with an Ethernet (RJ45) communication port for complete printer control. For updates and or data transfer the printer offers 2 ports: USB port or SD port. Limitation: SD up to 2 Gb supported, SD HC and SD XC are not supported.

Industrial Interface (option) The industrial interface offers a wide variety of inputs and outputs to meet special and more complex customer’s applications (see section Electronic- Industrial interface)  Connection of customers “trigger” signal (cell, switch, PLC),  Control of trigger signal by Inhibit signal input,  Connection of customers “encoder” signal,  Output for Warning and Alarm (opto-coupled and or Relays contact. The relays l contact could be served for example to stop the production line.  Connection of a second cell for object speed measurement,  Printer ready output signal,  Counters management (increment and reset) plus end value output signal,  Switching ON/OFF the printer by external signal,  Message selection from a predefined series of messages (library) by one input signal plus control of selection sense, ascending or descending. For head movement applications for example,  Message selection by message number (Hexadecimal or Binary coded),  Message print sense control (reverse printing)  Serial communication either RS232 or RS422 mode for complete printer control

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Main product features ■ History recording Several data are stored to facilitate the daily use of the printer by the customer and the intervention of the MI service technician. These data can be saved on a USB stick or SD card for analysis purposes.

Printing: print counts per message with start and end date and time over the last two months for the messages manually selected. Message selection by external signals is not taken into account.

Maintenance: All interventions (maintenance and or part replacement) can be recorded in the printer. This is a manual procedure (except the maintenance).

Availability / consumption: The availability of the printer (100% = printer always available without faults when needed) and average Additive consumption plus the average temperature (based on the ink temperature are measured for each month.

Warnings / Faults: Recent faults and warnings are recorded with a direct link to the running status history which can be of use for the service technician for diagnosis purpose.

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Main product features ■ Planet portal The aim of the DS Technical Support Planet is to give easier access to the information (last Technical Bulletin, BfSE, check lists…) plus Software/Firmware. The web link is http://blvsapep32:50000/irj/portal and the entry point is new technical support.

Entry point (Global support)

Entry point (CIJ support)

Entry point (9450 support)

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Pre-installation Installation Training

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Pre-installation Installation Training Notes:

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Pre-installation Installation Training ■ Pre-Installation Policy Pre-installation form For each new MI proposal, the solution has to be validated by the customer through the print sample process. For each installation project, a Pre-installation has to be performed in order to:  Define the customer need/application,  Check the feasibility,  Prepare correctly the installation,  Ensure efficient and professional installation. The form is a good tool for sharing information between sales and the technical department. The form is often needed as an attachment to the Business Opportunity (BO) form. To help the operation to fill the pre-installation, 2 “Pre-installation” forms are defined

« Ba

sic

ion allat t s n i Pre-

m » for

plex « Com

Dedicated for “Basic installation” (standalone machine with Photo-cell or/and tacky encoder). This pre-installation could be filled by the sale rep or by the Level 1 field service engineer.

on allati t s n i Pre

» form

Dedicated to Complex Pre-installation” form for non-basic installation**. This preinstallation could be filled by the Level 1 or level 2 field service engineers.

Note: A detailed installation guide is available in this book to remind each step of the installation process and to remind the installation rules for the CIJ technology. Non-basic installation: 9450 with Colos, head movement, complex mechanical integration, RS232 connection, Ethernet connection, Interface parallel, Data matrix, QR code, specific inputs outputs or difficult environment (temperature, humidity…).

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Pre-installation Installation Training Operator training For each installation, the Customer operator has to be informed on how to drive a CIJ printer. Most of the downtime under warranty is due to the lack of knowledge. At the end of installation, the printer should run properly if the operator customer is “autonomous” or if he is fully aware and convinced to follow a basic operator training.

Case#01 - Customer operator has never used an M-I CIJ printer before The operator should follow Basic training course (see section customer training). Information will be supplied after the installation (safety, start/stop, quick guide presentation, introduction of the MI training catalogue) and convince the customer the preventive maintenance is a key factor of success.

Case#02 - Customer operator has already used a MI CIJ printer before. A Short Basic instruction should be supplied after the installation (see section customer training). A customer having MI CIJ printer already installed have sufficient knowledge (safety, vocabulary, ink jet technology...) to receive this Short Basic instruction at the end of the installation.

Simplified installation process Each installation and the printing quality have to be validated in production mode with the customer and the “Installation certificate” has to be filled.

Markem Imaje Proposal

OOBCL

Installation certificate

Pre-installation

9450 Installation

Remark: Supply a “back-up printer configuration” card (messages, fonts, and printer setup) for the future maintenance operation with MI hot-line.

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Pre-installation Installation Training ■ Installation Guide Process description For customer, the most important contact is the MI technical services. Pre-installations and installations have a habit of setting the tone of how a customer views Markem-Imaje. You are the ambassador of MARKEM-IMAJE! It is expected that each service engineer uses all the available tools and training support to provide the best of their abilities to maintain a high level of customer service and technical expertise. Some rules and best practices to prepare the installation, behavioural, and installation techniques must be followed and observed for this first contact with the customer. These rules allow a successful installation to be ensured and minimize returns during the warranty period after the installation. In this section, all installation steps are described:  Step1: Validation of the customer project,  Step2: Preparation of the installation,  Step3: Installation of the printer,  Step4: Instruction/Training for the operator,  Step5: Validation of the installation  Step6: Report of the installation

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Pre-installation Installation Training Step 1: Customer project Validation

Print sample validation

Pre-installation

Cognex validation**

Step 2: Installation preparation Preparation of the Installation

Step 3: Installation

Installation validation

Printer back-up Message/font/Config

Step 4: Operator instruction Short basic instruction on flipchart

Step 5: Installation validation

Validation with customer

Installation certificate

Clean the installation area

Production follow-up

Physical Installation

Step 6: Report the Installation OOBCL **Cognex validation: In case of Mark & Read application please refer to the associated Mark & Read document and contact your local CoLos champion 9450 Book for Service Engineers 62/298

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Pre-installation Installation Training Step 1: Customer project validation Print samples process & Sampling activity The sampling activity is a free service offered to external and internal customers for validation of suitability for inks for clearly identified applications. For each MI proposal concerning a new application or new substrate, the ink choice has to be validated by the customer through the print sample process. The sample request form is available on Planet. Pre-installation Before making an offer it is necessary that a local service/sales engineer makes an evaluation of the application during a Pre-installation visit. The Pre-installation Form has been designed to be a guide for Salesmen or Service Engineers during this visit. It will help to clearly define the application, the type of printer, the type of print head and ink, the needed accessories, the connections with the printer and the environment. Don't hesitate to collect all data and fill all fields mentioned in the form. Add drawings or digital pictures if possible in order to define where the cabinet, the print-head, and accessories (tacky, photocell…) will be installed. During the pre-installation visit, it is important to behave like if you have to install the machine: 

Localization of the marking head and of the cabinet,



Detection signal and encoder mechanical coupling,



Mechanical brackets,



Availability of mains power, compressed air,



Electrical connections with customer's equipment

This pre-installation visit is strongly recommended in order to clearly define the customer need and to prepare and ensure efficient and professional installation.

Cognex validation In case of Mark & Read application please refer to the associated Mark & Read document and contact your local CoLOS champion

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Pre-installation Installation Training Step 2: Installation preparation In order to perform an efficient and professional installation, the installation has to be strongly prepared to avoid any surprise during the installation. Contact your sales & logistic representatives Liaise with the Sales department to check what was sold, what was ordered and the specific requirements for the installation (pre-installation form). Contact the Logistics department to confirm what was ordered and its delivery date. Check that the delivered parts and what the sales team sold match up, so as to minimize any surprises at customer site! Contact your customer It is the first contact with YOUR CUSTOMER: you have to be professional!  Establish a link between the customer’s representatives who will be responsible for the installation.  Arrange an appointment (define the date) and re-check the customer need by using the Preinstallation form filled during the pre-installation visit.  Check if the company has safety or quality issues that require special authorization or documentation (safety shoes, safety helmet, electrical qualification…).  Check that the delivered parts and what the Sales team sold match up, so as to minimize any surprises at customer site!  Check if they have completed any pre-installation work required (air pressure present, main power present near the installation area, specific bracket done by the customer…).  Check with your contact what printer and accessories have been delivered.*  Check with your contact the consumables that have been delivered (it could be a different carrier for consumable and printer).Check with your contact the production line could be stopped for the CIJ integration and then the production line will be ready to perform some test in production mode.

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Pre-installation Installation Training Step 3: Installation Installation at a customer’s site Meet your contact and confirm the plan for the installation  Confirm the plan for the installation according to your last exchange with your contact and with the information present on the Pre-installation form.  Respect the safety or quality rules to follow during your stay on the customer site.  Localize the materials and consumables delivered by MI.  Localize the production line where the installation has to be performed.  Identify the operators already trained or operators who have to follow the basic operator instruction.  Check the certified power plug.  Check the compressed air if required.  Check the grounding available near the printer.  Check the possibility to fix the stand on the floor.  Start and check the printer before to starting the installation.  If you replace an old machine, note the cable connections.  The printer has to be installed far from permanent crossing of mobiles or people.  Install the printer and accessories with the definitive bracket.  Perform the installation with vibration free on the printer cabinet, print-head, umbilical, accessories when the production line is active.  Perform installation within MI specification (T°, Printing distance, level print head/cabinet).  Check the umbilical positioning (no vibration, correct bent, no axis rotation and correct speedacceleration if movement…).  Install the head maintenance tray.  Check the cable routing and attach each cable in a professional way (check the grounding and shielding).  Once the installation is definitive, validate the message layout in production condition.  Once the message layout is validated, start a production follow-up and start your installation validation (see next chapter).  Enter the installation date in the factory settings to reset the counters for the maintenance alarms (see chapter software).

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Pre-installation Installation Training Installation validation When the physical installation is performed, please use the “Installation validation checklist” in order to control the installation rules for the CIJ technology. Once the installation is definitive, validate the message layout in production condition. Once the message layout is validated, start a production follow-up. If the speed of the line is variable, test the printer at the maximum speed.

Step 4: Short Basic instruction The Field Service Engineer gives Basic Instruction to the customer using a Flip-chart near by the printer (master file of the flow chart available on Planet). The instruction takes 2 to 3 hours. Number of attendees should be limited (5 maximum).

Step 5: Installation validation Before leaving the customer, there are documents to sign. Installation/intervention report + installation certificate form should be signed by the customer. In the case where the customer has to finish the installation by himself, ask him to note this down on the installation report Delivery order has to be signed by the customer Send the OOBCL form to local after-sales manager Before leaving, schedule a phone call with your contact to verify that his expectations, under a production situation, have been met.

Step 6: Report the Installation to MI Use the OOBCL process to report the installation to MI (See OOBCL paragraph)

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Pre-installation Installation Training

Basic pre-installation form 9450

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Pre-installation Installation Training MARKEM-IMAJE REFERENCE Date:

Your Reference:

Subsidiary / Distributor:

Country:

Salesman's name:

Tel.:

Service Engineer's name:

Tel.:

CUSTOMER REFERENCE Customer’s Name:

Group:

Address: Sales contact name:

Tel.:

Technical contact name:

Tel.:

Product line Name/Number:

ENVIRONMENT Ambient temperature

max.:

°C/F

Humidity

max.:

%

Working hours per year

Operating Temperature: from x to x °C (see IRS) dusty

wet

hours New Installation

Application:

Printer Replacement

Model :

9450 MODEL 9450 Type Option

11G IP56

11M

Umbilical length:

3M

6M

Angled umbilical

IP66

left

rear

right

CUSTOMERS PRODUCT DESCRIPTION Product type:

Size:

x

x

mm

Substrate: Surface:

Normal

Rough

Greasy

Humid

dusty

hot

Ink environmental Restrictions:

PRODUCTION LINE DESCRIPTION Speed: On Conveyor

Variable

Fixed

Maximum speed: m/min Main power supply available Yes No

Power Supply Product movement

Right to left

Minimum speed: m/min UPS required Yes No

Left to right

Up to down

Print head position Description of Head Location

vertical

horizontal

upside down

tilt

Picture will be useful F

INK Pre-treatment (Corona, flame, hot air) Ink & application constraints

Drying time available:

sec

Post-treatment (hot air, UV, heat) Other constraints: (Migration, condensation, sterilization etc…)

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Pre-installation Installation Training INK Sampling Ink validation Repeat for each individual product substrate and or colour

To do

in progress

Done

Customers site sampling

Date:

Accepted:

Yes

No

Local Markem-Imaje site sampling

Ref.:

Accepted:

Yes

No

GDS Markem-Imaje site sampling

Ref.:

Accepted:

Yes

No

Ink reference:

Additive reference:

Cleaning solution:

Additional remarks

JOB DESCRIPTION Location

On side

Top side

Bottom side

Job recovery from

9040

9020/9030

Other (to be specify)

Job description

Logo

Barcode

Font size

Neck

5,7,9,11,16,24,32 dots

Number of lines in a job:

ACCESSORIES Cabinet support

Customer table

Markem-Imaje stand and Bracket

Alarm

3 Lights 24V

2 Lights 24V

Cell

Customer’s alarm

External Signal

Mounting bracket photocell

MI Proximity Photocell

MI Reflection cell

Optic fiber

Photocell support

Two External Signals

Encoder spiked wheel

MI encoder (5000pulses)

Flexible coupling

MI encoder - Adjustable

Encoder Support

Location (specify) Encoder Markem-Imaje 7000 series needs signals A & B for marking

Encoder smooth wheel

Air pressure kit (IP56 only) Positive air pressure kit (IP56 only) Extraction system Job & System Back-up

Air pressure kit for dusty and humid environment Important: DO NOT USE for humid environment In case of strong safety rule….can be proposed memory card

(Highly recommended)

SERVICES Service agreements

PREMIUM

SERENITY

use & operating Customer training

LONGEVITY

Advanced maintenance

Number of operator per work shift: Number of work shift:

STANDARD

Number of technician per work shift: On-site training

COMMENTS Additional Information

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Pre-installation Installation Training

Complex pre-installation form 9450

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Pre-installation Installation Training MARKEM-IMAJE REFERENCE Date:

Your Reference:

Subsidiary / Distributor:

Country:

Salesman's name:

Tel.:

Service Engineer's name:

Tel.:

CUSTOMER REFERENCE Customer’s Name:

Group:

Address: Sales contact name:

Tel.:

Technical contact name:

Tel.:

Product line Name/Number:

ENVIRONMENT New Installation

Application

Printer Replacement

Min °C/F Ambient °C/F Difference between cabinet and head:

Temperature Humidity

% No

Yes Max =

Vibrations

No

Yes

No

Yes

Head / Cabinet distance

°C/F

Ink storage

°C/F

°C/F Remark: wet

%

Wetness:

No

Yes

Static electricity:

No

Yes

Remark :

Horizontal:

Working hours per year

Max

dusty

Air moisture Cleanness

Model:

cm / inch

Vertical:

cm / inch

hours

Environmental restriction

No

Yes

Precise:

9450 MODEL 11G

9450 Type Option

IP56

Air pressure kit

IP66

Umbilical length: Angled umbilical left

3M

rear

6M

right

Air pressure kit for dusty and humid environment

(IP56 only) Positive air pressure

11M

kit

(IP56 only)

Important: DO NOT USE for humid environment

CUSTOMERS PRODUCT DESCRIPTION + INK choice vs. Product Size: Product Type :

x

Type:

Substrate: Surface :

Adhesion constraint :

No

Ink environmental Restriction

No

Drying time available

x

Colour: Normal

Rough

Greasy

Humid

Dusty

Hot

Yes: Yes: s

Remarks: draw the product including the location of the printing, mention any conditions and limitations which have been accepted by the customer

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Pre-installation Installation Training PRODUCTION LINE DESCRIPTION Describe in plain text the production process and the customer’s needs in full detail.

Production line & Model

Product speed: Product movement:

Conveyor Mark:

Other: ________

Model:

(Maximum) Speed: Continuous

Wrapping/Film

Carrousel

m/min

Fixed

Intermittent

Variable

Rotation

Product rate

Product/hour=

Power Supply

Available

To be installed by the customer

Air supply

Available

To be installed by the customer

Cabinet fixation

MI

Customer

Comment / Solution:

MI

Customer

Comment / Solution:

Vertical

Horizontal

NA

One way printing

Hours/day =

Days/week =

Weeks/year =

UPS system required

Yes

No

Head fixation

Head movement Synchronization printer with process

Upside down

Reverse printing

Printer ON/OFF NA

Inclined

Comment / Solution:

Ready to print Printing

Standard Printing stop Product detection / Print signal Inhibit print signal Print Speed signal (Encoder / cell(s)) End of counter (Batch control) External warning

Comment / Solution:

External via Stop imp NA

MI

Customer Comment/Solution:

NA

MI

Customer Comment/Solution:

NA

MI

Customer Comment/Solution:

NA

MI

Customer Comment/Solution :

NA

MI

Customer Comment/Solution:

Visual

Acoustic

Production line STOP

MI

Customer Comment/Solution :

Serial COM

Behaviour : NA Behaviour : External message selection :

Numerical BCD Hex

User Profiles

No

Camera connexion

Yes

Sequential increment Reverse library

Serial protocol Ethernet Barcode reader

Colos Mark & Read

Description

No Yes * Connected to: Colos directly to the 9450 (Not available yet) * If yes, please refer to the associated Mark & Read document and contact your local CoLos champion

Remarks

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Pre-installation Installation Training SAMPLING Ink & application constraints

NA

Pre-treatment (Corona, flame, hot air)

Post-treatment (hot air, UV, heat)

Other constraints: (migration, condensation, sterilization etc…):

Customers site sampling Date: Accepted: Ink validation BU/Operation sampling lab Ref.: Accepted: Repeat for each individual product substrate and or DS Feasibility lab Ref.: Accepted: colour Ink reference : Additive reference : Cleaning solution : Drying system NA MI Customer Comment/Solution : Antistatic precautions NA MI Customer Comment/Solution :

Yes Yes

No No

Yes

No

JOB DESCRIPTION Location : Job window size: Job creation:

Job contents:

On side

Top side

Height:

Bottom side

Neck

Size :

Printer interface Logo Text size 5 , 7, 9 , 11 , 16 , 24 , 32 dots Date Postdate 1 2 3 4 5 6 Counter 1 2 ………15

External interface Shift code Barcode:____ Data matrix QR code Promotional coding

Auto dating Table manual update external update Variables fields

Job example:

MECHANICAL & ELECTRICAL INSTALLATION Customer table Cabinet support & maintenance tray

Markem-Imaje stand / table and Bracket Qty Part n°

Customer bracket Head fixation

will be present Specifications to be send

present & within spec

Description

present

will be present

Markem-Imaje stand / table and Bracket Qty

Part n°

Description

Remarks: draw the production line including the printer and all necessary accessories

ACCESSORIES Cabinet support

Alarm

Customer table

Markem-Imaje stand and Bracket

Markem-Imaje Alarm

Customer’s alarm

3 Lights 24V

Part n°

Acoustic

2 Lights 24V

Part n°

Light

bracket

Part n°

Production line stop

Remarks

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Pre-installation Installation Training ACCESSORIES Manual activation

Job Activation

Markem-Imaje :

Trigger

INC/TRG MESS

INHIBIT TRIG

External customer signal : Qty

Trigger

INC/TRG MESS Part n°

INHIBIT TRIG Description

Product detection

Cell

+Brackets

Bracket Accessory Location (specify in drawing)

Customer encoder

2 cells measurement

MI encoder Qty Speed

measurement

Encoder or Cell

Part n°

Description

Encoder Mounting Bracket Wheel coupling Location (specify in drawing)

Job system Back-up

memory card

(Highly recommended)

Draw the production line including the printer and all necessary accessories

NA

Mandatory

Customer implementation

Present

Will be Present

MI accessory Qty Antistatic

Part n°

Description

Brush Ground strap Mounting Bracket Location (specify in drawing)

SERVICES Service agreements

PREMIUM

SERENITY

use & operating Customer training

LONGEVITY

Advanced maintenance

Number of operator per work shift : Number of work shift :

STANDARD

Number of technician per work shift : On-site training

COMMENTS Additional Information:

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Pre-installation Installation Training 9450 Initial start-up instruction (approximately 30 minutes) An instruction sheet is added in the printer box, you should follow the instructions to ensure an efficiency installation.

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Pre-installation Installation Training Installation Validation Checklist Safety Installation safety compliance (“No smoking” sign, extinguisher, glass…)

 Not Ok

 Ok

Printer has to be installed far from permanent crossing of mobiles or people

 Not Ok

 Ok

No explosive environment and Ventilated location (see instruction manual)

 Not Ok

 Ok

Printer far from source of heat or fire or sparks

 Not Ok

 Ok

Printer has to be connected to suitable power supply & correct earth

 Not Ok

 Ok

Head maintenance tray installed

 Not Ok

 Ok

Presence of pressurization kit if difficult environment (humid and/or dusty)

 Not Ok

 Ok

Plant air clean & filtered if applicable

 Not Ok

 Ok

Presence of positive air pressure pump if dusty environment

 Not Ok

 Ok

No vibration on cabinet, umbilical, print-head and accessories

 Not Ok

 Ok

Machine installed with definitive bracket

 Not Ok

 Ok

Umbilical correctly installed (no vibration, correct bent, no axis rotation and correct speedacceleration if movement…)

 Not Ok

 Ok

Cables correctly attached

 Not Ok

 Ok

Cables not too long (mainly for RS232 connection)

 Not Ok

 Ok

Cable shielding correctly connected

 Not Ok

 Ok

Grounding of machine stands

 Not Ok

 Ok

Stands fixed on the floor

 Not Ok

 Ok

Printing layout validated by the customer

 Not Ok

 Ok

«Tacho step» parameter correctly set according to the tacho encoder installation

 Not Ok

 Ok

If barcode application, the barcode is readable

 Not Ok

 Ok

Production follow-up made

 Not Ok

 Ok

Print test at the maximum speed of the production line

 Not Ok

 Ok

Ensure the encoder is tensioned and making a good & clean contact with the conveyor

 Not Ok

 Ok

Head object distance is correct

 Not Ok

 Ok

The level distance between the head and cabinet is ok (see Ink Running Specification)

 Not Ok

 Ok

No leakage, no fault on the printer

 Not Ok

 Ok

Factory setting set correctly (including installation date and maintenance data)

 Not Ok

 Ok

Printer backup done (printer parameters and messages)

 Not Ok

 Ok

Printer maintenance suitcase complete & available

 Not Ok

 Ok

Printer manuals given and available for operator

 Not Ok

 Ok

Initial operator training supplied

 Not Ok

 Ok

Local MI technical service centre known by customer (phone, fax…)

 Not Ok

 Ok

Ink & additive safety data sheet known and available by the customer

 Not Ok

 Ok

Ink Running Specification sheet known and available by the customer

 Not Ok

 Ok

Consumable storage explained and available

 Not Ok

 Ok

The MI working area is clean after the installation

 Not Ok

 Ok

Installation

Operator information and documentation

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Pre-installation Installation Training 9232 Installation Certificate

Installation certificate

9450 printer

I hereby certify that I have read and acknowledge the Safety Data Sheet and general condition of use of the MARKEM-IMAJE Ink Jet Printer, as they were mentioned on the printer manual. I have noticed the drums of ink; make-up and cleaning solution must be closed and stored in a ventilated room. A copy of the material safety data sheets (MSDS) corresponding to the ink that I am currently using is in my possession and its contents were explained to me by ___________________, the Markem-Imaje Technician who performed the installation.

Yes

No

Operator has received the initial information on the printer





Manuals (instruction, user manual, etc…) have been provided





The user suitcase has been provided





The MI technical service centre is identified





Company Name: _______________________

Date: ________________

Name: _________________________

Signature:

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Pre-installation Installation Training Out Of Box Checking List OOBCL sheet is a web page available here: http://www.markem-imaje.com/services-support/support/oobcl-9450-9410 The rule is: one (1) installation = one (1) OOBCL

The main topics of the OOBCL sheet are the following: OOBCL topics

Description

General Information

Printer configuration Installation conditions FSE contact

Reception :Shipment & Packaging check

To report a logistic complaint

If the start-up takes less than 30 minutes, select NO. STARTING UP as per 9232 initial start-up instruction

If the start-up takes more than 30 minutes, select YES and additional fields will appear : - Ability to enclose log files and / or pictures - Description of the issue (Fault code, type of issue, replaced parts)

How did you fix the issue?

How the issue has been fixed (w/o part replacing)

Sales review

Available for any customer complaint

Remarks

The time spent to complete the installation CAPTCHA field to secure the data Submit button to send the OOBCL A additional button to save the information in case of multiple installation with the same configuration

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Pre-installation Installation Training ■ Customer Training Objectives  TCO reduction,  Printer availability

How customer training can help reaching objectives Most of the downtime under warranty is due to the lack of knowledge. Developing MI culture/values of training will increase customer operator capability to fix quickly minor events. Make operator customer autonomous by the end of the installation. A printer should run at customer site only if the operators are trained. Convince customers that preventive maintenance is important. Train Customer Technician to troubleshoot and replace defective parts by themselves. This will reduce TCO as the customer will only have to pay for the parts, not for a MI technician visit.

Deliverables All deliverables are written in English only and available on Planet. It is possible to export, translate, and import a Word file. Translation can be done locally. ► Short basic Instruction (flipchart format used after installation for retained customer) ► Training package (see the content of each level on the next page):  Basic Training Course  Advanced Training Course  Technical Training Course

What is different with CTP 9450? 9450 brings enhancement that will ease training: ► More consumable details are displayed from main screen (basic T) 

4 consumable autonomy indicators are displayed according with the ink and additive cartridges TAG data (basic T)

► 3 operator profiles are available and configurable (advanced T) 

Daily shut down: one stop type is available (basic T)



New features for the IC management (Technical T)



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Pre-installation Installation Training

Customer Training Package Operator and Technician Customer Short Basic Instruction (*)

Basic training course

Advanced training course

Technical training course

Printer safety rules Printer presentation Consumables identification (ACM)

X X

X X X

X

X

Consumables replacement

X

X

Start-up and shut-down the printer Be comfortable with Touch Screen Create, select and print a message Set message parameters Clean and prepare the print head Replace the ink and air filters Fix common faults

X X

X X X X X X X

Training objectives

Operator profiles config. & manag. Ink jet technology Fonts and resolution Accessories connection Back-up and restore Print head maintenance

X X X X X X

Ink circuit management Electronic circuit management Troubleshooting Parts replacement and adjustment Software update Service policy (maintenance agreement) Quiz Evaluation form

Duration

X

X

X

X X

2 or 3 hours (after installation)

6 hours

6 hours

X X X X X X

6 hours

 Note: Printer installation + Short Basic Instruction will become “Start-up Service”. SBI material used on site should be a “flipchart” . 9450 Book for Service Engineers 80/298

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Pre-installation Installation Training ■ Printer in Demo mode For demonstration purposes the printer can be start up in a DEMO mode. This mode is a special economic mode in terms of ink use at start-up which gives the possibility to start up the printer without using a full cartridge of ink. This mode also includes a draining function upon switching the printer off at the end of a demonstration. NOTES: The printer should be drained before transporting it in any kind of vehicle

Printer start-up Before starting the printer, the demo mode should be enabled in the Start Stop menu.

Once enabled, switch the printer on with the ink and additive cartridges. If the printer contains no ink it will transfer approximately 300cc (≈ 40mm ink level) of ink and fill the additive reservoir (± 150cc). The start-up takes about 10minutes. The printer is now ready for the demonstration. . NOTES: If the printer does contain ink the demo mode does not work, the printer will start-up normally The demo mode will switch automatically to normal mode if the ink level reaches the low level alarm. The printer will transfer the remaining ink of the cartridge. If the demonstration is much ink consuming, it is advisable to remove the ink cartridge once the initial transfer is terminated

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Pre-installation Installation Training Safely transporting the printer

When switching the printer off in demo mode, you will be proposed to drain the additive reservoir into the ink tank. If the printer is supposed to be transported in a vehicle you should answer yes and once the printer is off, drain manually the ink circuit. NOTES: If the ink level is more than 80mm the ink circuit must be manually drained before confirming the drain of additive to the ink tank to avoid overfilling. In demo mode and if pigment ink is used, it is recommended to clean manually the cartridge needle with additive when the ink cartridge is disconnected to the printer.

:

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After-sales

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After-sales Notes:

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After-sales ■ After Sales Policy General policy The after sales policy is based three pillars:

1. Design improvement a. b. c. d.

#1-Printer uptime securing

Print-head automatic clean up facility to limit print-head issue Ink circuit automatic clean up facility Local Printer diagnostic facility to help the customer to fix issue Remote printer diagnostic facility (Log file treatment by MI web tool)

2. Reuse of mature Ink circuit and Print module

1. Faster printer diagnostic

#2-Minimize printer downtime

e. Help to support local repair made by Customer maintenance f. Remote diagnostic facility (log file/log viewer) g. Advanced Management Consumable (consumable)

2. Embedded maintenance sequence a. Clean parts of the Ink circuit/Print head in case of issue

1. Printer support cost a.

Extended warranty period

2. Reduction of production stop #3- Reduce operation cost

a. b. 1. 2.

Automatic Daily clean up Improved startup/stop down process Easy Message change for Batch change Printing quality

3.

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After-sales Spare parts policies

Spare part policy for Ink Circuit The spare part policy is in line with the reduction of the TCO. There are no more complicated modules used, the ink circuit can be repaired at component level by customers and technician (pump, electro valves, filter, sensor….).

Spare part policy for Print Module Some components defined as spare parts of the print module are not suitable for print head maintenance operations at the customer’s site. We identified two (2) types of components for existing Print Module spare parts, relating to each type of intervention: Category 1: Suitable for service at customer site, Category 2: Suitable for service at MI workshop

Category 1: Suitable for service at customer site P/N

ENM46408

ENM40783

Description

Picture

Recommendations

4 Electro Valve Bloc (M/G head)

MI recommends using these parts for Print Module repair at the customer site.

Deflection Plates Kit (G head)

ENM46263

Deflection Plates Kit (M head)

ENM38980

Modulation Assembly GS (G head)

ENM40038

Modulation Assembly GL (G head)

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If changing these parts does not fix the failure, Print Module replacement is recommended

A49725

After-sales Category 1: Suitable for service at customer site

ENM47391

ENM39168

ENM47458

Modulation Assembly (M head)

Print head Board (M/G head)

Cover (including EHT block)

Category 2: Suitable for service at MI workshop P/N

Description

ENM38973

Gutter sensor

ENM38941

Picture

Recommendations

MI recommends using these parts for Print Module repair at a MI workshop only.

Gutter Block

ENR Policy Print module: consult the ENR list (M/G Print Module list)

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After-sales Maintenance policy The printer maintenance is based on 2 shifts (4000 h/year) or 3 shifts (6000 h/year) use. The maintenance is divided in two (2) types of maintenances:

Filter replacements >> Filter kit (A40989) The filter kit replacement has a fixed interval of 18 month and is in-depended of the running hours. In general this kit is replaced by the customer as on-site labour and travel cost are not included in a service agreement. The parts are included

Flushing, Pressure pump & filter replacement >> Maintenance kit (A40846) The maintenance kit has an interval depending of the ink type and is based on the printer running hours.

Service agreements Although the preventive maintenance can be done by the customer, Service agreements are highly recommended during the initial sale and every time when visiting a customer without service agreement.

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After-sales ■ Help desk Simulator A simulator of the printer is available to be able to guide the customer via the phone. This simulator should be installed on a PC. The version of the simulator follows the version of the printer software version. This allows having an exact copy on the pc as the customer’s printer. (See software chapter paragraph simulator for more information). Planet directory: New Technical support►CIJ►9450►Software and firmware download

Printer information When a customer requests a support, it is important to know the useful printer informations (Serial Number, installation date, software version…). Guide the customer: to display the printer information (Tools►Services►Information►Printer).

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After-sales Problem description in SAP Notification It is very important to fill in correctly the tab “Item” when creating a Notification upon a customer call. This information is used for all kind of statistics on local and global level. For this reason we ask the text fields to be filled in English whenever possible. The MI Help Desk (Engineer) fills in the fields “object part”, “problem” and “Text” based on his diagnostic. If no MI Service engineer (on site) intervention is needed, the MI Help Desk (Engineer) should also fill in the fields “Cause” and “Cause text” If an MI Service engineer intervention is needed, he has to fill in the fields “Cause” and “Cause text” when filling in the Service order. When creating a Service Notification, It is possible to select the Product Fault Code displayed on the equipment. First, select the equipment concerned and then select the Fault Code displayed on the equipment as follow.

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After-sales In case of failure of the printer without Fault Code displayed on the equipment, use the generic Problem Code divided into four domains Blocking, Non-Blocking, Other and Safety as follow:

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After-sales ■ On Site intervention When visiting a customer it is important not only to fix and answer, but also to survey the printers behaviour based on the “Printer histories” and propose solutions like for instance extra training.

■ Histories and running status The printer keeps history of several data. The “Printing”, “Availability / Consumption” and “Warning and Faults Histories are saved automatically. The maintenance data is entered manually and keeps track of all the parts changed. It is important when changing any part to enter it. This will help you and or your college upon a next visit.

Printing history

The Printing History enables the customer to consult the number of prints realized according to the job.

Notes: Messages selected by external signals are not recorded

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After-sales Maintenance history The printer has a maintenance record and should be used for each part replacement either by the customer or by a MI engineer. Refer to the operator’s manual for spare parts replacement recording. Always record any parts replaced. The maintenance record helps you and your team for each visit

File When transferring the Maintenance history a file is saved on the destination chosen. - Serial number_MainHistory_0.txt for the current month - Serial number_MainHistory_1.txt for the previous month The files are text files in which the data is semi-colon (;) separated. It can be visualized with Excel.

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After-sales (Printer) Availability (History) Basically, it expresses the time when the printer is available for production in relation to the time the printer is required to be available for production.

The availability is expressed in percentage over a period of one month. The history goes up to 24 months. The printer availability is based on 3 time counters (C1, C2 and C3) C

C1

C2

C3

Name

Description

Printer available (ready) for production

C1 starts as soon as the printer (read ink circuit) is switched on. It measures the time the printer is really available for production. The start-up time of the Ink Circuit is taken into account but not the shut down time of the ink circuit as once you press the off button the printer is no more demanded to be available. Any fault appearing during this time stops this counter. Clearing the fault makes this counter to continue

Printer required to be available

Repair time

Excluded fault Faults which do not stop the counter : 2050 – Head cover absent or not present 4010 – Time out viscosity measurement 4030 – viscosity too high 4040 – No more ink 4050 – No more additive 5120 – Missing plant air The jet ON or OFF has no influence

C2 starts and ends at the same time as C1. It Any fault occurring during this time does measures the time the printer is demanded not stop this counter to be available. C3 starts when C2 stops and faults are still active. It measures the time needed to repair the printer. When the printer is unplugged, the date and time are stored in memory to be able to calculate the real repair time C3 once Powering the printer does not stop this counter. the printer is powered on again. This counter stops when the printer is restarted (read ink circuit) or the fault is cleared.

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After-sales Calculation The printer availability is calculated over a period of one month. Availability = C1 / (C2+C3) A new month starts at 100% Leaving the printer off or unplugged without clearing the faults have a negative influence on the availability. Always switch the printer on after a repair to ensure correct functioning and let C1 > 0 Visualizations hou e w it ly u s

lt

t fau

Dai

Remark: The above diagram will be the same when a fault occurs during the IC stop cycle and or an excluded fault appears during production

op

ith use w Daily

st rinter p a t thou ed wi v l o s be at can ult th

a fa

Remarks: The availability will decrease until the fault is cleared, even if the problem has been solved. The above diagram will be the same when a fault occurs during the IC start or during maintenance operations (Head or IC draining flushing…). The availability is not influenced if a fault occurs during the IC stop phase.

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After-sales FF

se w Daily u

ower O nter p i r p a ult and ith a fa

Remarks: The repair time counter (C3) is not cleared after a power ON. So the availability will decrease until the next printer ON, even if the problem has been solved. Special cases For each month the printer remains off (read ink circuit) with C3 not counting (disabled), the availability will be set to 100%. C1= 0, C2 = 0, C3 = 0  Availability = 0 / (0 + 0) >>

Availability => 100%

For each month the printer remains off (read ink circuit) with C3 counting (enabled), the availability will be set to 0% C1= 0, C2 = 0, C3 = X  Availability = 0 / (0 + X) >>

Availability => -- %

In this case the availability will only increase if C1> 0

(Additive) Consumption (History) The additive consumption is monitored and displayed as an average per month. The Additive consumption is expressed in ml/h and it is refreshed every 10 min (jet on). Otherwise the value is updated upon a jet operation. It restarts at 0mL/h at the beginning of each month. The value of consumption depends on: temperature, ink type and umbilical length.

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After-sales Warnings / Faults (History) This history keeps track of recent faults and warnings (with a maximum of 33 lines) for the last 2 months.

Behind the faults you have a direct link to the “Running Status” with all the relevant data

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After-sales Consumable history This menu history keeps track of the last 100 cartridges (50 inks/50 additives) consumed by the printer. This menu could be consulted by customers.

Cartridge used as Joker (in red) No M-I consumable

M-I Cartridge (in black)

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After-sales Running status (History) file When the printer in powered on, it constantly buffers the printer parameters to create a log file. Approximately every 10 minutes a sample of the printer data is saved. When a fault occurs the preceding 10 minutes are saved. The printer displays a selection of parameters, the complete printer data can be transferred on a SD card or an USB memory stick These files are of extreme use for the development department and should always be attached to any technical claim addressed the TDS department

Approximately every ten (10) minutes

Last ten minutes upon fault

File When transferring the Running status, 2 files are saved on the destination chosen: - Serial number_PrnContexts_0.txt - Serial number_PrnContexts_1.txt Consult section Software - § File transfer for more details for more details about history files.

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After-sales

The files are text files in which the data is semi-colon (;) separated. It can be visualized with Excel.

Recorded printer parameter s

Header data (printer configuration): Printer S/N, head type, ink type, installation date…

The following data can be found in the file: Name

Description

Name

Description

JetSpeed

Speed of the jet (m/s)

ViscoSetPoint

Reference viscosity value

HeadTemp

Temperature in the head (°C)

AdditiveCounter

-

motorSpeed

Speed of the motor (rpm/mn)

tankInkLvl

Ink level in the tank

motorSpeedSetPoint

Reference of the speed motor(rpm/mn)

CKMin

pressure

Pressure of the Jet (bars)

CKMax

Sensor/Jet distance, nominal position offset

pressureSetPoint

Reference pressure of the jet (bar)

Piezo

Reference tension of the piezo

TempHardware

Temperature in the electronic compartment (°C)

BreakOff

Measured break of point

TempInk

Temperature of the ink (°C)

Recup

Rate of recuperation

Viscosity

Viscosity of the ink

FaultList

List of printer faults

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After-sales Start/Stop Log File When transferring the running status file, one (1) file will be added to the running status package that was transferred from the printer. This file is the “PrinterEventFile” which contains the start/stop sequence history of the printer.

This history file allows you to highlighted and erroneous use of the printer.

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After-sales

Repair on customer’s site For Field Service Engineer autonomy, MI provides: ► Troubleshooting guide: Description of faults/alarms with operations to solve them. ► Spare part sheet: Descriptions step by step of operation to replace defective parts. ► Adjustment sheet: Description step by step of operations to adjust parameters. ► List of special spare parts for FSE. ► List of accessories and basic spare parts (Available on Planet).

Technical bulletin In case of product modification/evolution, software release, quality issue… Technical bulletin are sent to the distribution team. Technical bulletins are available on Planet.

Software release For each new firmware release, a technical bulletin is sent to describe the new features and improvement implemented. Firmware files are available on Planet. It is very important the installed base takes advantage / benefits of all improvements included in each new firmware version. The instruction is to upgrade systematically “at the next visit” and to record the printer firmware version in SAP (for SAP countries). Before any upgrade, it is mandatory to pull the running status files of the printer to keep a backup of the events. Firmware retrofit progress will be monitored and measured by local Technical Managers.

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After-sales ■ Escalation process Reporting a technical issue A technical claim is sent to the TDS department, when a technical issue cannot be solved locally either because the expertise is not available or the problem is at development level.

When creating a technical claim it is advised to attach the running status (History) files of the printer to the claim.

Escalation process The reporting of a claim is exclusively done by using JIRA. Main steps of the Process are: The local level 2 escalates the request to TDS ► JIRA if local specialist needs support ► Print Sample if no local facilities to perform the sample

TDS investigates ► Internal database, tests in lab, request to R&E for help.

TDS proposes a solution within 48-72 hours ► Provides answer to Pre / Post sales information requests ► Executes printing sample & send it back with recommendations. ► Provides a short term action (solution or action plan) for claim.

Level 2 validates the proposal ► The L2 confirms acceptance of the proposed solution ► The L2 can request additional investigationis ► The L2 verifies the sample or requests additional samples. ► The L2 validates the proposed short term action ► The L2 requests another if the proposed action is not relevant. (Note: Long term action has to be proposed and validated as well).

Consult section Software - § File transfer for more details for more details about history files.

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After-sales

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Maintenance

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Maintenance Notes:

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Maintenance ■ General Regular maintenance

Replacement

Part Number

Who

Period

Replacement By customers Air & ink filters Filter kit replacement A40989

Air filter

Outlet fan filter

Air filter could be replaced before ink filter in case of dusty environment

Every 18 months

Ink filter

Pressure pump

Air & Ink filter Plus Pressure Pump

ENM5629

Replacement included in a maintenance service agreement or Replacement by customers

Maintenance kit (A40886)

Every 18 Replacement months included in a Or maintenance service Every 14 000 h agreement or (standard ink) Replacement by Every 6 000 h customers (micropigmented ink)

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Every 14 000 h (standard ink) Every 6 000 h (micropigmented ink)

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Maintenance Pressure pump replacement periodicity Due to the high flow in the pump (pressure + vacuum through Venturi), the estimated pressure pump life time is 14 000 hours for standard ink. For Special inks (see SP12) the estimated life time of the pressure pump decreases to 6000 or 8 000 hours according to the printer model.

Pressure pump flow = - Visco measurement + - Venturi system + - Ink pressure in the head

Ink filter replacement periodicity The printer has been designed mainly for 2 shifts (4000 h/year) or 3 shifts (6000 h/year) applications production. So we recommend replacing the ink filter 18 months after installation. It must also be changed every time the pump is replaced.

Ink filter flow = Ink flow in the head

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Maintenance ■ Maintenance alarms For both maintenances the customer is informed through alarms on the screen.

Filter Kit The filter kit replacement has a fixed interval of 18 month and is in-depended of the running hours.4 weeks before the filter kit replacement due-date, an alarm will raise.

4 weeks later

Note: The filter kit is replaced by the customer even when they have a service agreement (Except for special agreements)

Flushing & Maintenance kit Printer flushing and pressure pump replacement periodicity depend on the ink type used. When replacing the pressure pump, ink and air filters are replaced as well. The printer will set the correct interval depending on the ink configuration of the printer.

450 hours later

Notes: The Flushing & maintenance kit replacement is included a service agreement. Printer must be installed eight (8) weeks maximum after its production date. After eight weeks of storage, a printer must be rinsed to be stored again for eight weeks.

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Maintenance ■ Maintenance record & fault clearing Preventive maintenance The maintenance alarms (5210-5230) are only cleared from the list when recording a preventive maintenance in the maintenance record menu of the printer. Following the replacement of the kit, click on preventive maintenance menu of the printer (Services>Maintenance>Maintenance record).

1-Select Preventive maintenance menu

2-Select the corresponding kit

3- Enter the batch number of the kit

Note: The kit is now recorded and can be found in the maintenance history.

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Maintenance Curative operations The record of replaced parts shall be done for curative operations. All replacement of spare parts should be recorded by selecting predefined category of parts or by entering directly the batch number of the parts (Other parts).

Ink Circuit

Electronic

Print Head

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Maintenance ■ Next maintenance alarm reset The counter for the “filter kit” replacement alarm is reset to 18 months when entering the part replacement in the maintenance record as described above. When entering the part replacement of the “maintenance kit” in the maintenance record both counters, “Filter kit” and “maintenance kit “ replacement due-date and hours are reset as the maintenance kit contains the filter kit.

S e e c h a p t e r “ See section Software - § Preventive maintenance data for setting the installation date and or start date of maintenance agreement.

■ Maintenance history When recording the maintenance kit, the history is updated with the relevant data.

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Maintenance ■ Preventive Maintenance Check list (PM) General Information Date: DD/MM/YY

Field Service Engineer:

Service Order:

Company Name:

Printer model:  IP56  IP66

Contact Name: Address / Location:

Software & Version:

Serial #:

Options & Configurations:

# of Shifts Running:

City/State/Zip: Phone (optional):

Unit type:

 Production unit  Backup unit

General Appearance

YES

NO

Line #

Comment

Printer installed correctly. Ensure stands (Cabinet + Print head) are securely mounted. System free from obstructions. Cabinet in Good Condition. Overall appearance of equipment free of damage, clean and complete. Physical Connections secure and in good condition. Printer Currently in Use. Print head in Good Condition.

Environment:

 Dry  Damp  Wet  Hot  Cold  Dirty  Dusty (check all that apply)

Package per minutes : Pre & Post PM Checks Print a Test Image below or attach it to the report Review Print Quality with customer

Pre PM Post PM

Pre & Post PM Checks Print Trigger / Sensors Firmly Mounted, Connected and/or Adjusted Printer Alignment for Straight

Pre PM

Post PM

Prints

Printer Securely Mounted

Unit Functioning Correctly

Encoder or Substrate Speed, measuring device functionality

Overall Cleanliness of System

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Maintenance Flushing & Parts replacement The composition of the preventive maintenance kit A40846 is described in the following table:

Preventive Maintenance Kit

Required Tools

Part Number

No

A40846

No

ENM40209

Procedure

Recovery Tool - Gloves (A) -Adaptor -Caps - Tank 3L with pipe - Flushing pump

Air filter Quantity: 1

Consult User manual

Ink filter Quantity: 1

IP54 Outlet foam filter

Pressure pump Quantity: 1

3 mm Allen Wrench

3/32 Allen Wrench 3mm Allen Wrench, Spanner

ENM19134

ENM40830

ENM5629

Important: Printer should be rinsed prior to start the preventive maintenance, the maintenance includes parts replacement

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Maintenance

Pressurization kit filter

Quantity: 1 Replacement: 6 months (Depends on the air quality, can be adjusted accordingly*

Required Tools

Part Number

No

-

Procedure

Instruction sheet

■ Draining and rinsing recommendation Shut-down > 3 weeks For a printer stop > 3 weeks: the printer must be drained and rinsed. (See draining and rinsing procedure in the user manual) Once drained and rinsed, the printer can be stored away for up to two (2) months.

Storage time > 2 months If the storage time > 2 months, Drain and rinse it again. In storage condition, the printer must be drained and rinsed every two (2) months.

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Maintenance Cleaning and Checks (Wear protective gloves for all cleanings): Required Tasks

Material #

Task Performed

Replacement Recommended

Maintenance kit recorded in the maintenance record (to reset counter)

 Yes

-

Inspect for broken part on print head - recommend replacing

 Yes

 Yes

Clean display, check viewing of the display and touch screen functionality. If display is unreadable or damaged - recommend replacing.

 Yes

 Yes

Check rotation of ink cabinet fan

 Yes

 Yes

General appearance of ink circuit, no leaks, no bended tube

 Yes

 Yes

Adjust pressure pump by-pass (motor speed should be 2000 rpm) Pressure:_________

 Yes

Viscosity: _________

Fault detection: Head cover absent or not detected

 Yes

Jet out of gutter or not detected

 Yes

Drop deviation power supply failure

Advanced Consumable Management

Material #

Task Performed

Check the correct detection of the TAG

 Yes

Check the Joker volume

 Yes

Required Checks

Material#

Checked

Replacement Recommended

Adjustment Needed

Jet stable and centered

 Yes

 Yes

 No

Correct Break-off point

 Yes

 Yes

 No

Head/object distance as specified

 Yes

 Yes

 No

No vibrations on head and cabinet

 Yes

 Yes

 No

Position of umbilical (no vibrations, radius of curvature > 100 mm)

 Yes

 Yes

 No

Correct grounding of cabinet, head and stand

 Yes

 Yes

 No

-

 Yes

-

 Yes  No

-

-

Review current version of operating firmware and upgrade to latest version. Latest mandatory upgrades/improvements installed per TB

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Maintenance

Operational Test after Maintenance Verified

Description



Comments

Printer Start-up correctly with no errors or faults. Ink, verify the ink that is being used is still within its lot shelf life. Old ink may cause poor print quality.

Verified

Description



Comments

Print Registration - After reassembling printer run test prints on customers packaging and verify print is being applied to the correct location and you are able to adjust print position and still maintain print quality for operation. Select different jobs - Select different customer’s jobs and verify that they are selected and correctly printed. Status Beacon & LED System Check - Verify that all power, fault and warning indicators properly illuminate. Print Quality Acceptable to Customer - Is the final print job acceptable for customer’s production?

Comments & Recommendations:

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Maintenance ■ Print head operations This menu allows performing the basic head maintenance operation:

Unblock Nozzle: This function is used when there is no jet or the jet is deviated. Intro. Cleaning Solution: This function is used when the jet is deviated. Check Jet Stability: This function is used when the jet is unstable. Adjust jet: This function is used to set the position of the gutter if the jet is not centered in the gutter Jet stop: Stop only the jet. Not the Ink circuit Jet start: Restart the jet after a Jet stop.

Jet stop/ Jet stop The jet only needs to be stopped when performing maintenance on the print head. Re-start the jet after maintenance operation. Cleaning of the print head: ► Stop the jet. ► If the jet is stopped, the recovery valve is closed to prevent any ink being drawn into the recovery gutter. ► Place the print head vertically on its maintenance tray. ► Clean the print head (modulation assembly, charge electrode, deflection plates, and gutter block) with the cleaning solution. ► If the print head cover is dirty (inside or outside), hold it above the maintenance tray and clean it with the cleaning solution. ► Dry the print head and cover with the drying tool. ► Start the jet and check the jet stability ► If any faults, then place the print head in production position. 9450 Book for Service Engineers 118/298

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Maintenance Unblock Nozzle This function is used when there is no jet or the jet is deviated. There are three (3) phases in the cycle (phase 1-2-3).

B

A

C

D

The Status of the print head valves during these phases are the following:

H6 Pressure (A)

H7 Purge (B)

H8 Additive (C)

H9 Recuperation (D)

Phase 1

Open

Closed

Closed

Closed

Phase 2

Open

Open

Closed

Closed

Phase 3

Closed

Open

Closed

Closed

Phase 2 Phase 1 Phase 3

These phases follow each other automatically and the cycles repeat themselves as long as the “Unblock Nozzle” function is ON. Procedure ► Activate “Unblock Nozzle” operation in the menu ► If the jet appears, activate “Check Jet Stability” operation for approx. 30 seconds and check the jet position. ► If the jet is correct, stop it, clean the print head, dry and re-start the jet. If the jet does not appear within 15 minutes after selecting “Unblock Nozzle” operation, replace the modulation assembly.

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Maintenance Intro. Cleaning Solution This function is used when the jet is deviated. This function has only one phase and does not have a time limit. B

A

C

D

The Status of the print head valves during these phases are the following:

Phase 1

H6 Pressure (A)

H7 Purge (B)

H8 Additive (C)

H9 Recuperation (D)

Closed

Open

Closed

Closed

The pressure in the modulation chamber is negative the entire time the function is on.

Procedure ► Activate “Intro Cleaning Solution” operation in the menu. ► Use the cleaning solution under the nozzle in order to suck additive in the canon (20 seconds, alternatively air/additive) ► Activate “Check Jet Stability” operation for approx. 30 seconds and check the jet position. ► If the jet is correct, stop it, clean the print head, dry and re-start the jet. :

The additive suction can be checked in the print head (blue hose in the ink circuit compartment). Bubbles of air, additive and ink should flow from the conduit to the ink circuit.

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Maintenance Check Jet Stability This function is used when the jet is unstable. This function does not have a time limit.

The Status of the print head valves during these phases are the following:

H6 Pressure (A)

H7 Purge (B)

H8 Additive (C)

H9 Recuperation (D)

Phase 1

Open

Open

Closed

Open

Phase 2

Open

Closed

Closed

Open

Phase 1

Phase 2

The modulation assembly is always supplied with ink. Opening and closing of the drain solenoid valve makes modified the pressure in the modulation assembly, expel the air bubbles and stabilize the jet position in the gutter.

Procedure ► Activate “Check jet Stability” operation for 30 seconds. ► If the jet is correct, stop it, clean the print head, dry and re-start the jet

If it is necessary to replace the modulation assembly, stop the printer and refer to the chapter “Spare parts sheet/Modulation assembly replacement”.

Refreshment This function is used to ensure the same viscosity everywhere in the printer.

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Maintenance

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Troubleshooting

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Troubleshooting Notes:

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Troubleshooting ■ Introduction Before troubleshooting the printer, it is important to:  Know how to operate the printer,  Know what it can and what it cannot do.  Know the basic maintenance operations,  Know the basics of Ink jet,  Have read and understood the chapters of this book: Electronics, Hydraulics and Software The UI (User Interface) provides several screens which can be either passive with only information or active where you can modify a value or activate a component.

■ Profiles To prevent unskilled use of the active screens three levels of profiles are available:

Operators: These profiles are for standard daily use; these profiles are configurable according to the operator skills.

Advanced profile: All functions are available except date modification (Default password “0000”). This profile is able to configure parameters of Operator profiles.

MI profile: All functions are available including a special interface used mainly for development & manufacturing. This interface may be of help for the expert field service engineers. How to activate? (See Software section – MI Engineer profile)

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Troubleshooting ■ Status General status A general status overview of the printer can be obtained using status menu.

Parameters

Description

Jet status

Stopped / Running / Maintenance

Jet speed

Depending on the head configuration (Quality=20m/s or Speed=23m/s)

Pressure

Ink pressure to obtain the required Jet speed (the pressure depends on the ink type, its viscosity, its temperature and the hydraulic resistance) should be between 2,3 and 2,6bars for 20m/s jet speed and 3,2 and 3,4bars for 23m/s jet speed at 20°C

Motor speed

Motor speed to obtain the ink pressure (the speed is directly related to the pressure required for the jet speed) The efficiency of the pressure pump and thus the motor speed can be adjusted with the by-pass (~2000rpm)

Ink temperature

The temperature of the ink at the ink circuit level. It should be within the range according to the IRS of the ink used in the printer

Head Temperature

The temperature measured on the head board. It should be within the range according to the IRS of the ink used in the printer.

Printer counter

Number of prints done so far

Viscosity reference

It is the optimum viscosity the ink should have expressed in seconds. This value is ink and temperature related and used for the viscosity management

Viscosity

Actual viscosity of the ink. It should be close to the viscosity reference. If Viscosity >0, 3 sec above the reference  addition of additive to lower it If Viscosity < 0, 3 sec than the reference  the printer cannot interfere The value will automatically increase when the printer is running as the additive contained in the ink evaporates. Temperature change has a direct influence on the viscosity: When the temperature drops  the viscosity increases. When the temperature raises  viscosity decreases.

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Troubleshooting Parameters

Description

Recuperation level

Value representing the flow of ink/air in the gutter (measured in the gutter) Normal running values is between 250 and 700. When the ink jet is well centered in the gutter, a low value indicates a good suction and a high value a poor suction.

Piezo value

The voltage on the piezo to obtain controlled drop creation. This value is automatically calculated by the printer when launching the “Adjust break-off point” function. It can also be set manually in the MI-engineer interface. A count is equal to 0, 8 volt

Active phase number

A number between 0 and 11 indicating the phase used for optimum drop charge. Twelve phases are available (0-11). The phase giving the optimum drop charge is permanently calculated and adjusted if necessary. The number used does not indicate good or bad. A constant fluctuation of +/- 2 is normal. The break-off point and the jet alignment between the charge electrodes should be correct for good functioning of the automatic optimum phase calculation. A Bigger / unstable fluctuations indicate a problem which can be related to: head cleanness, adjustments, ink quality, or to a hydraulic / electronic problem

Ink level

The level of ink in the ink circuit measured in mm. The ink level is used for the viscosity management and the autonomy calculation. When the level drops below 30mm the printer will transfer the contents of a full cartridge to the ink circuit (in several steps). At 10mm the printer shuts down automatically to prevent hydraulic damage. At 15mm a second warning is raised to indicate that the ink cartridge should be replaced. At a first start-up after installation or draining + flushing, the ink level is around 90 mm after 1hour. When the ink cartridge is replaced at the first warning (30mm) the ink level is around 120 mm after 1hour.

Printer counter

The number of hours the printer has being powered on (mains connected).

Ink circuit counter

The number of hour the ink circuit has been running so far (printer on).

Filter kit replacement

The date the filter kit is due to be replaced. The replacement interval is 18 month for all inks. Four weeks before, the printer will warn the operator. The counter is set for the next 18 month at the date the parts are acknowledge in the maintenance record.

Maintenance kit replacement

The number of hours left before the maintenance kit should be replaced. The replacement interval depends on the ink: standard inks = 140000 hours and special inks = 6000/8000 hours interval. The counter is reset at the date the parts are acknowledged in the maintenance record. The Filter kit counter is reset as well as they are included in the maintenance kit.

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Troubleshooting ■ Maintenance menu The maintenance menu allows performing: 

Print head and Ink Circuit maintenance operations,



Draining and flushing operation,



Recording the maintenance operations,



Inhibition of faults.

Ink Circuit Maintenance menu This menu allows manipulating: 

Each individual active parts of the Ink Circuit (electro valves, transfer pump),



Each electro valve from the 4 electro valve block (Print Head), This menu gives also the status of main printer parameters (Pressure, motor speed, ink temperature, ink level and viscosity value)

Important Note: To manipulate this menu, it is very important to fully understand and have in mind the hydraulic scheme. For example, it is strictly forbidden to activate P1 if IC3 is in position 2-3

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Troubleshooting Ink Circuit Overview All parts are electrically controllable.

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Troubleshooting Print head Maintenance menu This menu is dedicated to the maintenance operations of the Print Head and it is divided in two sub menu:  “EV maintenance” includes an automatic cleaning sequence in case of blockage.  “All operation” which is a link to standard and specific maintenance operations.

EV maintenance is dedicated to clean/unblock electrovalves or modulation assembly in the print head. It includes the following automatic sequences:

 Ink level (tank) measurement  Unblocking ink EV  Unblocking nozzle (ink EV open)  Unblocking nozzle (additive EV open)  Unblocking and cleaning vacuum EV Note: This sequence can be activated in two (2) ways: Manually by selecting the “EV maintenance” icon in the head Maintenance menu or automatically for a 2060 Fault by selecting “Fix issue”.

All operations include the tools dedicated to the “standard” maintenance operations on the Head (Nozzle unblocking, Check stability, additive Introduction...etc.) plus an extra maintenance tool (Unblock gutter) to specifically unblock the gutter valve.

.

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Troubleshooting

This automatic sequence could be used if the recuperation Valve (H9) is still blocked after a manual activation  The motor speed is set to the speed reference (2000 rpm),  The Valve 4-Anti-pulse additive (IC4) is switched in 1-2 position,  The Valve 5-Additive supply (IC5) is switched in 2-3 position,  The Transfer Pump P2-Additive is activated,  The Valve 8-Additive (H8) is activated,  The Valve 9-Recup (H9) is activated and de-activated alternatively, 

After 3 minutes, the Transfer Pump P2-Additive is stopped and H9 is de-activated

 The Valve H8-Additive is de-activated,  The Transfer Pump P2-Additive is stopped,  The Valve 4-Anti-pulse additive is switched in 2-3 position

Note: Recuperation Valve is still blocked > Change the 4-ELV Block

Do not repeat the procedure > it could degrade the viscosity of the ink and induce overflow in the ink circuit.

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Troubleshooting The structure of the head maintenance menu is as follow:

Step1: Unblocking ink EV Step 2: Unblocking nozzle (ink EV open) Step 3: Unblocking nozzle (additive EV open) Step 4: Unlocking and cleaning vacuum EV

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Troubleshooting ACM information (TAG) From the MI Engineer menu, it is possible to consult the information about the consumable.

MI Data

Ink-UID

Remaining Joker volume: It is expressed in percentage of ink + additive volume available. The Joker volume is activated and decremented in case of non-detection of a cartridge (Alarm 4670/4680). The Joker volume is decremented by taking into account the ink transfer flow of the ink transfer pump. The joker volume is fixed at 8 litters (100%). - If MI data = 12.5%  Alarm 4730 Consumable issue - If MI data = 0  Alarm 4740 Critical consumable issue. The printer stops to pump the cartridge and works in autonomous mode. Unique Identification Number: MI identification number of the cartridge The printer records the last 50 UID (50 cartridges) consumed by the printer (refer to Logfiles). If a new cartridge have a UID already recorded  Fault“4690 Ink already used” is displayed If the UID is not a MI UID  Fault “4650 Ink Cartridge unknown” is displayed

Ink-RSSI

Received Signal Strength Indication: is the measurement of the power present in the received radio signal from the cartridge. The power range is [0; 7]. If Ink-RSSI = 0  No signal is received from the cartridge If Ink-RSSI = 7  the signal received from the cartridge is maximum

Ink-Cartridge batch number

Batch number of the additive cartridge

Ink-Reference

Reference of the Ink. Consult SP12 and IRS for more information about compatible ink.

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Troubleshooting Ink-cartridge expiration date

Expiration date of the cartridge Expiration date (– 1 month)  Alarm “4750 - Ink cartridge will soon reach the expiration date”. Expiration date  Alarm “4770 - Ink cartridge reached the expiration date”. The printer still pumps ink in the cartridge (no functional effect). Expiration date (+1 month)  Alarm “4790 - Ink cartridge reached the expiration date. The printer stops pumping in the cartridge until the ink level in the tank is empty.

Ink-remaining volume (cc)

Quantity of remaining ink into the current cartridge in cubic centimetre. A full cartridge is equal to 800cc.

Unique Identification Number: MI identification number of the cartridge The printer records the last 50 UID (50 cartridges) consumed by the printer (refer to Logfiles). Additive-UID

If a new cartridge have a UID already recorded  Fault“4700 Additive already used” is displayed If the UID is not a MI UID  Fault “4660 Additive Cartridge unknown” is displayed

Additive-RSSI AdditiveCartridge batch number AdditiveReference

Additivecartridge expiration date

Additiveremaining volume (cc)

Received Signal Strength Indication: is the measurement of the power present in the received radio signal from the cartridge. The power range is [0; 7]. If Additive-RSSI = 0  No signal is received from the cartridge If Additive-RSSI = 7  the signal received from the cartridge is maximum Batch number of the additive cartridge Reference of the Additive. Consult SP12 and IRS for more information about compatible ink. Expiration date of the cartridge Expiration date (– 1 month)  Alarm “4760 - Additive cartridge will soon reach the expiration date”. Expiration date  Alarm “4780 - Additive cartridge reached the expiration date”. The printer still pumps ink in the cartridge (no functional effect). Expiration date (+6 month)  Alarm “4800 - Additive cartridge reached the expiration date. The printer stops pumping in the cartridge until the ink level in the tank is empty. Quantity of remaining additive into the current cartridge in cubic centimetre. A full cartridge is equal to 800cc.

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Troubleshooting Safety reminder

To replace hydraulic parts in the ink circuit: The printer must be drained and unplugged from the main supply Use individual protection equipment

For basic maintenance operations on Print head: The print head must be placed on a maintenance tray Use individual protection equipment

To replace hydraulic or electronic parts in the print head: The printer must be stopped and unplugged from the main supply The print head must be placed higher than the printer cabinet Use individual protection equipment

To replace electronic boards in the printer: The printer must be stopped and unplugged from the main supply

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Troubleshooting

Troubleshooting tables

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Troubleshooting Number 0010 0020 0021 1000 1010 1020 1040 1500 1510 1520 1530 2000 2010 2020 2030 2040 2050 2060 2061 2070 2500 2510 2520 4000 4010 4020 4030 4040 4050 4060 4070 4080 4090 4100 4110 4120 4130 4140 4150 4160 4500 4510 4512 4520 4530 4540 4560 4570 4580 4590 4630 4640

Code Text

Type

Fault/alarm history corrupted Time/Date corrupted (RTC initialisation error) Unable to communicate with Print Unit via internal communication channel. Font used not available Algorithm used not available Trigger detected during printing Invalid job content Incorrect print speed Backup time too long for data flash Duplicate print attempt Print speed too low Communication error with print head Drop creation power supply failure Drop charge power supply failure Drop deviation power supply failure Electro valves power supply failure Head cover absent or not detected Jet not detected Jet out of gutter Drop (phase) detection Communication error with print head Jet not well positioned Adjustment break-off point interrupted. Time out emptying measurement chamber Time out viscosity measurement Ink level too high Viscosity too high No more Ink No more additive Cooling fan Failure Ink transfer pump blocked (P1) Additive transfer pump blocked (P2) Drain pump blocked (P3) Technology board electronic fault Technology board: ELV power supply fault Draining fault Level Sensor out of specification Previous Printer shutdown not complete Ink cannula clogged EV1 duct clogged Low additive level Low ink level Ink cannula clogged Time out ink level measurement Ink pressure out of range Motor speed out of range Ink temperature too high Viscosity too low Critical Ink Level Ink level too high Additive pressure too low Additive pressure too high

warning fault fault fault fault fault fault warning warning warning warning fault fault fault fault fault fault fault fault fault warning warning warning fault fault fault fault fault fault fault fault fault fault fault fault fault fault fault fault fault warning warning warning warning warning warning warning warning warning warning warning warning

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Link 0010 0020 0021 1000 1010 1020 1040 1500 1510 1520 1530 2000 2010 2020 2030 2040 2050 2060 2061 2070 2500 2510 2520 4000 4010 4020 4030 4040 4050 4060 4070 4080 4090 4100 4110 4120 4130 4140 4150 4160 4500 4510 4512 4520 4530 4540 4560 4570 4580 4590 4630 4640

A49725

Troubleshooting Number 4650 4660 4670 4680 4690 4700 4710 4720 4730 4740 4750 4760 4770 4780 4790 4800 5000 5010 5020 5030 5040 5050 5060 5070 5080 5090 5100 5110 5120 5130 5140 5150 5160 5271 5295 5298

Code Text

Type

Ink cartridge unknown Additive cartridge unknown Ink cartridge not detected Additive cartridge not detected Ink cartridge already used Additive cartridge already used Invalid ink cartridge reference Invalid additive cartridge reference Consumable issue Critical consumable issue Ink expiration date will be reached soon Additive expiration date will be reached soon Ink expiration date reached Additive expiration date reached Ink expiration date over Additive expiration date over Invalid production settings file (Default used) Time out on print unit initialisation Unable to save production settings Invalid printer settings file (Default used) Unable to save printer settings Printer Initialisation FAILED Unable to initialise the PU system DATA Unable to initialise the PU Machine DATA Printer can't execute the command here Unable to save printer functioning data low additive autonomy Critical additive autonomy Missing plant air External Communication Time Out External Communication Data Fault internal SD card test failed Unexpected procedure abortion USB stick probably not connected USB stick no file found for the job USB Unique coding unexpected variable number

warning warning warning warning warning warning warning warning warning warning warning warning warning warning warning warning fault fault fault fault fault fault fault fault warning warning warning warning fault warning warning warning warning fault Alarm fault

9450 Book for Service Engineers 138/298

Link 4650 4660 4670 4680 4690 4700 4710 4720 4730 4740 4750 4760 4770 4780 4790 4800 5000 5010 5020 5030 5040 5050 5060 5070 5080 5090 5100 5110 5120 5130 5140 5150 5160 5271 5295 5298

A49725

Troubleshooting ■ Error code & Troubleshooting chart In the table here after: “A” means Alarm (printing is possible) “F” means Fault (printing is impossible) The template of the troubleshooting table is the following:

According to the after sales policy for the print module, the TS STEPS are divided in two (2) categories as follow: TS Steps Categories

Symbol

Description The spare part to be changed is suitable for service at customer site.

Category#1

In the troubleshooting charts, the TS steps with the manufacturer symbol means that TS steps are authorized for break fix at customer site. (Only the 4ELV block, the modulation assembly or the EHT plates should be changed at customer site. If another component is defective, the complete print module should be replaced. The spare part to be changed is NOT suitable for service at customer site.

Category#2

In the troubleshooting charts, the TS steps with the home symbol: for break fix activity in workshop only;

(these operations are too difficult to be performed at customer site and should be performed in a MI workshop)

9450 Book for Service Engineers 139/298

A49725

Troubleshooting Troubleshooting Tables 0000 – 0999 NEP 9450

Fault/alarm history corrupted

INCIDENT

The fault and alarm history is emptied.

PROBLEM

The fault and alarm history is emptied.

CAUSE TS STEPS

9450

Power cut Cause: The Fault/alarm history has been erased due to the power disruption Action: The history file cannot be recovered, and a new file has been started. No action required

Time / Date corrupted RTC initialisation error

INCIDENT

No printing. Date is reset to 01-01-2008

PROBLEM

The system date is now set to 01-01-2008; the date previously had been OK.

CAUSE TS STEPS

0010A

0020F

Initialization error Lithium Battery on NEP board is out of order Cause: Check if time and date are correct [Setting ► Printer ►Date / Time] Action: Enter the correct time and date; save and exit. Cause: Lithium Battery on NEP board is out of order Action: Change the battery, Standard Model CR1220-3V

9450

Unable to communicate with Print Unit via internal communication channel

INCIDENT

Communication error

PROBLEM

The printer does not start up

CAUSE

TS STEPS

0021F

Volatile memory error - Channel in blocked state Software error Defective NEP board Cause: Check if error is permanent (hardware) Action: Disconnect the printer from AC power and reconnect Cause: Check if error is permanent (hardware cause) Action: Re-install software Cause: Defective NEP board Action: Replace NEP board and test

9450 Book for Service Engineers 140/298

A49725

Troubleshooting 1000 – 1499 Faults Printing 9450

Font used not available

1000F

INCIDENT

The selected message or the message received via external communication contains one or more fonts which are not available in the printer.

PROBLEM

The message cannot be printed.

CAUSE

TS STEPS

Required fonts are not available in the printer, or the font file is damaged. The Host Computer providing the font(s) for the message is offline, or the connection with the 9450 has failed Cause: Required fonts are not available in the printer Actions: Download the missing fonts used in the current message into the printer Delete the message and create a new message with existing fonts Cause: The Host computer providing the font(s) is offline or connection has failed Action: Check the communications with the host computer providing the fonts

9450

Algorithm used not available

1010F

INCIDENT

The selected message or the message received via external communication contains an algorithm which is not adapted to the print speed

PROBLEM

The message cannot be printed.

CAUSE TS STEPS

Print parameters are incorrect for this job Cause: Check and correct settings of print parameters Action: Modify job settings of the current message & if needed for future job/message [Setting ►Job/variable or Setting ►Printing]

9450

Job selected not available

INCIDENT

The printer receives a trigger (print go signal) during printing sequence.

PROBLEM

The message cannot be printed.

CAUSE

1020F

Position cell <> Print head Bad printer/ job settings Defective trigger Line noise interference from external devices connected to serial link

TS STEPS Cause: Position cell <> Print head Action: Decrease physically distance between cell and print head

9450 Book for Service Engineers 141/298

A49725

Troubleshooting 9450

Job selected not available

1020F

Cause: Bad printer/ job settings Action: Check job settings & print parameters [Setting ►Job/variable /Printing] Change the setting and test, check the message length, check the tacho division… Cause: Defective trigger Actions: Check electrical connection of tacho/cells. Replace tacho or cell and test. Causes: Line noise interference from external devices connected to serial link Actions: Check continuity of ground between printer, print head, conveyer, external device connected through RS232: Check with a scope that line noise interference does not disturb the printer (on serial link RS232 for instance).

9450

Invalid job content

INCIDENT

The selected message contains an invalid barcode input

PROBLEM

The message cannot be printed.

CAUSE TS STEPS

1040F

Wrong Data or inappropriate data defined in the Job Causes: Wrong Data or inappropriate data defined in the Job Actions: Check the correctness of the Job content (Rules are defined for barcode).

9450 Book for Service Engineers 142/298

A49725

Troubleshooting 1500 – 1999 Alarms Printing 9450

Incorrect print speed

INCIDENT

Printing speed too high with tachometer.

PROBLEM

Incorrect horizontal printing

CAUSE

Tacho division is not correct

TS STEPS

1500A

Causes: Tacho division Actions: Increase the tacho division [Job ► Job Setting]

9450

Backup time too long for data flash

INCIDENT

Backup time too long for data flash

PROBLEM

Not defined

CAUSE TS STEPS

1510A

Software bug Defective NEP Causes: Software issue Actions: Restart the printer Causes: Defective NEP board Actions: Change the NEP board

9450

Duplicate print attempt

INCIDENT

Two (2) required conditions: -“ Non double print” activated - 2 consecutive trigger received for the same message

PROBLEM

The second trigger is not taken into account.

CAUSE TS STEPS

1520A

Not defined Causes: Bad message timing Actions: Check timing of message sending versus trigger signal (Dtop) Causes: Bad printer configuration Actions: Deactivate the “Non double print” or/and the promotional coding option in the factory setting (if option is not used)

9450

Print speed too low

INCIDENT

Print speed measurement by cell (condition) The calculated print speed is too low to be treated ( time out)

PROBLEM

Incorrect print resolution

CAUSE TS STEPS

1530A

Print Speed setup is incorrect Causes: Print Speed setup is incorrect Actions: Check and correct setup for print speed measurement by cell(s)

9450 Book for Service Engineers 143/298

A49725

Troubleshooting 2010 – 2499 Faults Print Head 9450

Drop creation power supply failure

INCIDENT

The Head Board has encountered a fault to supply the 80V to the piezo

PROBLEM

No print

CAUSE

2010F

Dirty Print Head Defective Modulation Assembly Defective Print Head Board

TS STEPS

Causes: Dirty Print Head - Check cleanness of the Head Actions: Clean and dry the Head. Causes: Defective Modulation Assembly Actions: Replace the Modulation Assembly and test. Causes: Defective Print Head Board Actions: Clean the Print Head Board (ink deposit) and test it. ► If still fault, Replace the Print head board ► If still fault, Replace the Print Module

9450

Drop charge power supply failure

INCIDENT

The Board head has encountered a fault to supply the 350V for the drop charge.

PROBLEM

No print

CAUSE TS STEPS

2020F

Dirty Print Head Defective Print Head Board Causes: Dirty Print Head : Dirty charge electrode Actions: Clean and dry the charge electrode. Causes: Defective Print Head Board Actions: Clean the Print Head Board (ink deposit) and test it. ► If still fault, Replace the Print head board ► If still fault, Replace the Print Module

9450 Book for Service Engineers 144/298

A49725

Troubleshooting 9450

Drop deviation power supply failure

INCIDENT

Power consumption too high to create the Very High Voltage.

PROBLEM

No print

CAUSE

Defective or dirty EHT plate Defective Print Head Board Defective cover head (EHT block)

2030F

Causes: Defective or dirty EHT plate Actions: Clean and dry the Head. ► If still fault, Remove the left EHT plate and active the EHT plate from UI: [Services ►MI Engineer ►IUI for lab ►Head] and Switch ON the EHT.

► If no more fault, Replace the EHT plate; Re-adjust the break-off point. Causes: Defective Cover head Actions:

TS STEPS

► Replace the Head cover (including the EHT block) and test. ► If still fault, Replace the Print Module. Causes: Defective Print Head Board Actions: Visual inspection of the Print Head Board, ►

In case of ink deposit on board, clean it and test.

►

If still fault, Replace the Print head board,

►

If still fault, Replace the Print Module.

9450 Book for Service Engineers 145/298

A49725

Troubleshooting 9450

Electro valves power supply failure

INCIDENT

Pulse width modulation (hold tension of electro valve missing)

PROBLEM

No print - Electro valve power cut

CAUSE TS STEPS

2040F

Defective 4 ELV block Defective Print Head Board Causes: Integrity of the 4 ELV block electrical connection/Defective 4ELV block

Defective Print Head Board or connection Actions: Clean the connection board of the 4 ELV block if ink deposit on it and test. ► If still fault, Replace the 4 ELV block and test, ► If still fault, Check the electrical connection 4 ELV block<> Print head board ► If still fault, Replace the Print head board ► If still fault, Replace the Print Module

9450

Head cover absent or not detected

INCIDENT

No signal from cover sensor For safety reasons, the HT is off when the head cover is removed.

PROBLEM

No print

CAUSE TS STEPS

2050F

Defective magnet of head cover Defective (magnet) sensor Causes: Defective magnet of head cover - Check working of the magnet Actions: Simulate the head cover presence: Switch OFF the EHT [Services ►MI Engineer ► IUI for lab ► Head]. Hold a magnet against the recuperation assembly. Start the jet. ► If the stroboscopic led lit off, Replace the cover Causes: Defective sensor - Check working of the magnet sensor Actions: Check electrical connection Gutter block<>Print Head Board (flat cable). ► If connection is OK, Replace the Gutter block and test.

► If still fault, Replace the Print Module

9450 Book for Service Engineers 146/298

A49725

Troubleshooting Notes The fault 2060 is composed of two (2) faults: 2060 – Jet not detected & 2061-Jet out of the gutter, according to the jet status: we consider that the potential root cause are not the same.

2060/2061

2060-Jet not detected / 2061-Jet out of gutter

Fault 2060 during the starting up of the jet: The default is potentially due to a blockage of an electro valve after a printer shutdown. In this case, the printer proposes to fix this issue by starting the automatic “EV maintenance” sequence. Note: In case of unsuccessful of the procedure, perform the operations of the troubleshooting guide.

Step1: Unblocking ink EV Step 2: Unblocking nozzle (ink EV open) Step 3: Unblocking nozzle (additive EV open) Step 4: Unlocking and cleaning vacuum EV

Fault 2061 when the jet is running: To fix automatically this fault, a specific sequence could be launched by using the fix issue button.

Step 1: Unblocking nozzle (ink EV open) Step 2: Unblocking nozzle (additive EV open) Step 3: Unlocking and cleaning vacuum EV

9450 Book for Service Engineers 147/298

A49725

Troubleshooting 9450

2060-Jet not detected / 2061-Jet out of gutter

2060F/2061F

INCIDENT

The recovery detector did not detect the jet in the gutter or the detection was too weak or detect ink overflowing

PROBLEM

Jet stopped – No Print

CAUSE [Services ► Maintenance ► Fault override] Recuperation fault = inhibit Head cover fault = Inhibit

[Services ► Maintenance ► Head operations] Perform jet stability check

Perform a visual inspection of the jet, 4 cases:

Case#1 Jet is out of the gutter Case#2 No jet Case#3 Jet stable in the gutter with correct suction Case#4 Jet overflow

CASE#1 (FAULT 2060 DETECTED): JET IS OUT OF THE GUTTER Cause: Dirty nozzle plate, defective Modulation Assembly Actions: Perform maintenance and cleaning operations on the Print Head: Unblock Nozzle, check stability….. Use the user manual and the printer menu : [Tools ► Head operations] ► If still fault, replace the Modulation Assembly and test, ► If still fault, replace the Print Module.

CASE#1(FAULT 2060 NOT DETECTED): JET IS OUT OF THE GUTTER Causes: Jet not well positioned, dirty gutter sensor, sealing failure (Gutter sensor) Actions: ► Replace the Print Module ► Replace the Gutter Sensor UI: Go to [Services ► MI Engineer ► IUI for lab► Head] and perform the command “Jet start with additive” followed by the command “Jet stop with additive” in order to eliminate all residual ink.

9450 Book for Service Engineers 148/298

A49725

Troubleshooting 9450

2060-Jet not detected / 2061-Jet out of gutter

2060F/2061F

CASE#2 NO JET (INK IS UNDER NOMINAL PRESSURE) Causes: Clogged Nozzle plate OR Defective 4ELV block Actions: Perform maintenance and cleaning operations on the Print Head: Unblock Nozzle, check stability….. Use the user manual and the printer menu : [Tools ► Head operations] Note: Refer to IRS if a specific cleaning is required regarding the ink type. Check functionality of the Pressure valve: UI: Go to [Services ► Maintenance ► Ink circuit] and test the pressure valve H6, If no piston slaps: ► Replace the 4 ELV block and perform stability check. ► If still fault, replace the Modulation Assembly, ► If still fault, replace the Print Module.

CASE#3 JET OVERFLOW Causes: Defective 4ELV block, dirty suction, Venturi or Print Module blocked Actions: Check if the Recuperation valve H9 is not blocked. UI: Go to [Services ► Maintenance ► Ink circuit]. To unblock it : Perform a manual EV unblocking: press and hold down the valves command or launch automatic sequence “EV maintenance”. ► If still blocked, Replace the 4ELV block and perform stability check Note: Check if start/stop sequence are correctly performed by customer. (Start / Stop Log File) If the H9 = not blocked and no ink suction, perform a manual draining of the printer: ► Dismount the VENTURI and clean it. ► If still fault, replace the Print Module

9450 Book for Service Engineers 149/298

A49725

Troubleshooting 9450

2060-Jet not detected / 2061-Jet out of gutter

2060F/2061F

CASE#4: JET IN THE GUTTER WITH CORRECT SUCTION (NOT DETECTED OR INCORRECT DETECTION)

Case#4-1: Jet in the gutter, no overflow & Recuperation level > 800 Causes: Defective 4ELV – Gutter sensor Actions: Inhibit the Recuperation fault [Services ► Maintenance ►Fault override] Start the Jet and stop the Pressure valve H6 in order to stop the jet [Services ► Maintenance ► Ink circuit] Check the recuperation level [tools ►Head Operation]

If Recuperation level is still high (>100)

If Recuperation level is low [ 100]

Causes: Defective 4ELV contact (ink Causes: Dirty gutter sensor or sensor sealing deposit, poor contact...) or connection. failure. Actions: Actions: Dismount the 4ELV block & check the cleanness of the connection. If ink pollution clean it and test. ► On site, Replace the Print Module

► If still fault, Replace the Print Module ►

Replace the gutter sensor with its seal

Case#4-2: Jet in the gutter and Recuperation level <1 Cause: Gutter sensor & the Print Head board: defective connection. Actions: ►

On site, Replace the Print Module

Check if there is no short circuit between sensor spring contact and support plate. Check if the insulation part which protects the sensor spring contact is not broken or not mounted correctly.

9450 Book for Service Engineers 150/298

A49725

Troubleshooting 9450

Drop (phase) detection

INCIDENT

No Drop (phase) detection

PROBLEM

Jet stopped – No Print

CAUSE TS STEPS

2070F

Incorrect Ink parameters/Dirty print head Defective break off point / Modulation assembly/Gutter block connection Cause: Incorrect Ink or parameters Actions: Check the ink parameters. Check ink/additive in the printer parameter [Services ►Information ►printer] Check the quality, the viscosity parameters. Cause: Dirty Print Head Actions: Perform maintenance plus cleaning operations on the print head (Unblock Nozzle, check stability…). Use the menu: [Tools ►Head operations] Cause: Bad Break Off Point Actions: Perform an automatic Break off point (check if the jet speed is correct) ► If still fault, Replace the Modulation Assembly Cause: Defective Modulation assembly: No drop!

B

Actions: Test of ground continuity (< 10 Ohms): between Modulation assembly body (B) and the screw at the left (A). ► Continuity is NOK  Check the tightening of the screw A

► Continuity is OK  Change the Modulation Assembly Cause: Defective Modulation assembly: Bad break off point! Actions: Test the continuity Print Head Board<>Modulation assembly (Screw A <>Screw B).

A

► If continuity is OK, Replace the Modulation Assembly ► If continuity is NOK, Replace the Print head ► If still fault, Replace the Print Module

B

Cause: Defective gutter block connection/Gutter block Actions: Check the connection with the Print Head Board (flat cable) ► If connexion is OK, Replace the gutter block ► If still fault, Replace the Print Module Cause: Defective Print Head Board/Ink pollution on head Actions: Clean the Print Head Board (ink deposit) and Test ► If still fault, Replace the Print Head Board ► If still fault, Replace the Print Module

9450 Book for Service Engineers 151/298

A49725

Troubleshooting 2500 – 2999 Alarms Print Head 9450

Communication error with print head

INCIDENT

Received data not updated except drop charge set to 0 when printing

PROBLEM

No print or incorrect print

CAUSE TS STEPS

2000F/2500A

No communication between technology board and Print Head Board Cause: No communication Technology board Print Head Board Actions: Check electrical connections (umbilical) From umbilical to print head From umbilical to technology board ► If still fault, Replace the technology board

9450

Jet not well positioned

2510A

INCIDENT

Amplitude of drop charge is too weak / strong (forward / backward) and/ or Jet speed measurement out of limit (left / right)

PROBLEM

The print may be of bad quality. The print head may get dirty.

CAUSE TS STEPS

Dirty head Defective Modulation assembly Cause: Dirty head or defective Modulation assembly Actions: Check the cleanness of the head [Tools►Head operations] Perform maintenance plus cleaning operations on the print head (Unblock Nozzle, check stability….). ► If still fault, Replace the Modulation Assembly

9450

Incorrect break of point adjustment, jet maintenance advised

INCIDENT

The print head status is not consistent to perform a break off point.

PROBLEM

Incorrect print

CAUSE TS STEPS

2520A

Dirty head /Jet not stable Defective modulation assembly Cause: Dirty head or defective Modulation assembly Actions: Check the cleanness of the head [Tools►Head operations] Perform maintenance plus cleaning operations on the print head (Unblock Nozzle, check stability….). ► If still fault, Replace the Modulation Assembly

9450 Book for Service Engineers 152/298

A49725

Troubleshooting 4000 – 4499 Faults Ink Circuit 9450

Time out emptying measurement chamber

4000F

INCIDENT

The pressure transmitter did not sense the empty threshold level (atmospheric pressure reference value) within the predefined time.

PROBLEM

The printer stops immediately with a correct head shut down procedure.

CAUSE

TS STEPS

High pressure variations in the IC Clogged hose Defective or clogged parts of the IC Cause: High pressure variations in the IC Action: Check the vapour outlet circuit for any obstruction Cause: Clogged hose Action: check if the hose does not blow on top of the level sensor CP1 (IP66 version) Cause: Defective or clogged parts Actions: Check functionality of parts of the IC ► Check working of transfer Pump P1 and electro valves Ev1 [Services►Maintenance►Ink circuit maintenance] ► Check electrical connections of pump P1 & Electro valves IC1 If one is defective part: Drain the printer & replace It.

9450

Time out viscosity measurement

4010F

INCIDENT

Either the low or high level viscosity threshold where not reached within the predefined time.

PROBLEM

The printer stops immediately with a correct head shut down procedure.

CAUSE TS STEPS

Constant level electro valve (Ev2) : Defective or clogged Viscosity restrictor or Calibrated leak or Filtering connector clogged Cause: Defective or clogged Ev2 - Check functionality of parts of the IC Actions: Check electrical switching of IC2 [Services►Maintenance►Ink circuit maintenance] ► Check electrical connections of IC2 If EV2 is defective part: Drain the printer & replace It. Cause: Viscosity restrictor or Calibrated leak or Filtering connector clogged Action: Clean the filter and the calibrated leak Drain the printer, dismount calibrated leak 0,25mm; filtering connector connected and clean them.

9450 Book for Service Engineers 153/298

A49725

Troubleshooting 9450

Ink level too high

INCIDENT

The maximum ink level (135mm) has been reached.

PROBLEM

The printer stops immediately.

CAUSE TS STEPS

4020F

Incorrect ink parameters (partial transfer) Defective seal or level sensor CP1 Cause: Ink foam – Incorrect ink parameters Action: Check if the partial transfer is activated [Services►MI Engineer] Note: The IRS defines if the partial transfer mode should be activated. Drain manually the printer and activate the partial transfer mode if necessary Cause: Electrical connections of the level rods Action: Check the connections with the IC board and the ink tank Cause: Cleaning Maintenance sequences – Excessive use Action: Drain the printer and restart with fresh ink Cause: Calibrated leak clogged Action: Clean the filter and the calibrated leak Drain the printer, dismount the calibrated leak clean them. Cause: Defective seal or level sensor CP1 Action: Change the level sensor

9450

Viscosity too high

INCIDENT

The viscosity is 10 seconds higher than the reference viscosity

PROBLEM

The printer stops immediately with a correct head & IC shut down procedure.

CAUSE TS STEPS

4030F

Incorrect Ink parameters or Incorrect ink Defective or clogged parts of the IC Cause: Incorrect ink parameters Actions: Check ink type configured in the factory setting[Services ► MI Engineer] Cause: Defective or clogged parts of the IC Actions: Check electrical switching of IC2 [Services►Maintenance►Ink circuit maintenance] ► Check electrical connections of IC2 If EV2 is defective part: Drain the printer & replace It. Cause: Viscosity restrictor or Calibrated leak or Filtering connector clogged Actions: Clean the filter and the calibrated leak Drain the printer, dismount calibrated leak 0,25mm; filtering connector connected and clean them.

9450 Book for Service Engineers 154/298

A49725

Troubleshooting 9450

No more ink

4040F

INCIDENT

The ink level is 10mm and refill cycle from ink cartridge has failed. The ink level (= 10mm) is just enough for correct shut down and restart of the printer

PROBLEM

The printer stops immediately with a correct head & IC shut down procedure.

CAUSE

TS STEPS

Empty ink cartridge Defective or clogged parts Clogging of the Ink needle (only for contrast circuit using pigment ink) Cause: Empty ink cartridge Actions: Check the level of ink in the cartridge, If empty : Replace cartridge Cause: No ink transfer - Defective or clogged parts of the IC Action: Check the correct working of P1 and electro valves IC1, IC3 and IC7 [Services►Maintenance►Ink circuit maintenance] ► If one part doesn’t work, check its electrical connection or replace it. Cause: Clogging of the Ink needle - Check the cleanness of the ink needle Action: Clean the ink needle [Services►Maintenance►Ink circuit maintenance] Switch IC1 on way 3. Dismount the ink needle and clean it.

9450

No more Additive

4050F

INCIDENT

The remaining additive level in the reservoir of the IC is just sufficient for correct shut down and restart of the jet.

PROBLEM

The printer stops immediately with a correct head & IC shut down procedure.

CAUSE TS STEPS

Empty additive cartridge Defective or clogged parts of the IC Cause: Empty additive cartridge Action: Check the level of additive in the cartridge, If empty : Replace cartridge Cause: No additive transfer - Defective or clogged parts of the IC Actions: Check the correct working of P2 and electro valves IC5 [Services►Maintenance►Ink circuit maintenance] ► If one part doesn’t work, check its electrical connection or replace it. ► If P2 and IC5 work correctly. Drain the printer and clean the calibrated leak 0,25mm (connected to the additive anti pulse air pocket)

9450 Book for Service Engineers 155/298

A49725

Troubleshooting 9450

Cooling fan Failure

INCIDENT

Rotation signal is not detected from one or both fans

PROBLEM

If the fan does not operate correctly, the printer does not start or it stops.

CAUSE TS STEPS

4060F

Defective fan running Defective Fan command Cause: Defective fan running Actions: Make sure nothing is blocking the fan blades Make sure the fans are clean and turn smoothly Check if they are properly connected. Replace fan Cause: Defective Fan command Action: Check electrical Fan command Check on the board connector (with a multi meter) if the power supply of the Fan is OK. If not, replace the technology board or the NEP board.

9450

Ink transfer pump blocked (P1)

INCIDENT

The current draw is too high

PROBLEM

Printer stops

CAUSE TS STEPS

4070F

Defective transfer pump P1 Cause: Defective transfer pump P1 Actions: Test the pump in the maintenance menu [Services►Maintenance►Ink circuit maintenance] ► If defective, check the electrical connection ► If connection are OK, drain the printer and replace it

9450

Additive transfer pump blocked (P2)

INCIDENT

The current draw is too high

PROBLEM

Printer stops

CAUSE TS STEPS

4080F

Defective transfer pump P2 Cause: Defective transfer pump P2 Actions: Test the pump in the maintenance menu [Services►Maintenance►Ink circuit maintenance] ► If defective, check the electrical connection ► If connection are OK, drain the printer and replace it

9450 Book for Service Engineers 156/298

A49725

Troubleshooting 9450

Drain pump blocked (P3)

INCIDENT

The current draw is too high

PROBLEM

Printer stops

CAUSE TS STEPS

4090F

Defective Drain pump P3 Cause: Defective Draining pump P3 Action: Test the pump in the maintenance menu ► If defective, check the electrical connection ► If connection are OK, replace it

9450

Technology board electronic fault

INCIDENT

No initialization possible

PROBLEM

Printer does not start

CAUSE

Defective NEP board

TS STEPS

4100F

Cause: Defective NEP board Action: Replace the NEP board

9450

Technology board electro valve power supply fault

INCIDENT

Ink circuit electro valve power supply failure

PROBLEM

Printer does not start

CAUSE TS STEPS

4110F

Defective Techno board Cause: Defective Techno board Action: Replace the Techno board

9450

Draining fault

INCIDENT

No pressure variation detected

PROBLEM

Impossible to drain the printer

CAUSE TS STEPS

4120F

Defective drain pump P3 Cause: Defective Draining pump P3 Action: Test the pump in the maintenance menu ► If defective, check the electrical connection ► If connection are OK, replace it

9450 Book for Service Engineers 157/298

A49725

Troubleshooting 9450

Level sensor out of specification

INCIDENT

Prior to transfer a new ink cartridge the pressure transmitter test failed.

PROBLEM

The printer stops immediately with a correct head shut down procedure.

CAUSE TS STEPS

4130F

Defective seal of level sensor CP1 Defective level sensor CP1 Cause: Defective seal or level sensor CP1 Action: Defective level sensor ► Replace the level sensor

9450

Printer shutdown not complete

INCIDENT

The Ink Circuit has been stopped incorrectly.

PROBLEM

Risk of blocking hydraulic parts

CAUSE TS STEPS

4140

Incorrect using of the printer Power outages If it appears at the next start-up of the printer, the operator can start the IC only if Fault 4140 is cleared. Once Fault 4140 is cleared, it is saved in the Warning Fault history. To view the history of this alarm, refer to the Running Status file.

9450

Ink cannula clogged

INCIDENT

The ink cannula is clogged

PROBLEM

No ink transfer into the tank

CAUSE TS STEPS

4150F

Clogging of the Ink needle Cause: Clogging of the Ink needle - Check the cleanness of the ink needle Action: Clean the ink needle [Services►Maintenance►Ink circuit maintenance] Switch IC1 on way 3. Dismount the ink needle and clean it

9450

EV1 duct clogged

INCIDENT

The ink electrovalve IC1 is clogged

PROBLEM

No ink transfer into the tank

CAUSE TS STEPS

4160F

EV1 is clogged Cause: Clogging of IC1 Action: Replace the ink electrovalve IC1 (EV1)

9450 Book for Service Engineers 158/298

A49725

Troubleshooting 4500 – 4999 Alarms Ink Circuit 9450

Low additive level

INCIDENT

No level increase when adding solvent from the cartridge

PROBLEM

Printer starts using the additive from the reservoir of the ink circuit

CAUSE TS STEPS

4500A

The additive cartridge is empty. Defective or clogged parts of the IC Cause: The additive cartridge is empty Action: Replace the additive cartridge Cause: Defective or clogged parts of the IC Actions: Check the correct working of the pump P2 and electro valve IC5 [Services►Maintenance►Ink circuit maintenance] ► If defective, check the electrical connections ► If connections are OK, drain the printer and replace the part

9450

Low ink level

INCIDENT

The ink level in the ink reservoir is les then 25 mm. Refill cycle from ink cartridge has failed

PROBLEM

No functional effect

CAUSE TS STEPS

4510A

The ink cartridge is empty Defective parts Cause: The additive cartridge is empty Action: Replace the additive cartridge Cause: Defective or clogged parts of the IC Actions: Check the correct working of the pump P2 and IC1, IC7 and IC3 [Services►Maintenance►Ink circuit maintenance] ► If one is defective, check the electrical connections ► If connections are OK, drain the printer and replace the part.

9450

Ink cannula clogged

INCIDENT

The ink cannula is clogged (Production mode)

PROBLEM

No ink transfer into the tank. The printer still prints until the “4050 - No more additive” fault.

CAUSE TS STEPS

4512A

Clogging of the Ink needle Cause: Clogging of the Ink needle - Check the cleanness of the ink needle Action: Clean the ink needle [Services►Maintenance►Ink circuit maintenance] Switch IC1 on way 3. Dismount the ink needle and clean it

9450 Book for Service Engineers 159/298

A49725

Troubleshooting 9450

Time out ink level measurement

INCIDENT

The ink level did not stabilized within 10min

PROBLEM

The measurement is averaged and used

CAUSE

High pressure variations in the ink circuit

TS STEPS

4520A

Cause: High pressure variations in the ink circuit Action: Check the vapour outlet Check the vapour outlet circuit for any obstruction: Get the ink circuit out of the cabinet. Take care of electrical wires from CIJ board connected to the IC For IP65 version: check if the hose does not blow on top of the pressure transmitter CP1.

9450

Ink pressure out of range

INCIDENT

The ink pressure is lower than 1bar or higher than 4bar

PROBLEM

No functional effect

CAUSE

TS STEPS

4530A

Ink parameter Pressure pump Pressure sensor Cause: Incorrect Ink or parameters Action: Check the ink parameters [Services►MI Engineer] Cause: Worn Pressure pump Action: If Pressure < 1 bar Restart the printer. If the problem still occurs: Drain the printer and replace the pressure pump. Cause: Defective pressure measure Action: If Pressure > 3.6 bars Restart the printer. If the problem still occur : Replace CP2 pressure / temperature cell

9450 Book for Service Engineers 160/298

A49725

Troubleshooting 9450

Motor speed out of range

4540A

INCIDENT

The motor speed of the pressure pump is lower than 1000 rpm or higher than 3500rpm.

PROBLEM

Low print quality

CAUSE

Incorrect by-pass adjustment Clogged main filter or head filter Malfunctioning / Worn pressure pump

TS STEPS

Cause: Incorrect by-pass adjustment Action: Adjust by-pass to obtain a motor speed of 2000rpm Cause: Clogged main filter or head filter Action: Perform a complete rinsing of the printer Cause: Malfunctioning / Worn pressure pump Action: Drain the printer and replace the pressure pump.

9450

Ink temperature too high

INCIDENT

The temperature of the ink is > 60°C measured by CP2 (temperature cell)

PROBLEM

Low contrast of print Fault 2070 “Drop (phase) detection” may appear

CAUSE TS STEPS

4560A

Defective temperature measure Cause: Defective temperature measure Action: Restart the printer. If the problem still occur : Replace CP2 pressure sensor

9450

Viscosity too low

INCIDENT

The measured viscosity is < 10sec then the reference viscosity

PROBLEM

Risk of bad print quality

CAUSE

TS STEPS

4570A

Incorrect Ink types or Ink parameters Defective part (IC4) CP1 (pressure transmitter) seal Cause: Incorrect Ink type or parameters Action: check ink in the factory setting [Services►MI Engineer] Cause: Defective IC4 Actions: Check IC4 [Services►Maintenance►Ink circuit maintenance] ► If defective, check the electrical connections ► If connections are OK, drain the printer and replace the part. Cause: Defective level sensor CP1 Action: Replace the sensor

9450 Book for Service Engineers 161/298

A49725

Troubleshooting 9450

Critical ink level

INCIDENT

Printer on, Ink level measurement cycle

PROBLEM

No functional effect

CAUSE TS STEPS

4580A

The ink level in the ink reservoir is critical (15mm )and the ink cartridge is empty Cause: Empty ink cartridge Action: Replace the ink cartridge Note: See further fault 4040

9450

Ink level too high

4590A

INCIDENT

This warning will rise if a fix issue procedure 2060 is requested and the ink level is higher than Ink_level_Max-10mm ( 135mm)

PROBLEM

The ink tank is full

CAUSE TS STEPS

Excessive addition of additive in the tank (2060 fix issue procedure) Cause: Excessive addition of additive in the tank Action: Drain the printer Note: See further fault 2060/2061

9450

Additive pressure too low

INCIDENT

The additive pressure is lower than 1.5 bar

PROBLEM

Additive transfer issue in the reserve

CAUSE TS STEPS

4630A

Defective transfer pump P2 Defective additive pressure sensor Cause: Defective transfer pump P2 Action: Check if P2 running correctly [Services►Maintenance►Ink circuit maintenance] ► If defective, check the electrical connections ► If connections are OK, drain the printer and replace the part. Cause: Defective Pressure sensor Actions: Replace the Pressure sensor

9450

Additive pressure too High

INCIDENT

The additive pressure is higher than 5.5 bar

PROBLEM

Additive transfer issue in the reserve

CAUSE TS STEPS

4640A

Clogged part Cause: Clogged calibrated leak (0,25mm) Actions: Clean the calibrated leak 0,25mm (connected to the additive anti pulse air pocket)

9450 Book for Service Engineers 162/298

A49725

Troubleshooting 9450

Ink cartridge unknown

INCIDENT

The ACM doesn’t detect a Markem-Imaje ink cartridge

PROBLEM

The printer doesn’t transfer ink from the cartridge to the tank.

4650A

Printer ON: The printer still prints until the “4040-No more ink” fault. Printer OFF + Ink level tank >> 10mm: It starts and prints until the “4040-No more ink” fault. Printer OFF + Ink level tank ≤10mm: The printer doesn’t start.

CAUSE TS STEPS

No-MI cartridge Cause: No-MI cartridge Action: Check visually the identification label stuck on the cartridge (MI logo, ink batch number…). ► The printer runs with MI consumables.

9450

Additive cartridge unknown

INCIDENT

The ACM doesn’t detect a Markem-Imaje additive cartridge

PROBLEM

The printer doesn’t transfer additive from the cartridge to the tank.

4660A

Printer ON: the printer still prints until the “4050 - No more additive” fault. Printer OFF + Additive tank is not empty: it starts and prints until the “4050 - No more additive” fault. Printer OFF + Additive tank is empty: the printer doesn’t start.

CAUSE TS STEPS

No-MI cartridge Cause: No-MI cartridge Actions: Check visually the identification label stuck on the cartridge (MI logo, ink batch number…). ► The printer runs with MI consumables.

9450 Book for Service Engineers 163/298

A49725

Troubleshooting 9450

Ink cartridge not detected

INCIDENT

The ACM doesn’t manage detecting the ink cartridge

PROBLEM

No functional effect, the printer runs in Joker mode

CAUSE

Cartridge is not correctly inserted Cartridge identification (Tag) is not readable No identification on the cartridge (blank Tag/No Tag)

TS STEPS

Causes: Cartridge is not is not correctly inserted Actions: Check if the cartridge is correctly plugged

4670A

► If still fault, Replace the ink cartridge Causes: Cartridge identification (Tag) is not readable Actions: Check visually if the Tag on the cartridge is not damaged. ► If the tag is damaged, Replace the ink cartridge Note: if the use of a cartridge with a damaged tag is confirmed by the operator, the printer will use the Joker volume until a detection of a MI cartridge. Causes: Cartridge identification (Tag) is not present on the cartridge Actions: Check visually the presence of the tag on the cartridge. ► If no Tag, Replace the ink cartridge ► If tag is present, Check the strength of the signal (RSSI) -

9450

[MI Engineer menu ►Consumable]: If Ink-RSSI=0 & Additive-RSSI ≠ 0  Tag issue If Ink-RSSI=0 & Additive-RSSI = 0  Check the connection of the coax cables (Antenna board<> IC board)

Additive cartridge not detected

INCIDENT

The ACM doesn’t manage detecting the additive cartridge

PROBLEM

The printer doesn’t transfer additive from the cartridge to the additive tank

CAUSE

TS STEPS

4680A

Cartridge is not correctly inserted Cartridge identification (Tag) is not readable No identification on the cartridge (blank Tag/No Tag) Causes: Cartridge is not is not correctly inserted Actions: Unplug and plug and the additive cartridge ► If still fault, Replace the ink cartridge

9450 Book for Service Engineers 164/298

A49725

Troubleshooting 9450

Additive cartridge not detected

4680A

Causes: Cartridge identification is not readable Actions: Check visually if the Tag on the cartridge is not damaged. ► If the tag is damaged, Replace the additive cartridge Note: if the use of a cartridge with a damaged tag is confirmed by the operator, the printer will use the Joker volume until a detection of a MI cartridge. Causes: Cartridge identification (Tag) is not present on the cartridge Actions: Check visually the presence of the tag on the cartridge. ► If no Tag, Replace the additive cartridge ► If tag is present, Check the strength of the signal (RSSI) -

[MI Engineer menu ►Consumable]: If Additive -RSSI=0 & Ink -RSSI ≠ 0  Tag issue If Ink-RSSI=0 & Additive-RSSI = 0  Check the connection of the coax cables (Antenna board<> IC board)

ACM

Ink cartridge already used

4690A

INCIDENT

The ACM detects a cartridge identification number (UID) already recorded by the printer

PROBLEM

The printer doesn’t transfer ink from the cartridge to the tank. Printer ON: The printer still prints until the “4040-No more ink” fault. Printer OFF + Ink level tank >> 10mm: It starts and prints until the “4040-No more ink” fault. Printer OFF + Ink level tank ≤10mm: The printer doesn’t start.

CAUSE

No-MI cartridge

TS STEPS

Cause: No-MI cartridge Action: Change the ink cartridge – The printer runs with MI cartridge

9450

Additive cartridge already used

4700A

INCIDENT

The ACM detects a cartridge identification number (UID) already recorded by the printer

PROBLEM

The printer doesn’t transfer additive from the cartridge to the tank. Printer ON: the printer still prints until the “4050 - No more additive” fault. Printer OFF + Additive tank is not empty: it starts and prints until the “4050 - No more additive” fault. Printer OFF + Additive tank is empty: the printer doesn’t start.

CAUSE TS STEPS

No-MI cartridge Cause: No-MI cartridge Action: Change the additive cartridge – The printer runs with MI cartridge

9450 Book for Service Engineers 165/298

A49725

Troubleshooting 9450

Invalid ink cartridge reference

INCIDENT

The printer detects a bad ink reference regarding its configuration

PROBLEM

The printer doesn’t transfer ink from the cartridge to the tank.

4710A

Printer ON: The printer still prints until the “4040-No more ink” fault. Printer OFF + Ink level tank >> 10mm: It starts and prints until the “4040-No more ink” fault. Printer OFF + Ink level tank ≤10mm: The printer doesn’t start.

CAUSE TS STEPS

Factory setting error Manufacturing error Cause: Factory setting error Action: Check the ink reference in the factory setting [MI Engineer ►Factory setting] Cause: Manufacturing error Action: Change the cartridge

9450

Invalid ink cartridge reference

INCIDENT

The printer detects an invalid additive reference regarding its configuration

PROBLEM

The printer doesn’t transfer additive from the cartridge to the tank.

4720A

Printer ON: the printer still prints until the “4050 - No more additive” fault. Printer OFF + Additive tank is not empty: it starts and prints until the “4050 - No more additive” fault. Printer OFF + Additive tank is empty: the printer doesn’t start.

CAUSE TS STEPS

Factory setting error Manufacturing error Cause: Factory setting error Action: Check the additive reference in the factory setting [MI Engineer ►Factory setting] Cause: Manufacturing error Action: Change the cartridge

9450 Book for Service Engineers 166/298

A49725

Troubleshooting 9450

Consumable issue

INCIDENT

It remains 1 litre of Joker volume

PROBLEM

No immediate functional effect  Risk of 4740 Critical consumable issue

CAUSE TS STEPS

4730A

Consumable are not detected by the printer Cause: Consumable are not detected by the printer Action: see Alarms 4670 and 4680

9450

Critical consumable issue

INCIDENT

The Joker volume is over (MI data)

PROBLEM

The printer doesn’t transfer ink from the cartridge to the tank.

4740A

Printer ON: The printer still prints until the “4040-No more ink” fault. Printer OFF + Ink level tank >> 10mm: It starts and prints until the “4040-No more ink” fault. Printer OFF + Ink level tank ≤10mm: The printer doesn’t start.

CAUSE TS STEPS

9450

No-MI cartridge are used Cause: No-MI cartridge are used Action: Change the NEP board

Ink expiration date will be reach soon

INCIDENT

This alarm appears 1 month before the expiration date

PROBLEM

No functional effect

CAUSE TS STEPS 9450

Ink cartridge expiration date No action for FSE

Additive expiration date will be reach soon

INCIDENT

This alarm appears 1 month before the expiration date

PROBLEM

No functional effect

CAUSE TS STEPS

No action for FSE

Ink expiration date reach

INCIDENT

This alarm appears when the expiration date is reached

PROBLEM

No functional effect

TS STEPS

4760A

Additive cartridge expiration date

9450

CAUSE

4750A

4770A

Ink cartridge expiration date No action for FSE

9450 Book for Service Engineers 167/298

A49725

Troubleshooting 9450

Additive expiration date reach

INCIDENT

This alarm appears when the expiration date is reached

PROBLEM

No functional effect

CAUSE

4780A

Additive cartridge expiration date

TS STEPS

No action for FSE

9450

Ink expiration date over

INCIDENT

This alarm appears 1 month after the expiration date

PROBLEM

No functional effect

CAUSE

4790A

Ink cartridge expiration date

TS STEPS

No action for FSE

9450

Additive expiration date over

INCIDENT

This alarm appears 6 month after the expiration date

PROBLEM

No functional effect

CAUSE

4800A

Ink cartridge expiration date

TS STEPS

No action for FSE

5000 – 5999 Printer 9450

Invalid production settings file (Default used)

INCIDENT

Printer boot

PROBLEM

The printer application does not start

CAUSE TS STEPS

5000F

The file “ProductionSettings.cfg” could not be read. Cause: The file “ProductionSettings.cfg” could not be read. Action: Create a new configuration file

9450

Time out on print unit initialisation

INCIDENT

Printer boot

PROBLEM

The printer does not initialize and the printer cannot be started

CAUSE TS STEPS

5010F

Loading the application data from the NEP to the Print Unit not in time Cause: Loading the application data from the NEP to the Print Unit not in time he file “ Actions: Re-boot the printer Check if the “NOR-Flash disk is not full Re-install software Defective- NEP board: Replace it.

9450 Book for Service Engineers 168/298

A49725

Troubleshooting 9450

Unable to save production settings

INCIDENT

When modifying the HT and or piezo frequency

PROBLEM

Modifications not taken into account

CAUSE

The new settings could not be saved

TS STEPS

5020F

Cause: The new settings could not be saved Actions: Check if the “NOR-Flash disk is not full Defective- NEP board: Replace it.

9450

Invalid printer settings file (Default used)

INCIDENT

On printer boot

PROBLEM

Default values are generated and the printer boots normally.

CAUSE TS STEPS

5030F

The file “Printer9232Settings.cfg” could not be read Cause: The file “Printer9232Settings.cfg” could not be read Action: Set the correct values [Tools >Settings>Printing]&[ Tools>Settings>Printer>Configuration>Start/Stop] Once done confirm the modifications by pressing on “OK” button. This action will create a new file.

9450

Unable to save printer settings

INCIDENT

When modifying the customers preferences

PROBLEM

Modifications not taken into account

CAUSE

The new settings could not be saved

5040F

Cause: The new settings could not be saved

TS STEPS

Actions: Check if the “NOR-Flash disk is not full Defective- NEP board: Replace it.

9450

Printer initialization FAILED

INCIDENT

Followed by fault 5000 or 5010

PROBLEM

The printer application does not start

CAUSE TS STEPS

5050F

See faults 5000 and or 5010 -

9450 Book for Service Engineers 169/298

A49725

Troubleshooting 9450

Unable to initialize the PU system DATA

INCIDENT

Following fault 5010 and may also follow fault 5050

PROBLEM

The printer application does not start

CAUSE TS STEPS

5060F

Loading the application data from the NEP to the Print Unit not in time Cause: Loading the application data from the NEP to the Print Unit not in time he file “ Actions: Re-boot the printer Check if the “NOR-Flash disk is not full Re-install software Defective- NEP board: Replace it.

9450

Unable to initialize the PU Machine DATA

INCIDENT

Following fault 5010 and may also follow fault 5050

PROBLEM

The printer application does not start

CAUSE TS STEPS

5070F

Loading the application data from the NEP to the Print Unit not in time Cause: Loading the application data from the NEP to the Print Unit not in time he file “ Actions: Re-boot the printer Check if the “NOR-Flash disk is not full Re-install software Defective- NEP board: Replace it.

9450

Printer can’t execute the command here

INCIDENT

When pressing a key button

PROBLEM

None

CAUSE TS STEPS 9450

Minor software error Please report via a Technical deviation claim

Unable to save printer functioning data

INCIDENT

While printer on stage, printer functioning data is saved on a regular base.

PROBLEM

Previous value used

CAUSE TS STEPS

5080A

5090A

Printer functioning data could not be saved Cause: Printer functioning data could not be saved Actions: Re-boot the printer Check if the “NOR-Flash disk is not full Re-install software Defective- NEP board: Replace it.

9450 Book for Service Engineers 170/298

A49725

Troubleshooting 9450

Low additive autonomy

5100A

INCIDENT

Only once displayed, if the printer is powered off without clearing this alarm, it will be redisplayed on printer on / power on. The additive cartridge is empty. The remaining additive autonomy in the additive reservoir is 24 hours ≤ autonomy > 8 hours.

PROBLEM

The printer continues to use additive from the cartridge prior to use it from its reservoir

CAUSE TS STEPS

The additive cartridge has not been replaced at alarm 4500- low additive level Cause: The additive cartridge has not been replaced at alarm 4500- low additive level Actions: Replace additive cartridge Check correct positioning of the cartridge See further Fault 4540 No more additive

9450

Critical additive autonomy

5110A

INCIDENT

Displayed every hour, if the printer is powered off without clearing this alarm, it will be redisplayed on printer on / power on. The additive cartridge is empty. The remaining additive autonomy in the additive reservoir is ≤ 8 hours

PROBLEM

The printer continues to use additive from the cartridge prior to use it from its reservoir

CAUSE

The additive cartridge has not been replaced at alarm 4500- low additive level and 5100

TS STEPS

Cause: The additive cartridge has not been replaced at alarm 4500- low additive level Actions: Replace additive cartridge Check correct positioning of the cartridge See further Fault 4540 No more additive

9450

Missing plant air

5120F

INCIDENT

When starting ink circuit or while IC running on IP66 printers with head pressurization kit

PROBLEM

The ink circuit does not start or it stops

CAUSE TS STEPS

Plant air is not connected Cause: Plant air is not connected Actions: Check the plant air is connected: minimum pressure: 4 bars / minimum flow rate: 400l/h. Air conditioner: filter, pressure switch and connections.

9450 Book for Service Engineers 171/298

A49725

Troubleshooting 9450

External Communication Time Out

INCIDENT

When network connectivity used - Client request failed / not taken into account

PROBLEM

Client request failed / not taken into account

CAUSE

Communication error

TS STEPS

Cause: Communication error

5130A

Actions: Client shutdown/hung while communicating with the printer : Restart client Communication channel/link broken or unreliable : Check channel reliability Wrong communication protocol used at client side : check protocol used (refer to appropriate manual)

9450

External Communication Data fault

INCIDENT

When network connectivity used - Client request failed / not taken into account

PROBLEM

Client request failed / not taken into account

CAUSE TS STEPS

5140A

Communication error Cause: Communication error Actions: The requested command cannot be executed in the current machine context (notallowed operations, locked files, etc.). Check settings Malformed command due to channel transmission errors (detected via checksum) Check channel continuity Improper command due to a wrong protocol implementation at client side refer to appropriate manual

9450

internal SD card test failed

INCIDENT

On printer boot

PROBLEM

UI font is not loaded missing character are replaced by squares. Changing UI language not possible

CAUSE TS STEPS

Internal SD card is missing, corrupted or not identified Cause: Internal SD card is missing, corrupted or not identified Action: Check if the SD card on the NEP board meets the specifications

9450

Unexpected procedure abortion

INCIDENT

An issue has occurred during the break off point adjustment

PROBLEM

No functional effects

CAUSE TS STEPS

5150A

5160A

Fault (2060, EHT) during BOP No action

9450 Book for Service Engineers 172/298

A49725

Troubleshooting 9450

USB stick not probably not connected

5271F

INCIDENT

The doesn’t detect the USB stick containing the unique codes (Promotional coding)

PROBLEM

Printer doesn’t start the production

CAUSE TS STEPS

No USB key connected Cause: No USB key connected on the printer Action: Connect the USB key

9450 INCIDENT

PROBLEM CAUSE TS STEPS

9450 INCIDENT

PROBLEM CAUSE TS STEPS

USB stick no file found for the job

5295A

Promotional coding: There is no more file in the media Once the last file from the media is stored into the queue and deleted from the key. Printer stops to print No more file in the media Cause: No more file in the media Action: Add new files in the media.

USB Unique coding unexpected variable number

5298F

Promotional coding: The file format on the media is not correct No print Incorrect file format in the media Cause: Incorrect file format in the media Action: Check the format The first line must start with “ExtVar21”

9450 Book for Service Engineers 173/298

A49725

Troubleshooting ■ List of special Spare Parts for M-I Technicians The tables hereafter don’t include spare part from the catalogue. Print Module P/N

Description

Content

ENM46408

4 Electro valve Bloc

1 block fitted with 2 seals + 2 screws

ENM38973

Assembled gutter sensor

1 sensor + 1seal

ENM38941

Gutter block

Gutter block + 2 seals + 1 screw

ENM39168

Board - Head

1 board + 2 screws

ENM47458

A46265

Cover (including EHT block)

Cover with seal

Seal Kit - Head Sleeve: 3 seals

x1 front cover + x2 top of the print head + screws

Picture

9450 Book for Service Engineers 174/298

A49725

Troubleshooting Print Module (G head) P/N

Description

ENR/ENM49309_001 ENR/ENM49309_002 ENR/ENM49309_003 ENR/ENM49309_004 ENR/ENM49309_005 ENR/ENM49309_006 ENR/ENM49309_007 ENR/ENM49309_008 ENR/ENM49309_009 ENR/ENM49309_010 ENR/ENM49309_011 ENR/ENM49309_012

PRINT MOD-9450-1G-IP56-3M-KGS-STRAIGHT PRINT MOD-9450-1G-IP66-3M-KGS-STRAIGHT PRINT MOD-9450-1G-IP56-3M-KGL-STRAIGHT PRINT MOD-9450-1G-IP66-3M-KGL-STRAIGHT PRINT MOD-9450-1G-IP56-3M-KFGL-STRAIGHT PRINT MOD-9450-1G-IP66-3M-KFGL-STRAIGHT PRINT MOD-9450-1G-IP56-6M-KGS-STRAIGHT PRINT MOD-9450-1G-IP66-6M-KGS-STRAIGHT PRINT MOD-9450-1G-IP56-6M-KGL-STRAIGHT PRINT MOD-9450-1G-IP66-6M-KGL-STRAIGHT PRINT MOD-9450-1G-IP56-6M-KFGL-STRAIGHT PRINT MOD-9450-1G-IP66-6M-KFGL-STRAIGHT

Content 1 G head - 3m umbilical - IP56 - Standard inks 1 G head - 3m umbilical - IP66 - Standard inks 1 G head - 3m umbilical - IP56 - Standard inks 1 G head - 3m umbilical - IP66 - Standard inks 1 G head - 3m umbilical - IP56 - Ketone Free inks 1 G head - 3m umbilical - IP66 - Ketone Free inks 1 G head - 6m umbilical - IP56 - Standard inks 1 G head - 6m umbilical - IP66 - Standard inks 1 G head - 6m umbilical - IP56 - Standard inks 1 G head - 6m umbilical - IP66 - Standard inks 1 G head - 6m umbilical - IP56 - Ketone Free inks 1 G head - 6m umbilical - IP66 - Ketone Free inks

Print Module (M head) P/N

Description

ENR47017_CFG ENM/ENR47017_001 ENM/ENR47017_002 ENM/ENR47017_003 ENM/ENR47017_004 ENM/ENR47017_005 ENM/ENR47017_006 ENM/ENR47017_007 ENM/ENR47017_008

Print Module R2-9232-1M-Configurable Print Module-9232-1M-3M-IP56-Straight-K Print Module-9232-1M-3M-IP56-Straight-KF Print Module-9232-1M-6M-IP56-Straight-K Print Module-9232-1M-6M-IP56-Straight-KF Print Module-9232-1M-3M-IP66-Straight-K Print Module-9232-1M-3M-IP66-Straight-KF Print Module-9232-1M-6M-IP66-Straight-K Print Module-9232-1M-6M-IP66-Straight-KF

Content 1 M head - 3m umbilical: Ink + IP level configured in SAP 1 M head - 3m umbilical - IP56 - Standard inks 1 M head - 3m umbilical - IP56 - Ketone free inks 1 M head - 6m umbilical - IP56 - Standard inks 1 M head - 6m umbilical - IP56 - Ketone free inks 1 M head - 3m umbilical - IP66 - Standard inks 1 M head - 3m umbilical - IP66 - Ketone free inks 1 M head - 6m umbilical - IP66 - Standard inks 1 M head - 6m umbilical - IP66 - Ketone free inks

Hydraulic Compartment P/N

Description

Content

ENM40379

Cell – Peltier condenser

1 condenser + 1 seal + 2 screws

ENM38113

Strainer – Filtering connector

1 strained + 1 seal

ENM38107

Filter connector barbed

Filter 100µm

Picture

9450 Book for Service Engineers 175/298

A49725

Troubleshooting Hydraulic Compartment P/N

Description

Content

ENM38114

Venturi assembly Umbilical length = 3 m

ENM43471

Venturi assembly Umbilical length = 6 m

A43472

Restrictor for 6m length Hose barbed M5-2.7-0.2.5-

-

A36864

Restrictor for 3m length Hose barbed M5-2.7-0.3-

-

Picture

1 Venturi + 1 seal

Note: The 2 differences between Ink Circuit 3m/6m umbilical are the following:

Diff#02- Restrictors: A36864: Restrictor Umbilical 3 m A43472: Restrictor Umbilical 6 m

Diff#01- Venturi: ENM38114: Venturi assembly Umbilical 3 m ENM43471: Venturi assembly Umbilical 6 m

9450 Book for Service Engineers 176/298

A49725

Troubleshooting Electronic Compartment P/N

Description

Content

ENM48181

IC/RFID board 9450

-

ENM48472

Kit Nep + Techno

-

Picture

+

ENM48467

Display – Assembly

1 display fitted with its protection + 1 glue + 4 caps + 4 nuts

Tools P/N A40771

A41894

Description

Content

Flushing tool

Ink cannula on solvent cartridge adaptor.

Picture

M-I flushing technician 1 M-I flushing tool tool

9450 Book for Service Engineers 177/298

A49725

Troubleshooting ■ List of Spare Parts from catalogue (A48599)

9450 Book for Service Engineers 178/298

A49725

Troubleshooting

9450 Book for Service Engineers 179/298

A49725

Troubleshooting

9450 Book for Service Engineers 180/298

A49725

Troubleshooting Modulation assembly recognition For G head type, there are two types of modulation assembly relating to:  S: Standard inlet cone height,  L: Large inlet cone height. The shape of the hole in the nozzle affects the jet and the break-off point stability. For some type of inks a small cone improves jet/break-off point stability, for other inks a large cone is better. Refer to the Ink Running Specification to know which type must be used for the ink.

G Head

GL White cover

M Head

GS Black cover

-

EHT plate recognition There are different EHT plates mounted depending on the head type:

G Head

Common plate

M Head

G – plate

M head plate

9450 Book for Service Engineers 181/298

A49725

Troubleshooting ■ Draining and flushing the printer The MI technician draining and flushing tool has the same functionality as the disposable/recyclable maintenance kit. Tools / parts required: 

MI Technician tool,



Flushing adapter,



Waste drum,



Additive Cartridges (x2)

Connecting the MI technician tool Pull out the ink circuit (do not completely pull it out of the cabinet). Connect the M-I technician flushing tool as follow:

The MI flushing tool should be placed at the same level or slightly below the ink circuit

Securely fasten a loop above ink circuit for example over the cartridge holders Securely fasten the fir tree connector by sliding the clamp over the fir tree connector

Waste drum (3 liters minimum) Securely fasten this end of the hose to prevent any accidental spillage MI flushing tool composed of a draining pump (P3) and tubes Power supply the draining pump on the ink circuit connector

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A49725

Troubleshooting

Draining and Flushing procedure Refer to the user manual for the complete Draining and Flushing procedure. Once the printer is ready, disconnect the M-I technician flushing tool, dismount the empty cartridges and put in place the ink circuit. In order to avoid drying of the MI technician tool, connect the pump outlet tube to the inlet tube (stainless steel connector).

Storage time > 2 months If the storage time > 2 months, Drain and rinse it again. In storage condition, the printer must be drained and rinsed every two (2) months.

9450 Book for Service Engineers 183/298

A49725

Troubleshooting ■ Accessibility to the IC parts Objective Most hydraulics parts are located under the ink circuit: Electro-valves, Transfer pumps, Venturi, Filtering connectors, Viscosity restrictor…. In order to dismount and replace them, the ink circuit must be drained, pulled out and placed on its side outside the cabinet.

Procedure Recommendations: Do not pull the ink circuit out of the cabinet whilst mounted on a stand: printer can fall forwards. Perform this operation in a dust-free environment. Tools: 3 mm, 2, 5 mm Allen keys  Turn off the printer and unplug it from its AC outlet.  Place the printer on a table.  Remove the ink and additive cartridges  Unscrew the 2 locking screws of the cartridge support.  Pull out the ink circuit.  Put the ink circuit drainage outlet into a waste drum (A) (Wait five minutes minimum)  During this time, dismount the cartridges support plate (Three(x3) screws)  When there is no more ink in the drainage tube: remove the ink circuit from the printer. Move the “release” handle (on top of the ink circuit) in the direction of the arrow

A

NOTE: If you need to drain the additive reservoir as well, starts the printer before draining the printer and shut down the printer in DEMO mode. When the pop-up message appears asking to transfer the additive to the ink tank, drain the printer as described above and then confirm by clicking on yes leaving the draining outlet connected to the waste drum. Wait until the printer is off and there is no more fluid coming out.

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A49725

Troubleshooting B

 Disconnect the Techno board connectors (B).  Remove the ink circuit support (C),  Note: only for changing P1, P2, IC1, IC2, IC3 and IC5  Lay down the ink circuit on its side. The components are now accessible.  Pay attention to the hydraulic connection with the umbilical

c

9450 Book for Service Engineers 185/298

A49725

Troubleshooting ■ Spare parts sheets There are two types of spare parts sheets according to the after sales policy:

This symbol in the Spare parts sheets means that maintenance operations are authorized on customer site This symbol in the Spare parts sheets means that maintenance operations are only authorized in local workshops

The Spare Parts Sheets (SPS) in this section were written with preventive maintenance in mind.

During curative maintenance it is not always possible to follow the recommended procedures in full as described hereafter (e.g. it might not be possible to drain the ink circuit if a solenoid valve is stuck). In such cases we recommend taking all possible precautions to avoid spilling or splashing ink or make up. Whenever parts with seals are disassembled, they should be reassembled with new seals.

Always record any parts replaced. The maintenance record of the printer will help you and or your colleague at a next visit

9450 Book for Service Engineers 186/298

A49725

Troubleshooting

Spare parts sheets

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Troubleshooting ■ Spare parts sheets List of Spare part sheet available in this section:

SPS Print Module/Print head (SPS PHxx) SPS PH00 Print Module replacement (Without IC draining) SPS PH01 Replacing the Filter - head (G/M head) – ENM46708 SPS PH02 Replacing the 4 Electro valve block (G/M head) – ENM46408 SPS PH03 Replacing the gutter block (M/G Head) - ENM38941 SPS PH04 Replacing the Gutter Sensor (M/G Head) – ENM38973 SPS PH05 Replacing the Modulation Assembly (G Head) - ENM400338/ENM44528 SPS PH06 Replacing the Modulation Assembly (M Head) – ENM47391 SPS PH07 Replacing the Cover - including EHT block (M/G head) – ENM47458 SPS PH07 Replacing the Print Head Board – ENM39168

SPS Ink Circuit (SPS ICxx) SPS IC01 Replacing the Cell – Peltier Condenser – ENM40379 SPS IC02 Replacing the Pressure / temperature sensor assembly – ENM39006 SPS IC03 Replacing the Level sensor – ENM39084 SPS IC04 Replacing one (Common) Electro valve SPS IC05 Replacing the Rinsing Electro valves (EV6, EV7) SPS IC06 Venturi assembly – 3 m (ENM38114) – 6m (ENM43471) SPS IC07 Strainer – Filtering connector – ENM38113

SPS Electronic (SPS ELxx) SPS EL01 Replacing Boards – CIJ Technology + NEP – ENM48472 SPS EL02 Replacing Touch screen - ENM48467

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A49725

Troubleshooting SPS PH00

Print Module replacement (Without IC draining)

Special Tools

-

1/4

- Do not stop the ink Circuit. - Stop de jet in the head operation menu.

Prerequisite

- The print head shall be placed on its maintenance trail, - You will use meanly the ink maintenance menu to perform the steps below : [Tools►Services►Maintenance►IC maintenance]

Op. Location Remarks Step A : Rinsing of the purge circuit A1

In the maintenance menu:

A2

Close “Anti-pulse additive” (IC4) in position 1-2.

A3

Switch “Additive supply” (IC5) in position 2-3.

A4

Start the “additive transfer pump P2”.

A5

Open “Additive” (H8) and “Purge” (H7). Note: Deactivate ink transfer pump (P1) if active

A6

When additive becomes to cross the “Purge” : Press and hold down the “Purge” (H7) to repetitively switch it (time>10 sec)

A7

When the tube of purge is clean (full additive, no more ink): Close the “Additive” (H8) and stop “additive transfer pump P2”.

A8

Let the Purge tube (Ø1.6 mm) to absorb the air using the venturi aspiration. Does not close the “Purge” (H7).

9450 Book for Service Engineers 189/298

Tube of Purge: Blue tube Ø1.6 mm

A49725

Troubleshooting SPS PH00 Print Module replacement (Without IC draining)

2/4

Step B : Rinsing of the Recuperation circuit B1

Place the head in a beaker with 100 ml (or more) of additive identical to the one supplied with the machine.

B2

In the maintenance menu: Open “Recup” (H9) Remark: “Purge” (H7) is still open.

B3

When additive becomes to cross the recuperation tube(Ø2.7 mm): Press and hold down the “Recup” (H9) to repetitively switch it (10 sec or more).

B4

When the tube of recuperation is clean (full additive, no more ink): Remove the beaker and let the recuperation tube to absorb the air by aspiration. Note: Check that purge tube is still full of air (no Ink)

B5

When both Recup tube (Ø2.7mm) and Purge tube (Ø1.6 mm) are full of air: Set a motor speed reference of 0 rpm for the pressure pump.

B6

Close the “Recup” (H9) and the “Purge” (Ev7)

Recup tupe : Transparent tube Ø2.7 mm

Step C : Rinsing of the pressure circuit C1 C2

In the maintenance menu: Check that IC4 is still in position 1-2 & IC5 is still in position 2-3 Start the additive transfer pump P2 Open “Additive” (H8) and the “Pressure” (H6).

C3

When additive becomes to cross the pressure tube (Ø1.6mm): Press and hold down the “Pressure”(H6) to repetitively switch it (10 sec or more).

C4

When the pressure tube is clean (no more ink): Close the additive transfer pump P2, Close the Additive (H8) and the Pressure (H6).

C5

Unplug the printer from the main power.

C6

Drain manually the printer.

Pressure : Red tube Ø1.6mm

9450 Book for Service Engineers 190/298

A49725

Troubleshooting SPS PH00 Print Module replacement (Without IC draining)

3/4

Step D : Replace the Print module D1

During operation Keep a beaker close to you and paper.

D2

Cut the additive tube (1.1mm). Leave the stainless steel fir tree connector on the cable from the Ink circuit

D3

Cut the recuperation tube (2.7mm). Leave the stainless steel fir tree connector on the cable from the Ink circuit.

D4

Cut the Pressure tube (1.6mm). Leave the stainless steel fir tree connector on the cable from the Ink circuit.

D5

Cut the Purge tube (1.6mm). Leave the stainless steel fir tree connector on the cable from the Ink circuit.

D6

Disconnect mechanically and electrically the umbilical and replace by a new one.

Step E : Printer Configuration

E1

Check the printer configuration Install the last version of the software (if necessary)

Enter the MI password (MI profile) In the MI Engineer menu (ToolsServicesMI EngineerIUI for labHead): Set the EHT value which is indicated on the Print head.

E2

Remarks: 1- If the printer runs with the ink 9160: Add + 300V to the value which is indicated on the Print head. 2- If the printer runs with the ink 9243: Add + 200V to the value which is indicated on the Print head. In the Factory settings(ToolsServicesMI EngineerFactory settings): Set the “4ELV block” part number

9450 Book for Service Engineers 191/298

A49725

Troubleshooting SPS PH00 Print Module replacement (Without IC draining)

4/4

Step E : Start-up E1

E2

Before starting the printer Drain manually the tank by using the drain hose Start the printer Check the viscosity in the head operation menu. The condition is viscosity = Viscosity reference ± 2s If the viscosity is OK go to the next step (E3). Wait 10 minutes, if the condition is still not OK Unplug the printer from the main power, Drain manually the printer one more time, Re-start the printer

E3

Viscosity OK: In the head operation page, perform : Stability: 5 min Refreshment: 5 min

E4

When the jet is stable, clean the head et restart the jet.

E5

E6

Resetting the break-off point table: In the MI-Engineer menu (ToolsServicesMI EngineerIUI for labHead) set the piezo value to 0 to reset the entire table.

After the table reset, the printer will raise a Drop (phase) Detection fault (F2070). In order to avoid this problem set a piezo value to 150.

150

150

E7

Go to the Head Operations menu and perform a break off point adjustment

9450 Book for Service Engineers 192/298

A49725

Troubleshooting SPS PH01

Filter - head (G/M head) – ENM46708

Special Tools

-

Prerequisite

Turn off the printer and disconnect it from the AC power Take appropriate individual protections

1/1

Op. Location Remarks

Residual ink may come out Perform this operation in a dust-free environment

Disassembly Remove the cover head. 1

Unscrew the four (x4) screws holding the filter cover and remove it.

1

Residual ink may come out, take appropriate precautions

Remove the filter and the two (2) O-ring seals: 2 -

- One is in the cover, - The other is under the filter. Clean and dry the filter housing.

Reassembly

3

Change filter and seals. Put the cover back in place (Cross tighten) Re–assemble all parts in the reverse order.

2

Testing

Start the printer Check for leakages. Perform a Check stability sequence Record the replaced part in the maintenance menu of the printer

3

9450 Book for Service Engineers 193/298

A49725

Troubleshooting SPS PH02

4 solenoid valve block (G/M head) – ENM46408

Special Tools

-

Prerequisite

Turn off the printer and disconnect it from the AC power Take appropriate individual protections Keep print head higher than the printer cabinet

1/1

Op. Location Remarks

Residual ink may come out Perform this operation in a dust-free environment

Disassembly

1

Remove the cover head. Unscrew the CHC screws (x2) holding the 4 ELV block and remove it.

1

Pay attention to the seals (A): They could be stuck on the support (B): remove them if necessary. 2

Use cleaning solution to clean the mating surface on the 4 ELV block and the contact board and dry it. Seals (A) = One rectangular 3-hole gasket + one square 4-hole gasket.

B

2

Reassembly 3

A

Re–assemble all parts in the reverse order.

Testing In the maintenance menu, test electrically H6, H7, H8 and H9. Start the printer Check for leakages. Perform a Check stability sequence. Record the replaced part in the maintenance menu of the printer.

9450 Book for Service Engineers 194/298

A49725

Troubleshooting SPS PH03

Gutter block (M/G Head) – ENM38941

Special Tools

-

Prerequisite

Turn off the printer and disconnect it from the AC power Take appropriate individual protections Keep print head higher than the printer cabinet

1/1

Op. Location Remarks

Residual ink may come out Perform this operation in a dust-free environment

Disassembly Remove the cover head. 1

2

Disconnect the fat cable of the back cover (EHT) and remove it. Disconnect the flat cable (A) of the gutter block and unscrew the two (x2) screw of the print head board.

A

1

Insulation part

Release the gutter block (x1 CHC screw). Carefully remove the gutter block and clean the surroundings.

Reassembly Place the new seals : - O ring seal on the gutter block. 3

- Rectangular seal into the head plate.

2

Do not bend the flat cable

Testing

Start the printer Check for leakages. Check the recuperation level Check the state of the jet (stability, position in the gutter) Record the replaced part in the maintenance menu of the printer

3

9450 Book for Service Engineers 195/298

A49725

Troubleshooting SPS PH04

Gutter Sensor (M/G Head) – ENM38973

Special Tools

-

Prerequisite

Turn off the printer and disconnect it from the AC power Take appropriate individual protections Keep print head higher than the printer cabinet

1/1

Op. Location Remarks

Residual ink may come out Perform this operation in a dust-free environment

Disassembly Remove the cover head. 1

2

Disconnect the fat cable of the back cover (EHT) and remove it. Disconnect the flat cable (A) of the gutter block and unscrew the two (x2) screw of the print head board.

1

Insulation part

Carefully remove the gutter block (x1 CHC screw) and clean the surroundings. Remove the gutter sensor by pulling of the insulation part. Clean the surroundings.

Reassembly

3

Place the new seal between the 2 pins of the gutter sensor and place the sensor in the head.

2

Reassemble all part in the reverse order Do not bend the flat cable

Testing Start the printer Check for leakages. Check the recuperation level Check the state of the jet (stability, position in the gutter)

3

Record the replaced part in the maintenance menu of the printer

9450 Book for Service Engineers 196/298

A49725

Troubleshooting SPS PH05 Special Tools

Modulation Assembly (G Head) - ENM400338/ENM44528

1/1

Turn off the printer and disconnect it from the AC power

Prerequisite

Take appropriate individual protections Keep print head higher than the printer cabinet

Op. Location Remarks

Make sure that modulation assembly is conform with head type and ink

Disassembly Remove the protection cover to gain access to the Modulation assembly.

1

1 Unscrew the captive screw placed in the middle of the Modulation assembly.

2

Remove the modulation assembly by pivoting it to the right direction. This might need some force!

Reassembly

3

Replace the modulation assembly by a new one. Replace the two (2) O-ring. Fasten the screw “very” tight

2

Testing

Start the printer Check for leakages. Record the replaced part in the maintenance menu of the printer Adjust the break-off point

3

9450 Book for Service Engineers 197/298

A49725

Troubleshooting SPS PH06

Modulation Assembly (M Head) – ENM47391

Special Tools

-

1/1

Turn off the printer and disconnect it from the AC power

Prerequisite

Take appropriate individual protections Keep print head higher than the printer cabinet

Op. Location Remarks

-

Disassembly 1

Disconnect the electrical wire of the Modulation assembly (x1 CHC 1.5 mm).

2

Remove the modulation assembly (x2CHC - 1.5mm)

3

Remove the modulation assembly by pivoting it to the right direction.

1

2

This might need some force!

Reassembly

4

Replace the modulation assembly by a new one (ENM47391), Replace the two (2) O-ring.

3

Testing

Start the printer Check for leakages. Record the replaced part in the maintenance menu of the printer Adjust the break-off point

9450 Book for Service Engineers 198/298

A49725

Troubleshooting SPS PH07

Cover - including EHT block (M/G head) – ENM47458

Special Tools

-

Prerequisite

Turn off the printer and disconnect it from the AC power

1/1

Op. Location Remarks Disassembly 1

Remove the cover head (x3 CHC )

2

Carefully remove the cover and disconnect the flat cable by unclamping it from the connector (A).

3

Place the new seal on the new cover (B).

Reassembly

4

Reconnect the flat cable on the print head board (push the clamp of the connector). Position the cover and make sure that electrical wires are not squeezed at the top of the cover.

1

A

2

3

Testing B Start the printer Record the replaced part in the maintenance menu of the printer

9450 Book for Service Engineers 199/298

A49725

Troubleshooting SPS PH08

Print Head Board – ENM39168

Special Tools

-

Prerequisite

Turn off the printer and disconnect it from the AC power

1/1

Op. Location Remarks

-

Disassembly 1

Remove the cover head (x3 CHC).

1

Carefully remove the cover and disconnect: 2



The EHT flat cable (A)



The 4ELV block flat cable (B)



The umbilical electrical cables(C)



The gutter block connector (D)

Remove screw). 3

the

board

(x2

C

B

A

D

2

Phillips

Note: The 2 screws ensure the electrical continuity Pay attention to the insulation part of the gutter sensor pin.

Reassembly

4

Reconnect all connectors on the new print head board. Re-assemble all cables. Position the cover and make sure that electrical wires are not squeezed at the top of the cover.

3

Insulation part

Testing

Start the printer Record the replaced part in the maintenance menu of the printer

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A49725

Troubleshooting SPS IC01

Cell – Peltier Condenser – ENM40379

Special Tools

-

Prerequisite

Turn off the printer and disconnect it from the AC power

1/1

Op. Location Remarks

The Peltier condenser is a fragile part!

Disassembly Pull out the ink circuit. 1

2

3

On the top of the IC: Unscrew the two (2) fixing screws (A) of the slide and remove it Unscrew the three fixing screws (C) of the support and remove it. Unscrew the two fixing screws of the radiator (B) and remove it.

Disconnect the Peltier condenser and remove it. Remove the square seal under the Peltier condenser CAUTION: identify the correct positioning of the condenser (the red wire on the + side, the black wire on the – side).

A 1

2

Reassembly 4

Place the new seal. Connect and place the new Peltier condenser and re-assemble all parts in the reverse order.

3

Testing Start the printer Test it in the MI engineer menu

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A49725

Troubleshooting SPS IC02

Pressure / temperature sensor assembly – ENM39006

Special Tools

-

1/1

Drain manually the printer

Prerequisite

Turn off the printer and disconnect it from the AC power Take appropriate individual protections

Op. Location Remarks Disassembly

1

Cut and remove the clamp collar placed around the sensor. Unscrew the four CHC screws holding the assembly and remove it by pulling and turning.

2

Remove the seal and clean the surroundings.

1

Reassembly 4

Re–assemble all parts in the reverse order and make sure use the new seal.

Testing

2

Start the printer Check for leakages Adjust motor speed if necessary (see adjustment sheets section of the book).

3

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A49725

Troubleshooting SPS IC03

Level sensor – ENM39084

Special Tools

-

Prerequisite

1/1

Stop the printer Take appropriate individual protections

Op. Location Remarks

-

Disassembly When changing the Level Sensor, make sure the measurement chamber is empty before starting to replace the new sensor. Proceed as follow:

1



Activate IC1 (position 2-3)



Activate IC7 (position 1-2)



Activate IC3 (position 1-2)



Activate Ink Transfer Pump P1



Wait 30 seconds

1

Note: this operation avoids ink overflow of the measurement chamber.

2

Unscrew the screw & remove the clamp(C). Disconnect and remove the sensor by pulling it upwards.

Reassembly Place first the seal in the ink circuit to ensure correct tightness. 3

2

C

Reassemble the parts. Stop the Transfer pump

Testing Start the printer Check for leakage and correct working

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A49725

Troubleshooting SPS IC04

(Common) Electro valve ENM37928

Special Tools

-

1/1

Drain manually the printer

Prerequisite

Take appropriate individual protections Turn off the printer and disconnect it from the AC power

Op. Location Remarks

-

Disassembly

Remove the ink circuit support (A) (Nut 7mm) 1

Pay attention, do not bend the hydraulic tube Note: The ink transfer pump remains on the ink circuit support, pay attention to its hydraulic and electrical connections.

Disconnect the electrical according to the electrovalve 2

1

A

cable

Locating the direction of assembly of the EV before remove it (NC/NO position)

2

Remove the electrovalve

Reassembly 4

Mount the new electrovalve Mount the ink circuit support

Testing IC board

Test electrically the electrovalve in the maintenance menu. Start the printer

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A49725

Troubleshooting SPS IC05

Rinsing Electro valve (EV6,EV7)

Special Tools

-

1/1

Drain manually the printer

Prerequisite

Take appropriate individual protections Turn off the printer and disconnect it from the AC power

Op. Location Remarks Disassembly

Disconnect the electrical according to the electrovalve 1

cable 1

Locating the direction of assembly of the EV before remove it (NC/NO position) Remove the electrovalve.

2

Reassembly EV6 EV7 4

Mount the new electrovalve.

Testing Test the electrovalve in the maintenance menu. Start the printer

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A49725

Troubleshooting SPS IC06

Venturi assembly – 3 m(ENM38114) – 6m(ENM43471)

Special Tools

-

1/1

Take appropriate individual protections

Prerequisite

Turn off the printer and disconnect it from the AC power Ink circuit drained

Op. Location Remarks

Residual ink may come out, take appropriate precautions

Disassembly

1

Remove the hose from the connector

Bottom of the IC

1

Unscrew the venturi assembly. 2

Remove the seal and clean.

Reassembly 2 3

Re–assemble all parts in the reverse order and make sure you have placed the new seal

Testing Start the printer Check for leakages and correct functioning

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A49725

Troubleshooting SPS IC07

Strainer – Filtering connector – ENM38113

Special Tools

-

1/1

Take appropriate individual protections

Prerequisite

Turn off the printer and disconnect it from the AC power Ink circuit drained

Op. Location Remarks

Residual ink may come out, take appropriate precautions

Disassembly

1

Bottom of the IC

Remove the hose from the connector 1

2

Unscrew the strainer filtering connector. Remove the seal and clean.

Reassembly

4

2

Re–assemble all parts in the reverse order and make sure you have placed the new seal

Testing Start the printer Check for leakages and correct functioning

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A49725

Troubleshooting SPS EL01

Boards – CIJ Technology + NEP – ENM48472

Special Tools

-

1/1

Take appropriate individual protections

Prerequisite

Turn off the printer and disconnect it from the AC power Make a full back-up of the printer

Op. Location Remarks

Take anti-static precautions

Disassembly 1 1

Disconnect all connectors from the CIJ Technology board in the ink circuit compartment.

2

Remove the PSU (including fan).

board

rack

Disconnect all connectors which are connected to the NEP/CIJ boards. 3

2

Unscrew partially the two CHC screws (A) to release the NEP rack (including CIJ board).

Reassembly

4

Transfer the SD card (2Gb min) from the replaced NEP board to the new NEP board. Mount the new kit NEP board and CIJ board in the printer.

Testing Start the printer Check the firmware version embedded on the NEP board, if it is not the last one, install the last one. During installation, configure the Production setting factory (Ink type, printer type, and printer S/N, head configuration….)

3

A

Go in the MI engineer and set the EHT value indicated on the Umbilical A

Adjust the Break-off point

9450 Book for Service Engineers 208/298

A49725

Troubleshooting SPS EL02

Display - Assembly – ENM48467

Special Tools

-

Prerequisite

1/2

Take appropriate individual protections Turn off the printer and disconnect it from the AC power

Op. Location Remarks

The power supply rack (board + fan) must be dismounted!

Disassembly

1

2

Disconnect the flat cable and unscrew the four (4) nuts holding the display assembly.

Remove/ un-stick the plastic cover and remove the display assembly. Remove all glue residues and degrease thoroughly.

B

3

Unpeel the protective see-through film (A) on the conductive parts of the new display. There is one on each side.

4

Unpeel and fold the protective film (B) in two (2) opposite locations without totally removing the film.

A

A

B

9450 Book for Service Engineers 209/298

A49725

Troubleshooting SPS EL02

5

Display - Assembly – ENM48467

1/2

Carefully remove the film and set in place the new display. Stick the new display into position by using your thumbs to press all around the display.

Reassembly

4

Tighten the four (4) nuts by adjusting the display in the plane of the cabinet. Re-assemble all parts and re-connect all cables in reverse order.

Testing

Start the printer Calibrate the touch screen.

9450 Book for Service Engineers 210/298

A49725

Troubleshooting ■ Adjustment sheets Charge electrode The charge electrode is the only one mechanical adjustment on the print head. It could be necessary to adjust the charge electrode after modulation assembly replacement. The jet must be accurately adjusted in the centre of the electrode to ensure the best drop charge.

Positioning Screw

Locking Screw

Positioning Screw

Locking Screw

M head

G head

Proceed as follows to adjust the charge electrode while the jet is on:

 Loosen the Locking screw using 1,5 mm Allen key,  Turn right or left the eccentric positioning screw to adjust its position  Tighten the locking screw  Adjust in order to make the jet centered into the electrode.

9450 Book for Service Engineers 211/298

A49725

Troubleshooting Motor speed The motor speed must be set according to jet speed and umbilical length as follow: Motor speed

Jet speed

Umbilical length

2000 rpm +/-100

20m/s

3m

2000 rpm +/-100

23m/s

3m

2200 rpm +/-100

20m/s

6m

To set the motor speeds proceed as follows: 1-

Display the Head operations window.

2-

Check that the status of the printer is Ready

3-

Locate Motor speed and Jet(s) speed.

4- To set the motor speed, go to the Ink circuit maintenance menu, set the speed in the “Motor speed reference” field.

2.59

2000

9450 Book for Service Engineers 212/298

A49725

Troubleshooting

Adjust the by-pass in front of the pressure in order to obtain: Pressure (bars) = Pressure reference (bars)

By-pass adjustment

Allen key 3/32

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Troubleshooting Break-off point Adjustment This function allows adjusting automatically the tension provided to the piezo of the modulation assembly in order to transform the continuous jet into drops. This function is an integrated feature available in the head operations menu. The printer is locked during 15 minutes in order to perform BOP sequence. BOP sequence is composed of Jet stabilization (10 minutes) and Break-off point (3 minutes) as follow:

MI profile

Jet stabilization (10 min)

Break –off point adjustment (3min)

No

Correct Break-off point?

Yes Second time (x2)

Number of BOP failed attempts?

First time (x1)

Before a break off-point adjustment, the print head must be clean and the jet must be stable. The adjustment should be used when facing bad print quality or after changing the Modulation Assembly. For harch environment (T (°C)), it might be necessary to re-adjust it.

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Troubleshooting Resetting the break-off point table after a Modulation assembly replacement

 Go to the MI-Engineer menu, select “Head Status”  Click on button “MODIFY” for setting the piezo value

For MI Engineer

 Set the Piezo value to “0” and click “MODIFY” MI profile

Note: After the table reset, the printer will raise a Drop (phase) Detection fault (F2070). This is normal when the Piezo value is set to 0.

 Return to the Head Operations page and select “Adjust break off point”.

For customer

For customer:  Go to the The modulation assembly is included in the spare part catalogue: It can be ordered by customers. On the other hand, customers are not allowed to reset the break-off table from the MI-Engineer interface. That why, the entire BOP table can be reseted when the Modulation Assembly replacement Maintenance Record Menu is filled in.

After that, go to the Head Operations page and select “Adjust break off point”.

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Troubleshooting

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Electronics

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Electronics Notes:

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Electronics ■ Diagram bloc Diagram bloc is the following:

Industrial interface (Optional)

Touch screen Screen adapter

Power supply

Techno board

Print Head Board EHT Block

NEP board

(+24V only)

Ink circuit board/RFID

Electrovalves

Pumps

Antenna Board

Sensors

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Electronics ■ Power supply The power supply only delivers 24Volts. All other required voltages are generated on the different boards based on the 24V. The power supply is short circuit protected.

■ NEP board The NEP board is divided in 2 different units: DAta Management Unit and the Print Unit. The NEP board is mounted directly on the Technology interface board. The Data management Unit is based on windows CE 6.0 operating system and handles the standard functions and data which do not require real time action. The data can be either internal or external. 

User Interface (Message creation, setting parameters…),



Communications (Ethernet, USB …),



Data storage (on board memory + extension by SD card)

The Print Unit is based on Markem-Imaje operating system and handles the print specific functions and data which require real time action. It processes data coming from the Data Management Unit from the specific technology interfaces. Computing the data needed to drive the print head: Message preparation, variable elements (counters…), message transformation (raster generation…), print sequencing

Techno board

NEP board

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Keyboard

JTAG Connector

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USB OTG

GPIO + SPI + I²C

PHY Ethernet

NEP Core Connector (200)

Reset

USB Host

COM 2

IMX27

1 6

3 2

Print Unit 2 Extension Connector (80)

1 6

1 6

FPGA

GPIO + SPI + I²C

Flash 64 MO

Industrial Interface

DDR 64 MO

Ethernet 10/100

SD Card

1 6

GPIO (16)

supplies 1.2v/1.5v 1.8v/2.5v

RTC

JTAG/BDM Connector

1 6

Flash 4/8 MO

ColdFire 5207

3 2

SDRAM 16 MO

Battery

SRAM 512 KO

1 6 Power

COM 1

Power supplies 2.75v / 1.35v

Electronics Block diagram NEP board

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Print head / Ink circuit

COM 1

Screen

Electronics ■ Technology interface board The technology interface board is the interface between the NEP board and the print technology used, in this case CIJ. The NEP board is mounted directly on this board and is electrically connected through one connector. The two main functions are:  Mechanically assuring the fixation and accessibility of the USB connector and the SD slot  Electrically dispatching and collecting all the signals from the technology concerned. These signal are adapted (amplified, converted, opto-coupled, filtered, buffered …) if needed on this board. Adaptive card for CIJ technology: 

SD socket,



USB port Host and Device,



Ethernet (10/100 Mb) connector,



Trigger, Encoder, Beacon connectors,



Power supplies +3.3, +5 +15V.

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Electronics Component lay-out Technology interface board Encoder accessory

Alarm accessory

Power supply ly

ly

Trigger accessory Status LED

ly Touch screen (Interface)

ly

ly

Ethernet ly

Industrial interface

USB device

ly

Electronic Fan

USB host

ly SD card ly

Umbilical (PMAI Head) ly INK circuit

IC Motor

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IC Fan

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Electronics Block diagram Technology interface board +24V Display screen

+15V

Buffer

Print head

+5V Data

Assembly

Clock

Touch screen

Controller

LVDS ELV

Ethernet

Electro valve driver

Fault

NEP board connector

Pump USB device

USB host

SD slot

3V3 24V

Fault Pump Fault

Transfer pump driver (3x) Pressure pump driver

Plant air (only IP65) 24V Data

Industrial Interface

+5V

Power supply

+15V

24V indus

Trigger

24V indus

Encoder

24V indus

Fan (x2)

24V

Rotation

Ink circuit

24V indus

Encoder Trigger 3x Alarm

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Electronics ■ Ink circuit board (A48181) This board is located in the ink circuit compartment. It has two functions: ► RFID functions: It transmits/receives data from/to the antenna board. ► Ink Circuit functions: It provides supplies to IC electrovalves, pumps and sensors and it transmits data from IC monitoring (pressure, level sensors) to the NEP board.

J1

Internal use

J2

Pressure solvent sensor CP3

J3

Level sensor CP1

J4

Ink pressure sensor CP2

J5

Level electrodes (Calibration and overflow)

J6

PELTIER cell

J7

Recuperation pump

J8

ELV7

J9

Draining pump

J10

NEP (flat cable)

J11

ELV6

J12

Additive pump

J13

ELV5

J14

Ink pump

J15

ELV4

J16

ELV3

J17

ELV2

J18

ELV1

J19

Antenna board

J20

Antenna board

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Electronics ■ Print head board All the analog signals of the print head are processed directly on the print head board. The print head board communicates with the NEP using Low Voltage Differential Signaling (LVDS) via the Technology board. For each drop creation a full serial data exchange is established between NEP board and print head board.

Component lay-out Print head board

Gutter Block

Ground

EHT Block

Umbilical Block 4 electro valve

Block 4 electro valve

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Electronics Block diagram Print head board Pressure Additive Gutter

4 ELV Driver

+80V

Temperature sensor

Piezo

Purge

Piezo Amp 0v

Fault

Charge Amp

Ombilic

FPGA

CLK

Deflection plate

- 15V CLK Value Fault

Bloc EHT

strobo Led Power control

Measurement Amp

+24V +15V +5V

+350V Power supply management

+80V -15V +3.3V

Recuperation clock

+1,5 v

Cover detection

Ink resistance reference

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Phase (speed) sensor

DAT A

Gutter detection

LVDS

Charge electrode

+ 350V

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Electronics ■ Industrial Interface board The industrial interface board is optional. It is used when the application needs other in and outputs then provided with the 3 connectors for the photocell, encoder and illuminating alarm accessories. All input and outputs have a status led.

Component lay-out Industrial interface board

Technology board

J1 connector Status LED (E/R Techno board)

J5 connector

J2 connector

Status LED (Optional inputs)

J3 connector

J4 connector

J6 connector Wire section: 1.5 mm² max.

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Electronics ■ Input /Output specification Characteristics of Industrial Power supply Voltage = + 24VDC, Power = 500mA max. This power supply is separated from the +24V of the printer and managed on the Technology interface board. It is used to power the 3 external accessory connections on the side of the cabinet and available on the industrial interface board. The power consumption of the accessories connected on the cabinet should be taken into account when connecting any accessories peripherals to the industrial interface. Input types: Opto-coupled Sense ( -/+) insensitive +5 to +30 Volts Auto current limited : 10kHz (encoder 250kHz) Protection diode accepts up to 70V reverse voltage Bi- mode (P / N)

Note: Refer to the technical specifications of the accessories for further details. Output type: Transistor (Opto-coupled) Sense ( -/+) sensitive +50 Volts/ 100mA Bi- mode (P / N) Relay: +30 Volts / 1A maxi

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Electronics Trigger & encoder There are two different ways to connect trigger or encoder: ►Using the standard accessory connectors

J13 CELLULE

J11 TACHY

Black = Trigger Blue = Encoder

These 2 inputs are simply routed on the Industrial interface board. The actual electronics, to treat the signals, are on the Technology board. They are available even when the (optional) industrial board is not fitted. CAUTION: The accessory connectors for these 2 signals are in parallel with the connections on the industrial interface board.

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Electronics ►Using the optional industrial interface connections

J2

J2

Industrial interface board J2 1

GND

2

+24V

3

ENCODER COMMON

4

ENCODER CH-B

5

ENCODER CH-A

6

TRIGG-a

7

-

8

TRIGG-b

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Electronics Alarm & Fault (Ready) There are three different ways to connect trigger or encoder: ►Using the standard connectors

J12 BEACON

Yellow = Illuminating alarm

Ready Alarm Fault

Three (3) signals are used: Ready, Alarm and Fault.

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Electronics

RL40 RL41

J5

J6

Using Relays 2 relays are available on the industrial interface board (RL40/RL41) + 30 Volts / 1A maxi Transistor (opto-coupled) P or N Mode +50 Volts/ 100mA

J6

Alarm NC Alarm Com

Alarm NO Fault NC Fault Com J5 Fault NO

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Electronics

Industrial interface board J5 1 3 5 7 9 11 13 15

ALARM COM FAULT COM FAULT NC GND

2 4 6 8 10 12 14 16

Industrial interface board J6

ALARM NC ALARM NO FAULT NO

1 3 5 7 9 11 13 15

FAULT+ FAULTALARM+ ALARM-

2 4 6 8 10 12 14 16

In the I/O configuration, select the alarm and fault relay configuration

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Electronics Serial link Data Transmission

J5

TXD-1 : Data V24/RS232C (serial 1) TXD-2 : Data V24/RS232C (serial 2) TX2+ and TXD2-: Data RS422 (serial2) Data Reception RXD-1 : Data V24/RS232C (serial 1) RXD-2 : Data V24/RS232C (serial 2) RX2+ and RXD2-: Data RS422 (serial2)

Note: (Ground) Common with V24/RS232C (only)

In the network connectivity, configure the serial link

Refer to the “Network interface Manual” for detailed information.

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Electronics Miscellaneous inputs These inputs are only available on the industrial interface board. They are isolated from each other. Inputs are opto-coupled with automatic current limitation. (P or N Mode, + 5 to + 30V, 10 KHz)

Industrial interface board J3 1 3 5 7 9 11 13 15

GND INHIBIT TRIG-a INHIBIT TRIG-b INC/TRG MESS-a INC/TRG MESS-b LIBRARY SENSE-a LIBRARY SENSE-b COUNTR INCRy-a

2 4 6 8 10 12 14 16

+ 24V CELL2-a CELL2-b INVERSE MESS-a INVERSE MESS-b COUNTR INCRx-a COUNTR INCRx-b COUNTR INCRy-b

Industrial interface board J4 1 GND 2 3 COUNTR RESETx-a 4 5 COUNTR RESETx-b 6 7 STOP PRINT-a 8 9 STOP PRINT-b 10 11 MODE-a 12 13 MODE-b 14 15 GND 16

+ 24V COUNTR RESETy-a COUNTR RESETy-b ON/OFF-a ON/OFF-b

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Electronics Message number This input is only available on the industrial interface board. It consists of 8 inputs with one common to simplify the connection (opto-coupled with automatic current limitation) P or N Mode, + 5 to + 30V, 10 KHz

Industrial interface board J2 1 3 5 7 9 11 13 15

GND

COM DATA-b D7-a D5-a D3-a D1-a

2 4 6 8 10 12 14 16

+ 24V

D6-a D4-a D2-a D0-a

Refer to the “Network interface Manual” for detailed information.

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Electronics Miscellaneous outputs These transistor (opto-coupled) outputs are only available on the industrial interface board (except Ready, see Alarm and Fault) They are isolated from each other. P or N Mode +50 Volts/ 100mA;

Industrial interface board J6 1 3 5 7 9 11 13 15

PRINTER READY+ PRINTER READY FAULT+ FAULTALARM+ ALARM OUT-1+ OUT-1-

2 4 6 8 10 12 14 16

PRINTGPRINTG + OUT-3+ OUT-3COUNTR END + COUNTR END OUT-2+ OUT-2-

Refer to the “Network interface Manual” for detailed information.

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Electronics Network The network input is standard available (no need for optional industrial interface board). The RJ45 connector is on the Technology interface board. On the side of the printer there is a cable gland available to pass a network cable. RJ45 connector

Cable gland

The Ethernet connection could be configured in two different modes:

 DHCP mode (Dynamic Host Configuration Protocol)

 Fixed IP address mode

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Electronics ■ Input / output signals description Printing Settings [Top-Object mode] It determines if the printer should continue printing after the trigger signal: Select “Stop” >> message printing stops as soon as the trigger signal returns to low. Select “Continue” >> message printing continues even if the trigger signal returns to low.

message

Test print example 123456789

«TRIGGER» Message printed in continue mode

Test print example 123456789

Message printed in stop mode

Test print example 1

[Operation] “Job Number Select” activated«TRIGGER» is de-activated. (See § “Job selection Inputs”)

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Electronics [Horizontal resolution (1/10)] It determines the horizontal print resolution in dots/cm which is equal to Htrame/cm. The print speed should be equal to the object speed to be true. The default value is 28, equal to the [Vertical resolution (1/10)] [Vertical resolution (1/10)] Different choices of vertical resolution according to the message content (Data matrix, QR code) and according the head object distance.

[Non Double printing] This setting prevents a message to be printed more than once. After a message has been printed a new message should be selected or send through external communication. (This function is not compatible with selection by parallel interface or library mode). [Operation] should be set to “Standard”

[Trig active edge] Determines at which edge of the trigger signal the printer starts printing. “Rising” >> the rising edge is taken into account for printing. “Falling” >> the falling edge is taken into account for printing. message

Test print example 0123456789AB

«TRIGGER» Rising edge Falling edge

Test print example 0123456789AB Test print example 0123456789AB

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Electronics Job setting [Mode] Determines the printing action related to the “trigger signal”: ”Unique” >> one print per trigger signal ”Repetitive” >> the message is repeated as long as the trigger signal is active. The spacing between the messages is set in the [Repetitive interval] setting. [[Trigger active edge] should be “Rising” ”Multitop” >> the message is printed x times as defined in the setting [Multitop number] and with a spacing as defined in the setting [Repetitive interval]. [Trig filtering (µs)] “XXX µs” >> the minimum time the signal should be active before taking it into account. The default setting is 200µs. Noise on the trigger input can cause random “unexpected” prints. Modifying this value can eliminate this phenomenon. [Forward margin] / [return margin] The margin is the spacing (delay) between the trigger signal and the actual start of printing. It allows exact horizontal positioning of the message on the object to be printed without mechanical adjustments of the cell and or the print head. The value can be from 3 to 9999 and represents either mm or Htrames depending of the [unit] setting. This value is saved with the job. [Unit] Unit is used in combination with [forward margin] / [return margin] and [Repetitive interval “mm” >> the margin or the interval value entered is a distance expressed in mm, The Object speed should be entered correctly or in the case of speed measurement (cell or encoder) it should be setup correctly. The [Horizontal resolution (1/10)] setting should be set to the default value 28 for correct distance conversion of the margin or interval into mm. “Htrame” >> the margin or the interval represents empty rasters. The value of the [Horizontal resolution (1/10)] has a direct influence on the margin and or the interval; a low resolution increases the margin or interval and vice versa. Secondary function(s): Object Speed measurement A trigger signal generated by a cell, detecting the object to be printed, can also be used for its speed measurement. In this case the signal from the cell is used to generate two internal signals: print trigger and print speed.

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Electronics ONE CELL SPEED MEASUREMENT Main function Measure the object speed. The object speed is measured using 1 cell. The cell should be connected to the trigger input. The time of cell activation by the object together with the manually entered object length [Intercell length] is used to calculate the object speed (see object speed section). See software configuration section

Trigger Photocell Detector Objet Conveyor

9mm < Object length < 1097mm

Behaviour / related setting The signal from the cell is used to generate two internal signals: Print trigger & Print speed. Following the above the printer can only start printing once the object has passed the cell. Printing starts on the falling edge. Time measurement

Trigger input

Object 1 speed

Object 2 speed

Object 3 speed

Internal Trigger Print margin printing

Object 1

Object 2

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O

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Electronics Software configuration Parameters

Set to

Notes

[Speed measurement]

cells

-

[Number of cells]

1 cell

-

[Trig active edge]

rising

-

[Intercell length (mm)]: [Trig filtering(µs)] [Dtop filtering (µs)]:

9mm < Object length < 1097mm

The correct value is internally forced. Any value entered is not taken into account.

N/A

For Quality = 0, 98 x object length

Product speed

Enter the object length in mm.

For speed 1, 13 x object length

-

Object speed The speed measurement needs a minimum object speed for correct functioning. This minimum depends on the object length and the printer configuration. Vmin (mm/s) = Object length (mm) x Piezo frequency (hertz) 65535 G Quality = jet speed 20m/s ==> Piezo frequency = 64350 Hertz G Speed = jet speed 23m/s ==> Piezo frequency = 74000 Hertz As a first rule to calculate the minimum speed you can use the following calculation: For G-Quality = 0, 98 x object length For G-speed 1, 13 x object length There is no limit on the maximum speed (except the maximum printing speed allowed by the printer according to the message content).

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Electronics TWO CELL SPEED MEASUREMENT Main function Measure the object speed. The object speed is measured using 2 cells: One cell is connected to the TRIGGER input on the printer cabinet. The second cell is connected to the CELL2 input on the industrial interface. Industrial interface Use CELL2-a and CELL2-b

See software configuration section Trigger

Cell2

Objet Conveyor

D

9mm< D< 1097mm 9mm < Object length < 1097mm

Behaviour / related setting The time measured together with the manually entered Intercell length is used to calculate the object speed. The CELL2 signal should rise before the next object detection by the TRIGGER cell. The TRIGGER cell starts a timer and the CELL2 stops the timer.

Trigger input Cell2 input

Object 1

Object 2

Object 1

Object 3

Object 2

Object 3

Internal Trigger Print margin printing

Object 1

Object 2

Object 3

Time measurement

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Electronics Software configuration Parameters

Set to

[Speed measurement]

Notes

cells

-

[Number of cells]

2 cells

-

[Trig active edge]

rising

-

[Intercell length (mm)]:

9mm < Object length < 1097mm

Enter the distance between the 2 cells in mm.

N/A

The correct value is internally forced. Any value entered is not taken into account.

[Trig filtering(µs)] [Dtop filtering (µs)]:

For Quality = 0, 98 x object length

Product speed

For speed 1, 13 x object length

-

Printing adjustment Use the forward margin parameters to adjust printing in the printing field.

Encoder Main function Accurate synchronization of printing (print speed measurement) Related setting Parameters

Set to

Notes

[Speed measurement]

Tacho

[Tacho division]

The tacho division is a number between 1 and 63 and is used to divide the pulses received from the encoder.

Depending on the mechanical transmission of the object speed to the encoder and the encoder used, the number of pulses per mm of object movement will differ. The tacho division input allows dividing the amount of pulses in order to obtain the required 2.8 pulses per mm which correspond to the print resolution.

Behaviour / related setting [Tacho step (µm)] : Enter the distance between two pulses in µm MI Encoder pulse (rpm)

circumference wheel (mm)

Theorical “tacho step”

2500

200

80 µm

5000

500

100 µm

5000

200

40 µm

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Electronics Alarm & fault Main function Inform the operator about the status of the printer through the illuminated accessory Behaviour / related setting

Secondary function(s) Alarm output and the fault output are available on the industrial interface board. This signal can be used to manage the production line: to stop the conveyer for example.

PRINTER READY Main function Informs when the printer is ready to print (jet on and ready to print) This signal is available on the Yellow alarm connector and on the industrial interface board. On the accessory connector it is connected to the green light of the 3 element alarm.

INVERSE MESS Main function Reverse the print sense. It starts with the last raster and ends with the first raster based on the actual print sense of the job.

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Electronics INHIBIT TRIG Main function Inhibit the «TRIGGER» signal. The « INHIBIT TRIG » signal should be present at least 30µs before the «TRIGGER» signal for correct functioning.

Behaviour / related setting [Operation]: Only taken into account for “Standard job” operation [Active edge]: “Rising edge”: Trigger signal is inhibited when the signal is present at least 30µs before the rising edge of the «TRIGGER» signal. “Falling edge”: Trigger signal is inhibited when the signal is present at least 30µs before the rising edge of the «TRIGGER» signal and remains till after the falling edge. See further Trigger.

INHIBIT TRIG

No Print

Trigger

INHIBIT TRIG Trigger

No Print Active edge = Rising

INHIBIT TRIG Trigger

Print Active edge = Falling >30us

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Electronics Job (Message) selection Inputs MODE – COMMON DATA / D0 ~ D7 – INC/TRG MESS – LIBRARY SENSE A mix of these functions allows to set the starting point (first message to be printed) when using a message library and incrementing or decrementing message selection.

Main function Switching between:  Hexadecimal or BCD  Message selection (from the library) by number or by increment (next/previous).

COMON DATA / D0 ~ D7 Job (Message) number selection. INC/TRG Mess Validates the job number proposed on inputs D0 to D7 and starts printing of the job. LIBRARY SENSE Determine the sense (numerical ascending or descending order) of the library.

Job Selection

D0 to D7 Inputs

MODE Input

Confirmation and/or comments

Start Printing

Standard JOB

Manually

NA

NA

-

TRIGGER

0

Hexadecimal

JOB NUMBER SELECT

Job number selected by parallel interface or by UI.

1

BCD

Choice

LIBRARY (Library creation required)

First job number to be printed selected by parallel interface or by UI.

INC/TRG MESS (The Trigger input is not used)

DO…D7

0

DO…D7

INC/TRG MESS LIBRARY SENSE=0 the job number increases.

INC/TRG

LIBRARY SENSE=1 the job number decreases

INC/TRG

MESS

TRIGGER

1 MESS

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Electronics ON / OFF Main function Switch on or off the printer with an external command. Behaviour / related setting: Depending on the actual status of the printer it will switch on or off when activating the «ON / OFF» input. This input is monitored as soon as the printer is booted up.

COUNTR INCRM x & y Main function Increment a counter by external command. The increment value depends on the settings of the counter. Behaviour / related setting There are 15 counters available. The inputs x and y can be set in any counter and the same counters can be used in different messages. Activating an input affects all the counters in all the messages programmed with this input. Increment type ”Input x” >> the counter is incremented by the value set in “step value” when input «COUNTR INCRMx» is active. ”Input y” >> the counter is incremented by the value set in “step value” when input «COUNTR INCRMy» is active. ”Input x or y” >> The counter is incremented by the value set in “step value” when input «COUNTR INCRMx»or «COUNTR INCRMy» is active.

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Electronics COUNTR RESET x & y Main function Reset a counter by external command. Behaviour / related setting There are 15 counters available. The inputs x and y can be set in any counter and the same counters can be used in different messages. Activating an input resets all the counters in all the messages programmed with this input. External reset ”Input x” >> the counter is set to its initial value when input «COUNTR RESETx» is active. ”Input y” >> the counter is set to its initial value when input «COUNTR RESETy» is active. ”Input x or y” >> the counter is set to its initial value when input «COUNTR RESETx» or «COUNTR RESETY» is active.

COUNTR END Main function Give an external signal when the counter has reached its end value. This output can be set in any counter and to more than one counter at the same time. Activate output ”No” >> the output «COUNTR END» is not activated at when the counter has reached its end value. ”Yes” >>the output «COUNTR END» is activated when the counter has reached its end value.

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Electronics CONNECTOR ENCODER COMMON ENCODER CH-A ENCODER CH-B TRIG-a / TRIG-b CELL2-a / CELL2-b INHIBIT TRIG -a INHIBIT TRIG -b COUNTR RESETx -a COUNTER RESETx -b COUNTR RESETy -a COUNTR RESETy -b COUNTR INCRMx -a COUNTR INCRMx -b COUNTR INCRMy -a COUNTR INCRMy-b COUNTR END + COUNTR END – COM DATA-b D0-a … D7-a MODE-a MODE-b INC/TRG MESS -a INC/TRG MESS -b LIBRARY SENSE -a LIBRARY SENSE -b INVERSE MESS -a INVERSE MESS -b ON/OFF-a ON/OFF-b STOP PRINT –a STOP PRINT -b PRINTER READY + PRINTER READY – OUT-1 + OUT-1 – OUT-2 + OUT-2 – OUT-3 + OUT-3 – PRINTG+ PRINTG–

LED

Designation

ENCA ENCB TRIG CELL

ENCODER COMMON ENCODER CHANNEL A ENCODER CHANNEL B TRIGGER CELL 2

INHT

INHIBIT TRIGGER

RESx

COUNTER RESET x

RESy

COUNTER RESET y

INCx

COUNTER INCREMENT x

INCy

COUNTER INCREMENT y

CEND

COUNTER END

D0 … D7

DATA

SEL

MODE

IMES LIBS

INCREMENT / TRIGGER MESSAGE LIBRARY SENSE

INVM

INVERSE MESSAGE

ONOF

ON/OFF

STOP

STOP PRINTING

RDY

PRINTER READY

OUT1

OUT1

OUT2

OUT 2

OUT3

OUT 3

PRIN

PRINTING

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Electronics CONNECTOR

RXD-1 RTS-1 TXD-1 CTS-1 RXD-2 + RXD-2 – TXD-2 + TXD-2 – RXD-2 TXD-2

LED

RXD1

Parameters

RS232-1

TXD1 RS-422

RXD2 TXD2

RS232-2

PRINTER (TXD) ALARM COM ALARM NC ALARM NO

RS232-IMP PRINTER RXD PRINTER TXD ALARM COMMON ALARM NORMALLY CLOSED ALARM NORMALLY OPEN

FAULT COM FAULT NC FAULT NO

FAULT COMMON FAULT NORMALLY CLOSED FAULT NORMALLY OPEN

PRINTER (RXD)

ALARM + ALARM – FAULT + FAULT –

ALRM

ALARM

FAUL

FAULT

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Electronics

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Hydraulics

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Hydraulics

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Hydraulics ■ Diagrams of the hydraulic circuit

21 12 10

37

8 5

17

3

9 11

6

27

13

7

4 28 24

1

22 23 34

20

35

30 19

15

31

25

16 29

32

36 18

33

14

2

1 2 3 4 5 6 7 8 9 10 11 12

Additive cartridge Ink cartridge Additive reservoir Level chamber Measurement chamber Ink reservoir Constant level chamber Additive anti pulse air pocket Condenser + Peltier cell Pressure transmitter Ink anti-pulse bellows Main filter

13 14 15 16 17 18 19 20 21 22 23 24

Pressure + temperature sensor Pressure pump Venturi Ink transfer pump (P1) Additive transfer pump (P2) Electro valve 1: Ink supply (IC1) Electro valve 2: Constant level (IC2) Electro valve 3: Ink level (IC3) Electro valve 4: Antipulse/additive (IC4) Electro valve 5: Additive supply (IC5) Drain hose Ceramic calibrated tube

25 26 27 28 29 30 31 32 33 34 35 36 37

Calibrated leak 0,25mm Calibrated leak 0,25mm Additive filter Filtering connector 100µm Filtering connector Ink head filter 4 electro valve block Modulation assembly Gutter block Additive pressure sensor Electro valve 6: Rinsing valve(IC6) Electro valve 7: Ptr Rinsing (IC7) Tank Level rods

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Hydraulics ■ Part identification Filter Filters in connectors are identifiable by a cut around the fitting.

Additive anti pulse Air pocket

Antipulse/additive (IC4)

Additive FILTER CONNECTOR BARBED FILTER 100 µm (ENM38107)

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Hydraulics

Venturi assembly ENM38114 (3m) ENM43471 (6m)

Filtering

connector (ENM38113)

CONNECTOR BARBED FILTER 100 µm (ENM38107)

CONNECTOR BARBED FILTER 100 µm (ENM38107)

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Hydraulics

Level rods

level rod (Overflow)

level rod (Low level)

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Hydraulics Ink Circuit start –up Step1: Check required ink level to work When IC is starting up, the ink level Electro valve IC3 is switched alternatively on way 1 and way 3, the level in the measurement chamber increases while the required minimum level to work is exceeded. Note: If the ink level is not sufficient to work correctly: the circuit will pump the ink cartridge in order to fill the ink reservoir. CP1

Step 2: Emptying the level chamber and initializing the pressure transmitter A draining of the measurement chamber is carried out and a calibration of the pressure transmitter CP1 is done. The ink goes from the level chamber to the ink reservoir: Ink transfer pump P1 is activated, Ink supply Ev1 and ink level Ev3 are switched on way 3.

Step 3: Minimum level of ink in the level chamber The ink goes from the ink reservoir to the level chamber through Ev3 switched on way 1 until the minimum level is reached.

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Hydraulics

Step 4: checking additive reserve level The additive goes from the cartridge to the additive reservoir until the additive reservoir overflows into the level chamber: Additive transfer pump P2 is activated, Additive supply IC5 is switched on way 1. The overflow is detected by level increase in the level chamber.

Step 5: the pressure pump starts The motor speed of the pressure pump MP1 increases until the former reference pressure is reached. Step 6: the reference pressure is achieved The ink circuit is ready and the jet can be started. Now the viscosity measurement begins. The print head starts. 1NC

3NO

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Hydraulics Print head start-up Step 1: Print head cleaning The additive transfer pump is activated, recuperation valve is opened. When the pressure in the additive line measured by the pressure sensor reached the required value to rinse, the additive electrovalve H8 is opened. The print head is cleaning with an additive jet.

During this phase: - Purge H7 is opened, - Pressure H6 is opened, - Transfer pump P2 is stopped, - Additive H8 and Purge H7 are closed, The jet is detected and the speed is monitored. The printer is ready to print.

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Hydraulics Viscosity measurement

Step 1: filling the constant level chamber V4 IC2 is switched on way 1 in order to make the ink going to the constant level chamber.

Step 2: emptying the level chamber V2 A draining of the measurement chamber is performed. The ink goes from the measurement chamber to the ink reservoir: Ink transfer pump P1 is activated, Ink supply IC1, IC7 are switched on way 3. IC3 is switched on way 1. The constant level chamber is still overflowing.

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Hydraulics Step 3: waiting high level in the level chamber P1 stops when the level chamber is empty. The printer measures the time necessary for ink to reach the high level in the measurement chamber to get the viscosity value in seconds. The ink comes from the constant level chamber through the calibrated ceramic tube. The constant level chamber is still overflowing. Calibrated ceramic tube

Notes: If the measured viscosity is too low (<10s/reference)  Warning 4570 viscosity too low If the measured viscosity is two high (>10s/reference)  Warning 4030 viscosity too high If no measure  fault 4010 Time out viscosity measurement Step 4: end of viscosity measurement Additive addition The viscosity value is now measured; the ink level measurement can now begin.

Ink level measurement

Step 1: stopping constant level chamber filling Ev2 is switched on way 3 in order to make the ink going to the ink reservoir instead of the constant level chamber. The ink goes from the constant level chamber to the measurement chamber through the calibrated ceramic tube.

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Hydraulics

Step 2: balancing the constant level chamber and the ink reservoir Ev3 is switched on way 1 in order to make the ink going from the ink reservoir to the constant level chamber (or vice versa if the level in the level chamber is higher than in the ink reservoir).

Step 3: Stability in the level chamber When the level is stable in the level chamber the ink transfer is complete. The level is the same in the level chamber, the constant level chamber and the ink reservoir Then ink level is measured in the level chamber.

Step 4: end of ink level measurement Once the ink level has been measured, the viscosity measurement starts again.

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Hydraulics Ink transfer phase Step 1: Ink cartridge detection If the ink level in the tank is below the rod level (A). An ink transfer phase is commanded. The printer checks the data content of the TAG The ink transfer phase starts with a detection test of ink cartridge (Tag content). Furthermore, before each phase of ink transfer, a “forced” draining of the measurement chamber is carried out.

Step 2: Filling the ink tank During ink transfer phase, ink inside the cartridge is pumped by ink circuit during two minutes. The ink goes from cartridge to the ink tank: Ink transfer pump P1 is activated, IC7 and IC1 and IC3 are switched on way 1.

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Hydraulics

Step 3: Rinsing the ink needle After the transfer of the ink cartridge, the ink needle is rinsed using additive from the reserve. Additive transfer pump P2 is activated; IC6, IC7 and IC1 are switched on way1. The additive pressure injected in the needle is controlled by the additive pressure sensor.

Step 3: stability in the level chamber After each phase of ink transfer, the ink level is measured in the level chamber. The level must be the same in the level chamber, the constant level chamber and the ink reservoir. While the level of ink does not exceed the limit level, previous steps (1 and 2) are carried out.

Note: After each transfer, the volume in the cartridge (Tag) is updated.

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Hydraulics ■ Jet start-up and shut-down During printer start-up and shut-down, the modulation assembly is pre-rinsed at jet start-up and post-rinsed at jet shut-down in order to guarantee an optimum start-up of the jet and longer jet stability during normal operation. The recuperation channel is also rinsed as the additive follows the same trajectory as the ink.

4 Electrovalves block Additive Ink Purge

Recuperation

1

A

3 6

A

5

B 2 Modulation assembly

B 7

A

B

A

B

4

Gutter

Depending on the ink type and the ink temperature, different cycles will be used. The difference will be noticed for example in the number of activations of head elv’s. The ink pressure for jet start-up is based on the last memorized pressure giving a correct jet speed. At each jet shut-down (and or printer shut down) the pressure is memorized for the next jet start-up. The pressure of the additive is close to the ink pressure needed for a correct ink jet (between 2 and 3 bars) This pressure guarantees the smooth passage from additive to ink during jet start-up and vice versa during jet shut down. The recuperation channel is sealed from ambient air as soon as the jet is off. This avoids ink drying in the recuperation channel and eventually ink spilling through the gutter.

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Hydraulics ■ Jet principles Break off point (BOP) The break off point is where a drop separates from the jet and should occur between the charge electrodes. An incorrect break off point results in satellite drops (little drops between the main drops) and/or insufficient or no drop charge. The break off point can be observed with a magnifier. Behind the charge electrode there is a led which lights at the frequency of the piezo to be able to observe the drops “frozen”. The break off point is automatically optimized in relation to the temperature by adjusting the voltage applied to the piezo in the modulation assembly. Automatic BOP Adjustment The optimum break-off point is determined automatically by the printer and stored in a table each time a “break-off point adjustment” is activated. This table is divided in ten temperature ranges of 5°C depending on the temperature measured in the print head (from 5 to 54°C). For each range of temperature corresponding an optimum break-off point value (PZ0 ……. PZ9). The table is the following: 5°- 9°

10°- 14°

15°- 19°

20°-24°

25°- 29°

30°- 34°

35°- 39°

40°-44°

45°- 49°

50°- 54°

PZ0

PZ1

PZ2

PZ3

PZ4

PZ5

PZ6

PZ7

PZ8

PZ9

40°-44°

45°- 49°

50°- 54°

Note: The value stored is a count value. A count is equal to 0,8Volt. The set point changing is linear between 2 non-consecutive values. If the temperature is over 54°C, the piezo value PZ9 is used

Example: 3 values are stored in the table.

5°- 9°

10°- 14° 150

15°- 19°

20°-24°

25°- 29°

30°- 34°

35°- 39°

250

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Hydraulics These values can be displayed from the MI engineer menu:

0 150 0 0 250 0 0 0 300 0

From these values the printer is able to attribute a piezo value for each temperature range. Piezo 350 300

49

45

250 25

29

200 150 10

14

100 50 0 0

10

20

30

40

50

60

Temperature

Notes: For a new printer, only one value is stored in the table. If only one value is stored, this value is used in the entire table. The table is filled or updated for each “break-off point adjustment “(Any previous value is overwritten).

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Hydraulics Phase determination (Charge synchronization) The optimum charge synchronization is determined by charging two consecutive drops (out of twelve) at 12 different phases. When these 2 drops pass the phase detection cell it will sense a current peak. The phase resulting in the highest peak is the one used for charge synchronization.

Jet speed calculation The jet speed is calculated using V=d / t (m/s). The distance d is the height of the active part of the detecting sensor. The time t is the travel time of a drop over the distance d.

Piezo frequency Each modulation assembly could be supplied by two different frequencies: 64,35KHz (G head20m/s), 74 KHz (G head - 23m/s) and 83,30KHz (M head - 20m/s).

Jet position The shape of the detection cell (gutter sensor) allows detecting the Back – Front position of the jet. The amplitude of the signal reveals the left – right position of the jet.

BOP

t = travel time passing detection cell (one drop)

Gutter Sensor

d

Back - Front

Jet speed (v) = d/t

Left - Right

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Hydraulics ■ Jet in the gutter principle The presence or non-presence of ink in the gutter is measured with a current in the gutter assembly. The actual conductivity of the ink is measured elsewhere and used as reference to obtain an accurate measurement. 3 cases are possible: The current is to low indicating no or insufficient ink flow in the gutter >>>> “Jet out of gutter or not detected” fault follows. The current is too high, indicating an overflow of the gutter >>>>> “Jet out of the gutter or no detected” fault follows. The current is within the limits >>>> No fault

Ink

Gutter Comparator

R ink

A

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Hydraulics

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Software

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Software ■ General Operating system The 9450 printer application software runs on Windows CE 6.0 CORE operating system. The operating system is not embedded but installed at the factory on the NEP PCB. It consists of two parts:  NEP-EBOOT (Boot loader)  NEP-NK (WinCE OS)

9450 application software The application software uses several configuration files.

ProductionSettings.cfg: This file contains the factory settings for correct functioning of the machine. Some values are common and others are relative to the machine configuration (ink type / head configuration / IP level)

Note: In some cases you might need to change it (See §“Factory configuration setup”)

Package Version & Print unit Print unit boot Operating System boot FPGA Print Head FPGA NEP OS data management WIN CE User Interface Data management

The print head electronic circuitry is build up around a FPGA. This means it needs to be programmed. This cannot be done in the field. Print head PCB are programmed in the factory. 9450 Book for Service Engineers 276/298

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Software ■ Software installation / update procedure General A software update should only be performed following and if requested through a Technical Bulletin. Special attention should be paid to the compatibility of the software with the hardware of the printer. As it is very important that installed base takes an advantage / benefits of all improvement included in this new software version (corrections and new features) the instruction is to upgrade systematically “at the next visit” and to record the printer firmware version in SAP (for SAP countries). Recording procedure in SAP are the following:  Update Firmware Version of Equipment Directly In SAP: CRM-SU-DOC 022 V1  Capture Firmware Version of an Equipment Using MST: CRM-SU-DOC 024 V1  Update Firmware Version of Equipment via TRT: CRM-SU-DOC 023 V1

Software package The software package consist of the original software for the printer and for the same version a simulator which can be installed on a PC.

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Software Preparation Firmware release is available and downloadable from planet using a USB key or a SD card (up to 2 Gb).

Entry point (Global support)

Entry point (CIJ support)

Entry point (9450 support)

Entry point (9450 Firmware)

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Software Firmware Installation (Standard) Before any upgrade, pull the running status files of the printer.  Disconnect the printer from the AC power  Plug the USB key in the printer and Reconnect from the AC power  The printer will automatically boot from the media and the installation starts automatically  First, the printer executes the package checker to check the integrity of the data

Please, do not quit the package checker when is running Pay attention, in some cases if the OS version is obsolete, the package checker could be executed two times

 The Installation program will check the version installed and remove all irrelevant files (ignore any faults messages like “file not found”),

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Software

 Several applications for the different platforms will be installed / updated.  This process will take approximately 10 minutes. Do not interrupt the update procedure  Configure the factory parameters according to the customer needs and the hardware configuration of the printer as follow: Selectable ink type (commercial name)

Select the IP level (IP55 or IP65)

Selectable head type (G or M)

P/N of 4ELV block, check on the print head if P/N matches

Selectable umbilic lenght (3 or 6m)

Contrast circuit: Not applicable

Select: - Quality (20m/s) - Speed (23m/s)

Unique coding option

By default, the production settings reflect the printer configuration. Take a particular care when modifying them: all is not possible or allowed

 Click on Next>> and Create All files to validate the configuration

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Software

 Click on Exit and disconnect the printer from the AC power  Remove the USB Key containing the firmware. Otherwise the printer will re-install the software at the next power on.  Capture the firmware version of the printer in SAP:

Installation Report In cases of software installation issues, a report named InstallLog (.txt), containing the installation history is available and downloadable from the NOR Flash of the printer File explorer. This report traces all steps of the installation and highlights potential installation issues. The procedure to upload to an SD card is as follows:

The text file is structured as follows:

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Software ■ Factory configuration setup The Factory settings menu is a special configuration tool available to configure the printer. This tool is launched automatically after a software update. It can also be launched through the “MI Engineer” interface. [Tools►Service►MI Engineer►Factory settings] This tool gives you the following possibilities:  Configure the printer (Hardware),  Set the data for the maintenance warnings,  Erase histories

Printer configuration The MI 9450 printer application firmware uses several configuration files. These files are created in the MI factory for each individual printer as some of them depend on the printer configuration (Ink type, printer type, IP level…). Check and enter the correct settings concerning the printer. Selectable ink type (commercial name)

Select the IP level (IP55 or IP65)

Selectable head type (G or M)

P/N of 4ELV block, check on the print head if P/N matches

Selectable umbilic lenght (3 or 6m)

Contrast circuit: Not applicable

Select: - Quality (20m/s) - Speed (23m/s)

Unique coding option

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Software

Click on Next>> and Create All files to validate the configuration

Re-boot the printer by disconnecting the printer from the AC power Check in the information page for the correct printer configuration and software version.

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Software Preventive maintenance data The preventive maintenance data is used to calculate and warn the customer when the next maintenance is due; that consists in replacing filter kit & maintenance kit. In the case the printer has lost the history, it is possible to set manually the dates of the last interventions based on the maintenance contract or service order. [Tools ►Service►MI Engineer►Factory settings] Press on the « Advanced » button (1) then on the « prev maint data » button

Enter the correct date and Ink circuit running hours and press on the « Save » button.

Press the « EXIT» button. Disconnect/Reconnect the printer from the AC power.

9232 CAPACYT tool This tool is not compatible with 9450

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Software Histories erasures The history files of the printer can be erased in the case they do not reflect the reality. Press on the « Histories » button (1). Choose the histories type (2) to erase and/or the number of month to delete (3).

1 2

3

■ Interface for MI Service engineer A dedicated MI engineer interface is available on the printer. This interface is protected under the MI engineer profile.

Note: Most functions are for development purposes or dedicated to perform some specific operations like: configuration of the ink partial transfer, calibration of Ptr2, reset of the Break-off point table, test of external signals…..

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Software

Printer Status

Head Status

Modification of the Piezo value EHT value modification Jet Start/Stop with/without additive Modification of the Break-off point table

Electrovalves

EV1 Pipe/Cannula cleaning sequence (In case of blockage) Checking of EV1 pipe sequence P1 cleaning sequence (In case of blockage)

Commands Partial transfer activation

Standby mode (Not available)

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Software

Test of Alarms and faults

Consumables information (Signal detection, remaining volume, batch number…)

Windows explorer

Photocells, tacky, Peltier auto tests Test of the touch screen

Not available

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Software MI engineer profile The MI engineer profile is a hidden advanced profile. It is activated by a dynamic password based on the date of the printer.

To activate the MI engineer profile, hold down the advanced button more than 2 seconds and enter the MI password

Password calculation: 1- Write down today’s date: DD/MM/YYYY 2- Divide each number by four and record the remainder in the box provided 3- Add one (1) to each number and record the sum in the box provided EXAMPLE: 29 MAY 2002 DAY DAY MTH MTH YR YR YR YR

DAY DAY MTH MTH YR YR YR YR TODAY'S DATE DIVIDE BY

4

4

4

4

4

4

4

4

1

1

1

1

1

1

1

1

REMAINDER ADD 1 TODAY'S PASSWORD

TODAY'S DATE

2

9

0

5

2

0

0

2

DIVIDE BY

4

4

4

4

4

4

4

4

REMAINDER

2

1

0

1

2

0

0

2

ADD 1 TODAY'S PASSWORD

1 3

1 2

1 1

1 2

1 3

1 1

1 1

1 3

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Software ■ History (Log) file General When the printer runs, it constantly buffers the printer parameters to create a log file. Printer parameters are saved into a log file every 10 minutes and when a fault occurs, the previous 10 minutes are saved. The printer displays a selection of parameters, the complete printer data can be transferred on a SD card or an USB memory stick These files are extremely valuables for R&D department and should always be attached to any technical claim addressed the TDS department

Files Transfer The log file can be transferred on USB/SD card by using the transfer function.

FRxxxxxxxx_CartridgeEventFile_0.bin: It is an encrypted binary file. It contains ACM data. FRxxxxxxxx_BopDataFile_x: These files are dedicated for R&D (expertise). FRxxxxxxxx_CartridgeHistoryFile_x: These files compile data from the Consumable history menu (last 100 cartridges consumed). FRxxxxxxxx_IcTsDataReportFile_x: These files give the history of maintenance sequence executed automatically by the printer. FRxxxxxxxx_PrinterEventFile_x: These files give the various printer status change (Start-up, printing, Power OFF…) FRxxxxxxxx_PrnContexts: These files give the recording of printer parameters, alarms and faults.

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Software Files Use

FRxxxxxxxx_CartridgeEventFile_0.bin: This file is encrypted and has to be decrypted by a decoder available on Planet. The decoder transforms the binary file (.bin) in text file (.TXT).

Printer configuration

Number of ink cartridges M-I used Number of solvent cartridges M-I used Number of ink cartridges without tag Number of solvent cartridges without tag

The last 50 ink cartridges UID (UID Ink)

The last 50 solvent cartridges UID (UID solvent)

The state of the Joker volume

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Software FRxxxxxxxx_IcTsDataReportFile_x: These files give the history of maintenance sequence executed automatically by the printer.

dd/mm/yy

hh:mm

Sequence number: 1=P1 cleaning (in case of blockage) 2= Check of IC1 (EV1) duct or ink needle 3= Cleaning IC1 (EV1) duct or ink needle (in case of blockage)

Sequence Result (see table hereafter) Sequence Number 1 2

3

Sequence Result 0 1 0 1 2 0 1 2

Remarks

Printer side

P1 is unblocked P1 is blocked No issue on IC 1 & cannula IC1 is blocked Ink cannula is blocked Success of the sequence Sequence Fail: IC1 is not unblocked Sequence Fail: Ink cannula is not unblocked

Fault 4070 - Ink transfer pump blocked (P1) Fault 4160 - EV1 duct clogged Fault 4150 - Ink cannula clogged

Ink Cannula

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Software FRxxxxxxxx_CartridgeHistoryFile_x: These files compile data from the Consumable history menu (last 100 cartridges consumed).

This file provides: - Installation date of a new cartridge, - UID of the cartridge, - Signal detection of the cartridge (true or false), - Not MI cartridge (True =Not MI, False=MI cartridge) - Ink/Additive reference, - Batch Number, - Expiration date, - Cartridge counter

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Software FRxxxxxxxx_PrnContexts: These files give the recording of printer parameters, alarms and faults.

Header data (printer configuration): Printer S/N, head type, ink type, installation date…

The following parameters can be found in the file: Name

Description

Name

Description

JetSpeed

Speed of the jet (m/s)

ViscoSetPoint

Reference viscosity value

HeadTemp

Temperature in the head (°C)

AdditiveCounter

-

motorSpeed

Speed of the motor (rpm/mn)

tankInkLvl

Ink level in the tank

motorSpeedSetPoint

Reference of the speed motor(rpm/mn)

CKMin

pressure

Pressure of the Jet (bars)

CKMax

Sensor/Jet distance, nominal position offset

pressureSetPoint

Reference pressure of the jet (bar)

Piezo

Reference tension of the piezo

TempHardware

Temperature in the electronic compartment (°C)

BreakOff

Measured break of point

TempInk

Temperature of the ink (°C)

Recup

Rate of recuperation

Viscosity

Viscosity of the ink

FaultList

List of printer faults

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Software ■ Copy screen At any time and whatever the status of the printer, you can make a copy of the screen. This can be useful for training material as well when encountering a problem and you need to visualize it (for example when creating a Technical claim towards the TDS department).

Preparation

This function is only available using a SD card. Create a Text file on a SD card called “CopyScreen.txt”.

Use Insert the SD card in the printer containing the “copyscreen.txt” file. The printer will detect the file and automatically create a bitmap file type “YYMMDD-HHMMSS.bmp”. Remove and re-insert the SD card for each copy screen request. Blinking of the screen indicates the file has been created and is saved on the SD card

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Software ■ Simulator A simulator is available which runs on a normal windows pc. This tool is very useful for training purposes and for the Help Desk to guide a customer through the printer.

Installation & Launching Download simulator file from planet, unzip it on your hard drive disk. In the folder “simulator” click on the file “IUI9032_Windows.exe” to launch the simulator

Use Simulates a printer on: CTRL+1 => simulate Warning / CTRL+2 => simulate Fault CTRL + SPACE => simulate a trigger ALT + F4 => while in the main window, close and exit the application.

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Software ■ Algorithms Codification The 9450 algorithms are *.mia files loaded into the 9450 printers. Codification of the algorithms is as follows: HJDD_RR_LxDO_YT_zzz_NNNN.mia Algorithm number from 0001 to 9999 Number of drops used for a complete printed raster Y =L for linear / N for Non linear T = P for Pre-engineered / F for Calculated / D for linear with dynamic repositioning / S for high Speed L = number of lines DO = number of Drops per line Vertical resolution (1/10 mm) DD = Head/object distance in millimeter J = N for Normal jet speed (G head: 20 m/s) H for High jet speed (G head: 23 m/s) H = G for G head – M for M head

Example: GN10_28_3X07_LD_051_1006.mia G head - Normal jet speed - Head/object distance 10 mm Resolution 28 3 lines of 7 drops Linear - with dynamic repositioning 51 drops used for a complete raster Algorithm number 1006

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Markem-Imaje Industries 9, rue Gaspard Monge 26501 Bourg-lès-Valence Cedex - France tel: 33 (0)4 75 75 55 00 Fax: 33 (0)4 75 82 98 10

February 2015

http://www.markem-imaje.com

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